CN115067402A - Gantry double-column type rolling machine with floating type gland and automatic rolling method thereof - Google Patents

Abstract

The invention belongs to the field of tea processing equipment, and particularly relates to a gantry double-column type rolling machine with a floating type gland and an automatic rolling method thereof. The gantry pressing device comprises a rack and a gantry bent beam arranged on the rack, wherein a pressing structure is arranged on the gantry bent beam so as to drive a pressing cover to generate vertical lifting action, and the pressing cover is arranged at the pressing structure in a floating manner; the method is characterized in that: the rolling machine further comprises a first floating sensor for monitoring the current floating state of the gland; the first floating sensor can obtain the floating time data or floating height data of the gland in a specified time period, and then judge the current rolling pressure stage of the rolling machine. The invention can accurately detect and judge the current rolling pressure stage in real time in the rolling process, and has the advantages of low updating cost and high detection efficiency, thereby laying a solid foundation for realizing automatic rolling.

Description

Gantry double-column type rolling machine with floating type gland and automatic rolling method thereof

The priority of the "electric rolling pressure monitoring method and the corresponding rolling control device" with application number 202110749902.5, applied on number 07/02/2021, is claimed in this application, and the original accepting and accepting mechanism is china.

Technical Field

The invention belongs to the field of tea processing equipment, and particularly relates to a gantry double-column type rolling machine with a floating type gland and an automatic rolling method thereof.

Background

The rolling is the most common tea making process, the disc type rolling machine is commonly used in China to replace manual work, and during rolling, the rolling barrel and the rolling disc rotate horizontally and oppositely, so that fresh leaves are repeatedly rolled and rolled under the combined action of the side wall of the rolling barrel, the pressure of a gland, the reaction force of the rolling disc and the friction force of ribs, and finally the fresh leaves are tightly rolled into strips and tea juice overflows. A rolling process generally comprises a plurality of pressure stages, i.e. an air pressure stage-a light pressure stage-a medium pressure stage-a heavy pressure stage, etc.

In recent years, main tea making processes such as enzyme deactivation, carding, drying and the like are popularized with single machine automation and continuity, only a rolling machine has a small amount of application in a continuous production line of a large-scale tea factory due to the high price and common effect of the existing automatic rolling device, and most of small and medium tea factories rely on manual pressure adjustment of workers in the whole process. With specific reference to fig. 1, see the description in the invention patent with the patent name "tea leaves rolling machine with automatic floating device" with the publication number CN 103766516A: comprises a frame 10 and a kneading disc 20 which is arranged on the frame 10 and is fixedly connected with the frame 10, a kneading barrel 30 which generates relative movement with the kneading disc 20 is arranged above the kneading disc 20, and tea leaves to be kneaded are placed in the kneading barrel 30. The kneading barrel 30 is connected with a transmission mechanism which can make the kneading barrel generate movement, and a pressurizing structure 40 which can apply force to the inside of the kneading barrel is arranged above the kneading barrel 30. The pressure regulating screw rod 41 can move up and down through the pressurizing structure 40 such as a pressure regulating hand wheel, and the up-and-down movement of the pressure regulating screw rod 41 drives the gland 60 to move up and down, so that the effect of pressurizing and decompressing the tea leaves is achieved. The pressure adjusting screw 41 is screwed to a screw boss 71, and the screw boss 71 is elastically reciprocatingly installed at the gantry beam 70 through the buffer spring 42. The gland 60 is hung at the bottom end of the pressure regulating screw rod 41 in a floating mode of hinging or matching with a stepped hole in a floating mode; in order to ensure the action accuracy of the gland 60, two groups of guide rods 50 are additionally arranged, the guide rods 50 are guided and matched on the gantry bent beam 70, the bottom ends of the two groups of guide rods 50 are connected with each other through the auxiliary bent beam 51, the pressure regulating screw rod 41 penetrates through a mounting hole in the auxiliary bent beam 51 and then is integrally fixed in the mounting hole through a radial pin and the like, the bottom end of the pressure regulating screw rod 41 is in floating connection with the gland 60 through the optical axis 43, a gap obviously exists between the auxiliary bent beam 51 and the gland 60 at the moment, and the gland 60 is additionally provided with a second floating space outside the built-in buffer spring 42. During working, for the structure, a kneading master cannot see the floating of the pressing cover clearly only by naked eyes, and most of the kneading master is judged by combining experience with operation time and the like, so that the kneading master obviously puts high requirements on the kneading master, has extremely poor universality and extremely high error rate, particularly needs to accurately distinguish pressure stages such as air pressure, light pressure, heavy pressure and the like at present in due time, and obviously increases the operation threshold suddenly. Of course, people have been expecting to monitor the twisting pressure changes by means of measuring values by means of pressure sensors; however, the tea leaves which are originally loose in the kneading barrel in the whole kneading process can be rolled into lumps at any time and become high, the tea leaves impact the gland to cause the kneading pressure to be increased sharply, and the pressure is reduced sharply during the loosening process; in the stage of light pressure and air pressure, the change of the height of fresh leaves from loose to conglomerate is the largest, and the actually measured light pressure instantaneous peak value kneading pressure is often larger than that of heavy pressure, so that the whole course of actual data acquired by the pressure sensor is severely fluctuated with extremely large fall and strong randomness, and the actual data is difficult to be used for judging the pressure even after being filtered by an algorithm, so that the measuring and calculating result is unsatisfactory, and the pressure sensor is gradually abandoned.

As the industry can not make a breakthrough in the aspect of rolling pressure detection for a long time, large rolling machines in China still mainly produce rolling single machines with manual pressure regulation, most automatic continuous rolling equipment selects to abandon rolling pressure detection, and a pressurizing hand wheel is rotated at regular time and regular time according to a set program in a mechanized mode.

In addition, the main body of the existing rolling machine is made of cast iron, so that the rolling machine is extremely durable, the average service life of the rolling machine exceeds 15 years, namely, a large number of manual pressure-regulating rolling machines of different manufacturers and types exist in the industry, and the existing equipment of the manufacturers at present is replaced by simply using a brand-new rolling machine, so that the difficulty is obviously great. Therefore, it is a technical problem to be urgently needed by those skilled in the art to provide a method for monitoring kneading pressure that can be used as an external hanger and attached to a conventional kneading machine while overcoming the interference of rotation and up-and-down floating of a gland due to rolling of a leaf mass during kneading, so as to reduce updating cost and promote popularization and application while ensuring detection efficiency and data accuracy.

Disclosure of Invention

The invention aims to overcome the defects of the prior art and provide the gantry double-column type rolling machine with the floating type gland, which can accurately detect and judge the current rolling pressure stage in real time in the rolling process and has the advantages of low updating cost and high detection efficiency, thereby laying a solid foundation for realizing automatic rolling.

In order to achieve the purpose, the invention adopts the following technical scheme:

a gantry double-column type rolling machine with a floating type gland comprises a rack and a gantry camber beam arranged on the rack, wherein a pressurizing structure is arranged on the gantry camber beam so as to drive the gland to generate vertical lifting action, and the gland is arranged at the pressurizing structure in a floating manner; the method is characterized in that: the rolling machine further comprises a first floating sensor for monitoring the current floating state of the gland; the first floating sensor can obtain the floating time data or floating height data of the gland in a specified time period, and then judge the current rolling pressure stage of the rolling machine.

Preferably, the pressure regulating screw is in threaded fit with a screw shaft sleeve, the screw shaft sleeve and the gantry curved beam are elastically connected with each other through a buffer spring, so that the force accumulation and the force release of the pressure regulating screw in the vertical direction can be realized to move downwards, the bottom end of the pressure regulating screw passes through a floating type mounting gland of an optical axis serving as an extension section, and the pressure regulating screw is in fixed connection and fit with an auxiliary curved beam with a guide rod for guiding the action direction of the pressure regulating screw; the rolling machine further comprises a second floating sensor for monitoring uplink data of the pressure regulating screw or the screw shaft sleeve, wherein the uplink data comprise floating time data or floating height data of the pressure regulating screw or the screw shaft sleeve in a specified time period, so that the current rolling pressure stage of the rolling machine is comprehensively judged by combining the floating data of the gland.

Preferably, the first floating sensor is arranged at the auxiliary bent beam, and the sensing end points to the gland; and a support is arranged at the gantry bent beam, a second floating sensor is arranged at the support, and the sensing end of the second floating sensor points to the pressure regulating screw or the screw shaft sleeve.

Preferably, after the data of the capping floating time or the data of the capping floating height within a specified period of time are obtained, the current rolling pressure stage of the rolling machine is judged by a floating time ratio method based on the capping floating time data or a floating height average variance value method based on the capping floating height data.

Preferably, the floating time proportional method comprises the following substeps:

collecting the total time consumption of the upward floating of the gland in the appointed time period, calculating the proportion eta of the total time consumption in the appointed time period by the following formula, and comparing the proportion eta with the data of the set rolling pressure stage to distinguish the rolling pressure stage according to the proportion eta:

wherein:

t is the duration of a specified time period;

t is the total time of the upward floating of the gland;

the floating height mean variance method comprises the following substeps:

continuously collecting the floating height of the gland in the rolling process in a specified time period, storing the floating height of the gland into a plurality of arrays, and then respectively calculating the average value and the variance value of the arrays; setting rolling pressure stage data, and comparing the average value of the floating heights with the rolling pressure stage data to judge the air pressure, the heavy pressure and the overweight; the variance value representing the size of the gland fluctuation is compared with the rolling pressure phase data to distinguish light pressure from medium pressure.

Preferably, after each floating sensor is installed, manually controlling pressure and rolling, separating the whole rolling process by appointed time periods, continuously acquiring the floating height data of the gland or floating time data of the gland in the rolling process in each appointed time period, and storing the data by classification marks at the rolling pressure stage of the current manual pressure control rolling; then, establishing a convolutional neural network model, and putting the data stored by the classification marks into the convolutional neural network model for deep learning to obtain corresponding model parameters so as to obtain the convolutional neural network model with the corresponding model parameters; and finally, normally testing the capping floating height data or the capping floating time data, and comparing the capping floating height data or the capping floating time data with a convolutional neural network model with model parameters to obtain a result.

Preferably, when the floating time ratio method is adopted, the set twisting pressure stage data is as follows: the air pressure stage area is (0, 15% ], the light pressure stage area is (15%, 60% ], the medium pressure stage area is (60%, 98% ], the heavy pressure stage area is (98%, 100%), and the overweight stage area is 100%.

Preferably, when the floating height mean square error method is adopted, the set rolling pressure stage data is as follows: the average value area of the air compression stage is (0, 3), the average value area of the heavy compression stage is (20, 27), the average value area of the overweight stage is (27, 30), the variance value is not required to be compared in the above stages, when the average value falls into (3, 20), the variance value is calculated, the light compression stage is in the variance value falling into (0, 15), the medium compression stage is in the variance value larger than 15, and the units of the above numerical values are all mm.

Preferably, each floating sensor is a proximity switch or a travel switch or a distance sensor.

Preferably, the automatic rolling method based on the gantry double-column type rolling machine with the floating type gland is characterized by comprising the following steps:

s1, selecting a twisting curve and starting twisting;

s2, lowering the gland and sealing the inlet of the kneading barrel for standby;

s3, starting twisting of the Nth section of the twisting curve;

s4, continuously acquiring data by each floating sensor;

s5, when the current collection period is finished, obtaining the rolling pressure stage of the current rolling machine through the data obtained by the corresponding floating sensor, comparing the current pressure of the current rolling pressure stage with the set pressure of the set rolling pressure stage, if the current pressure is greater than the set pressure, controlling the gland to rise so as to reduce the rolling pressure, if the current pressure is less than the set pressure, controlling the gland to fall so as to improve the rolling pressure, and if the current pressure is equal to the set pressure, entering the next step;

s6, judging whether the current twisting stage is up, if not, returning to the step S4; if yes, entering the next step;

s7, judging whether all the twisting stages are finished, if not, returning to the step S3 to start the twisting of the next stage of the twisting curve; if yes, ending all rolling stages.

The invention has the beneficial effects that:

1) during actual working, the twisting pressure in the twisting process needs to overcome the dead weight of the pressurizing structure, and then the pressure is converted into random floating of the gland; in view of this, the invention develops a new method for judging the rolling pressure stage by collecting and calculating the floating rule of the gland, rather than directly collecting the specific pressure value, thereby obviously overcoming the interference of directly collecting the rolling pressure value and finally effectively and reliably judging the current rolling stage of the rolling machine. The scheme of the invention can particularly and accurately judge the medium and light pressure stages with severe rolling pressure fluctuation, and has remarkable effect.

2) Because the leaf mass is continuously reduced in the rolling process, the leaf mass can be slowly and quickly reduced by one third in 3-5 minutes after the beginning of rolling, and then the leaf mass can be slowly reduced by about one half in the whole continuous rolling process, so that the actual rolling pressure can be automatically reduced even if the artificial pressurization is not carried out, because the leaf mass is gradually reduced; at the moment, the height of the gland is required to be continuously detected and adjusted through the pressurizing structure, so that the gland is continuously pressed downwards, and the leaf mass cannot be contacted. The traditional manual rolling is carried out for several circles at will, the whole rolling process of the black tea is generally over 60-90 minutes, and the pressure is adjusted for 2-3 times in the whole manual process. In view of this, the present invention provides a first floating sensor a and detects only a floating gland in a targeted manner. On the other hand, when only the first floating sensor for the floating state of the gland is used, the floating of the gland incorporating the damper spring can be actually predicted by the gland operation: for example, the floating cover is in a floating state for more than 95% of the time, and the buffer spring is considered to be compressed; the medium pressure is considered when the gland floats up all the time, and the heavy pressure is considered when the pressure is continuously increased for 3-5 circles in the state. When the gland is measured singly, the air pressure and the light pressure can be distinguished through the gland, and then the continuous floating and continuous pressurizing strategies are followed.

3) The gland of the C-type double-floating rolling machine can additionally and independently float, the minimum rolling pressure can be greatly reduced to about 10 jin from 40 jin, the C-type double-floating rolling machine is very suitable for rolling high-value tender raw materials, the tea rolling quality can be obviously improved, the broken tea rate is reduced, the technical and experience requirements on a rolling master are higher due to the need of controlling the double pressure, the rolling master needs to spend more energy in the whole rolling process and pay attention to the pressure regulating hand wheel frequently, otherwise, the rolling effect is inferior to that of a common rolling machine, and the popularization degree of the rolling machine is still not large. By using the technical scheme of the invention, independent floating of the pressing cover of the rolling machine can be detected independently or double floating of the pressing cover can be detected respectively, and the whole process is automatically controlled, so that common workers can exert the great advantages of the C-type double-column gantry rolling machine in the light and medium pressure stages without training, the built-in buffer springs are triggered as few as possible in the light and medium pressure stages, floating light pressure is realized only by the self weight of the independent pressing cover, the rolling machine can effectively exert the rolling effect and automatic production of the rolling machine, particularly in the light and medium pressure stages, and the rolling machine with long history and excellent rolling effect is expected to go out of an international keen black tea production area after the learning and using difficulty is greatly simplified, and is widely popularized and applied outside the Huangshan city.

4) Further, in particular use, the present invention may also be used with two floating sensors. Wherein the first floating sensor only monitors the gland itself to determine the empty kneading and gently kneading stage, because the buffer spring does not work almost at this time, the tea kneading is actually realized completely depending on the floating action and the self weight of the individual gland. The second floating sensor is used for judging subsequent stages, namely a medium-pressure stage, a heavy-pressure stage and the like, more accurately and pertinently by detecting the floating of the built-in buffer spring, and the buffer spring starts to participate in the twisting process at the moment, namely the additional prediction and pre-pressurization process when the first floating sensor is independently adopted is replaced. Through the detection process of the form division, the actual detection precision of the invention can be further improved, so that basic guarantee is provided for the subsequent efficiency and precision operation of automatic rolling.

5) On the basis of the scheme, the floating sensor is only used for actual measurement, and only the existing software is needed to be matched for measurement and calculation to obtain the rolling pressure in the working process, so that the rolling pressure detection device is not limited in the invention, can be directly applied to rolling machines of other models at present, preferably only needs to be provided with an inductive proximity switch to form the first floating sensor, can detect the rolling pressure, is extremely low in updating cost and beneficial to popularization, and is particularly suitable for most of various medium and small tea factories in China.

6) Certainly, when in actual use, the floating sensor can be directly and horizontally aligned with the pressure regulating screw or the screw shaft sleeve, so that the direct displacement monitoring effect is realized; and a detection sheet can be arranged on the screw shaft sleeve to realize the purpose of indirect displacement monitoring. Such as: through the detection piece of installation horizontal plate face form on the pressure regulating screw rod, the response end of floating sensor only need plumbous vertical this detection piece can this moment, can realize its predetermined data acquisition purpose equally.

For the model without the screw shaft sleeve, a floating sensor can be directly arranged in the model without the screw shaft sleeve, so that the floating time data or floating height data of the buffer spring can be detected in a targeted manner, and the model is also similar to the model in which the screw shaft sleeve or the pressure regulating screw rod connected with the buffer spring is directly detected, and the description is omitted here.

By combining the technical effects, because the rolling machine is generally too durable, most of the tea yield in China is born by a large number of old rolling single machines of various small and medium tea plants until now, and the small and medium tea plants are rarely replaced by new rolling machines with high cost for automation, if a truly feasible automatic modification scheme of the old rolling machines is provided, a large amount of manpower is saved while the appearance and the quality of the tea making products in China are greatly improved.

Drawings

FIGS. 1 and 2 are two mounting embodiments of the present invention;

FIG. 3 is a block diagram schematically illustrating the structure of the electronic control system of the present invention;

fig. 4 is a view showing an automatic rolling method of the present invention.

The actual correspondence between each label and the part name of the invention is as follows:

a-first floating sensor B-second floating sensor C-support

10-frame 20-kneading disc 30-kneading barrel

40-pressurizing structure 41-pressure regulating screw 42-buffer spring 43-optical axis

50-guide rod 51-auxiliary camber beam 60-gland 70-gantry camber beam 71-screw shaft sleeve

Detailed Description

For ease of understanding, the specific structure and operation of the present invention is further described herein with reference to FIGS. 1-4:

the invention aims to provide a rolling pressure monitoring method which can overcome the interference of gland rotation and up-and-down floating in the rolling process, can detect and judge the rolling pressure in the rolling process, is universal for various rolling machines, has low cost and is easy to install. More specifically, the invention provides an automatic rolling control device which is used for detecting and controlling rolling pressure by applying the method, is used for modifying various new and old rolling machines, has low cost and is convenient to install, and the automatic rolling control device can be finally applied to a double-column gantry type rolling machine with a floating gland shown in figures 1-2, thereby realizing the preset purpose.

First, the basic principle and the working process of the rolling pressure monitoring method of the invention are briefly described as follows:

in the rolling process, the names of pressure stages such as air pressure, light pressure, medium pressure, heavy pressure and the like mislead many people to try to detect the rolling pressure by various methods to distinguish the pressure stages. The invention provides a method for naturally judging the current rolling pressure stage without directly obtaining an accurate numerical value of the rolling pressure by reversing the thinking in another way.

In the pressurizing structure of various domestic kneaders, a certain up-and-down floating space is provided for the gland 60 through the built-in buffer spring 42, but the floating amplitude is mostly only 2-5 cm, and the kneading barrel 30 and the gland 60 always rotate horizontally in the kneading process, so that the floating of the gland 60 is difficult to see in the practical production.

As the main production area of the three major high-aroma black tea Qimen black tea in the world, a double-floating rolling machine with a floating gland, namely a C-type double-column gantry rolling machine with a floating gland 60 and a buffer spring 42 as shown in figures 1-2, is used in Huangshan city for decades; the gland 60 and the auxiliary camber beam 51 are nested through an optical axis 43 which is an extension section of the tail end of the pressure regulating screw 41, and the gland 60 is provided with a second extra floating space outside the built-in buffer spring 42 by means of the suspended gland 60 and a section of gap reserved between the auxiliary camber beam 61 and the gland 60. Because the second floating is not buffered by a spring, the pressing cover 60 directly impacts the auxiliary camber beam 51 to generate a clattering sound every time when being extruded by the leaf mass in the rolling process, the pressing cover 60 randomly floats up and down to generate an impact sound in the whole rolling process, and no sound is generated all the time only when the pressing cover 60 is jacked at the upper limit for a long time (the state indicates that the leaf mass in the rolling barrel 30 is difficult to roll due to the fact that the rolling pressure exceeds the limit), so that in the working process, for the structure, a rolling master cannot see the floating of the pressing cover 60 clearly only by naked eyes, most rolling leaf states scattered on the rolling disk and experience are observed to judge, the high requirement is obviously provided for the rolling master, the universality is extremely poor, the error rate is extremely high, particularly, the rolling master needs to timely distinguish pressure stages such as air pressure, light pressure, heavy pressure and the like, and obviously increases the operation threshold suddenly. So far, by installing at least one floating sensor (namely installing the first floating sensor a and the second floating sensor B at one or simultaneously), the invention continuously counts the floating times and time consumption of the gland 60 in a specified time period, and finds that the higher the proportion of the time of floating the gland 60 in the total time is, the larger the actual twisting pressure is; the reason is that the existing rolling and pressurizing structure provides rolling pressure through self weight, the buffer spring 42 mainly provides a floating space, the rolling pressure is simulated through the self weight of the gland 60 and the magnitude change of the non-added alternative floating simulation rolling pressure in the rolling process, the principle of the invention is similar to PWM pulse width modulation simulating different voltages by changing high and low level duty ratios, and the preferred proportion rule of the floating time of the gland 60 is similar to the voltage judged by reading the duty ratio of PWM.

The reason why the second floating of the collected individual gland can significantly improve the detection accuracy with respect to the class C twin-column gantry type kneader shown in fig. 1-2 is as follows:

the kneading machines of all types apply kneading pressure through the dead weight of a pressurizing structure, the gland 60 must float up and down during kneading to drive the leaves in the kneading barrel 30 to roll into a mass, the single-arm screw rod type gland only needs to overcome the dead weight of about 12 jin of the gland and about 40 jin of the strut, but the gland of the A-type and B-type double-column gantry kneading machines needs to overcome the dead weight of the main screw, the guide rod, the auxiliary camber beam and the gland together for rising, namely the kneading of the kneading machines is that the leaves are lowest and the gland and the pressurizing structure can be pushed to float upwards integrally by receiving 40 jin of kneading pressure, which is obviously higher than the optimum pressure of a light pressure process, the empty kneading time is forced to be greatly prolonged to replace the light pressure during actual kneading, otherwise, the crushing rate is extremely high, but the double-column gantry kneading machine is an absolute mainstream of a tea factory.

The C-type double-column gantry rolling machine shown in fig. 1-2 can additionally and independently float for the second time after the gland 60 is stressed due to a special structure, the gland 60 alone only weighs about 10 jin, namely, the minimum impeller group in the rolling process can push the gland 60 to float upwards independently only by receiving 10 jin of rolling pressure, and the whole pressing structure can be pushed to float upwards for the second time after the rolling pressure exceeds 40 jin, so that the minimum rolling pressure can be obviously reduced by the double-floating structure. When the pressure is light, the pressure can be controlled by a rolling master to float and pressurize only by the single gland 60 without basically extruding the built-in buffer spring 42, so that the tea-leaf rolling device is very suitable for rolling high-value tender raw materials, the rolling quality of tea leaves can be obviously improved, and the tea-breaking rate can be reduced. Therefore, independent floating of the gland of the C-type double-column gantry type rolling machine in the rolling process is preferably detected through the installation of the sensor, and compared with the scheme of detecting the built-in buffer spring (corresponding to floating of the whole pressurizing structure), the rolling pressure in the middle and low pressure ranges can be more accurately controlled, and the special advantage of double floating of the C-type rolling machine is brought into play.

To this end, one of the solutions of the present invention has been clarified, that is, by installing at least the first floating sensor a on the pressurizing structure 40 of the rolling machine, as shown in fig. 1, the floating data of the pressing cover 60 in a specified time period is continuously collected by the first floating sensor a during the rolling process, and the current rolling pressure stage is judged by the rolling pressure calculation method, so that the automatic judgment of the rolling pressure stage can be realized.

The floating of the pressing cover 60 means that the pressing cover 60 floats up and down within a certain range along with the rolling of the impeller in the rolling barrel 30 during the rolling process when the pressing cover 60 is not actively controlled to ascend and descend by rotating the pressure regulating handwheel.

The rolling pressure stage refers to a pressure stage described in the rolling process of the stages of air pressure, light pressure, medium pressure, heavy pressure and the like, although a rolling worker cannot know the precise magnitude of the rolling pressure easily in the actual rolling process, the current rolling pressure stage can be naturally judged by observing rolling leaves and experience, and the present invention simulates the behavior and naturally judges after acquiring the floating data calculation rule of the gland 60 through the floating sensor.

Since the above-mentioned floating data of the gland 60 only needs to distinguish each rolling pressure stage, it is preferable to only collect the switching value of whether the gland 60 floats upward to meet the basic requirement, and it is more accurate to collect the accurate floating distance of the gland 60. That is, the first float sensor A is preferably a proximity switch, more preferably an inductive proximity switch, other proximity or travel switches may be used to detect that the gland 60 is floating. Preferably, one proximity switch is installed to determine whether the pressing cover 60 floats upwards, and the accuracy can be improved by installing a plurality of proximity switches to collect data of different heights of the pressing cover 60 floating upwards respectively.

Of course, the first floating sensor a may also be a distance sensor, including but not limited to an infrared sensor, a laser sensor, an ultrasonic ranging sensor or a displacement sensor, etc., and the accurate distance of the detection gland 60 floating each time can more accurately judge the current rolling pressure stage, only the cost is high and a large amount of tea hairs float in the air of the tea factory, and the emitting port is easily shielded to cause a fault after long-time work.

The rolling pressure calculation method is preferably a proportional method of the floating time of the gland 60, in this case, the floating sensor may preferably be a proximity switch or a travel switch, and by collecting and calculating the proportion of the total time of floating the gland 60 in a specified time period to the specified time period, the larger the proportion is, the larger the rolling pressure is, and the longer the specified time period is, the more accurate the result is. Because only pressure stages such as air pressure, light pressure, heavy pressure and the like need to be distinguished, the method can carry out preliminary judgment by actually measuring for 5 seconds, and can carry out accurate judgment by 45 seconds. The specific numerical ranges are shown in table 1 (the same model is different due to different pressurizing structures and materials):

TABLE 1 pressure grading table for various types of kneaders

For example: the detection object is a type C double-column type with a floating gland shown in fig. 1-2, that is, the type of the present invention, and at this time, the specified time period is set to 60 seconds, the first floating sensor a detects that the gland 60 floats up 5 times in 60 seconds, and the floating up takes 15 seconds in total, and the ratio η is (15/60) × 100% × 25%, referring to table 1, which indicates that the light pressure stage is currently performed.

It should be noted that: the first 3-5 minutes of each twisting does not need to be detected, because general workers can start the twisting after the twisting barrel 30 is filled with twisting leaves, at the moment, the fully loaded twisting leaves in the twisting barrel 30 start to roll along with the rotation of the twisting machine, and the leaf group expands and upwards frequently extrudes the gland 60. However, after several minutes the originally fluffy rolled leaves initially clump, the volume will be reduced by at least one third, and it is only meaningful to detect the floating of the gland 60 afterwards. This means that, in the initial few minutes of rolling, the pressure of the leaf mass is actually applied to the leaf mass from light pressure to medium pressure, although it is technically called as air pressure, and therefore, detection is not required at this stage, so that erroneous judgment is avoided.

Further, on the basis that the first floating sensor a measures the floating time data of the gland 60 as shown in fig. 1, the present invention can also achieve the purpose of self-judging the current rolling stage of the rolling machine by detecting the floating height data. Meanwhile, based on the floating height data and the floating time data, the judgment process can be optimized by relying on a neural network calculation method.

The method for averaging the floating height by detecting the floating height data is characterized in that the floating height of the gland 60 in the rolling process is continuously collected by a distance sensor in a specified time period and stored into a plurality of groups, then the average value and the variance value of the plurality of groups are respectively calculated, the floating height is the air pressure when the average value is close to 0 (indicating that the gland 60 is not floating), the heavy pressure is close to the floating limit of the gland 60 of the current machine type, and the light pressure and the medium pressure are distinguished by comparing the variance value (indicating the fluctuation size of the gland 60) when the residual value, namely the average value, is in the centered range.

Assuming that the rolling stage is set to be an air pressure stage, a light pressure stage, a medium pressure stage, a heavy pressure stage and an overweight stage, the judgment conditions of each rolling stage are as follows:

air compression: the average displacement value is less than or equal to a set lower limit threshold;

light pressing: the displacement mean value is smaller than the upper limit threshold value and larger than the lower limit threshold value, and the displacement variance value is smaller than or equal to the set variance value threshold value; the upper threshold is greater than the lower threshold;

medium pressure: the displacement mean value is smaller than the upper limit threshold value and larger than the lower limit threshold value, and the displacement variance value is larger than the variance value threshold value;

heavy pressing; the average value of the displacement is greater than or equal to the set upper limit threshold value.

The method specifically comprises the following steps:

when the object is the single-arm screw rod type rolling machine with the buffer spring, the average value area of the air compression stage is (0, 8), the average value area of the heavy compression stage is (40, 55), the average value area of the overweight stage is (55, 60), and the variance values are not required to be compared in the above stages, when the average value falls into (8, 40), the variance value is calculated, the light compression stage is the variance value falling into the (0, 50) area, and the medium compression stage is the variance value larger than 50;

when the object is a double-column gantry type rolling machine with a buffer spring, the average value area of the air compression stage is (0, 5), the average value area of the heavy compression stage is (30, 40), the average value area of the overweight stage is (40, 45), and the variance values do not need to be compared in the above stages, when the average value falls in (5, 30), the variance value is calculated, the light compression stage is the variance value falling in the (0, 25) area, and the medium compression stage is the variance value larger than 25;

when the object is a C-type double-column gantry rolling machine with a floating gland and a buffer spring and the detection object is a gland, the average value area of an air compression stage is (0, 3), the average value area of a heavy compression stage is (20, 27), the average value area of an overweight stage is (27, 30), the variance values do not need to be compared in the above stages, when the average value falls into (3, 20), the variance value is calculated, the light compression stage is the variance value falling into the (0, 15) area, and the median value is the medium pressure stage when the variance value is more than 15;

the units of the above numerical values are all mm.

More specifically, the following table 2 can be referred to (the same model is different depending on the pressurizing structure and the material):

TABLE 2 pressure grading table for various types of kneaders

The basic preset conditions of table 2 are: the floating range of a gland of the single-arm screw type buffer spring is 0-60 mm, the floating range of a gland of the double-column type buffer spring is 0-45 mm, and the range of a C-type double-column floating type gland machine type to which the invention belongs is 0-30 mm; of course, the floating range of commercially available models varies from manufacturer to manufacturer. Because there are mechanical vibration and sensor error in the twisting process, the ranges of air pressure and heavy pressure can be considered to leave a certain margin.

During calculation, taking a class C double-column floating gland type as an example: after continuous sampling, an average value is calculated to distinguish air pressure from heavy pressure, for example, the average value is 3mm, the air pressure is within the range of 0-5 mm, if the average value is 10mm, an array variance is calculated to distinguish light pressure from medium pressure, the medium pressure is determined when the variance value is greater than 15, and the light pressure is determined when the variance value is less than 15. The first floating sensor A of the C-type double-column floating gland type for detecting the independent floating cap is preferably a Sharp GP2Y0A51SK0F infrared ranging sensor, the ranging range is 2-15 cm, and the other sensors are preferably VL53L0X laser ranging sensors.

On the basis of the method, after the floating sensor is installed, a skilled rolling master is requested to manually control and roll, the whole rolling process is separated by appointed time periods such as 60 seconds, then the floating height of the gland 60 in the rolling process is continuously collected in each appointed time period and is respectively stored in an array, and then each array is classified and marked and stored in a rolling pressure stage manually judged by the master. After a large amount of manual rolling data are collected, the arrays are classified and put into a convolutional neural network such as a random forest decision tree training model. The optimal selection of the Luxin ESP32-S3 single chip microcomputer and the ESP-DL deep learning frame is realized according to the comprehensive cost, performance and requirements. And after the model training is finished, the current rolling pressure stage can be judged. The machine learning algorithm is accurate and even can copy the operation style of a designated rolling master, but a large amount of manpower is needed for respectively acquiring data training models for different machine types and different tea types, the main control cost and the sensor cost are high, and the actual measurement is accurate.

With regard to the installation position of the floating sensor, it should be noted here that the preferred installation position of the floating sensor also differs for different types of kneaders. Domestic mainstream kneaders can be divided into two major types, namely a single-arm screw rod type kneader and a double-column gantry type kneader shown in figures 1-2 according to different pressurizing structures; the latter is further divided into three types, i.e., a type a in which the gland 60 cannot rotate independently, a type B in which the auxiliary girder 51 is added to allow the gland 60 to rotate independently, and a type C in which the auxiliary girder 51 is added to allow the gland 60 to rotate independently and float doubly with a gap reserved.

Machine is kneaded to single armed lead screw formula on the market, accessible buffer spring provides certain floating space for the gland, and wherein the sensor accessible that floats is fixed on the cantilever beam through the support, kneads the in-process and makes buffer spring shrink when the gland atress, can drive gland and pillar and shift up, and it is protruding from the cantilever beam surface to trigger the sensor that floats when the pillar top. In the practical process, a proximity switch is preferably arranged to detect whether the gland floats upwards or not; of course, it is also conceivable to add an additional sensor to detect that the gland is greatly floated, thereby improving the determination accuracy.

A conventional A-type and B-type double-column gantry rolling machine provides a certain floating space for a gland through a buffer spring, wherein a second floating sensor B is fixed on a gantry camber beam through a support, the buffer spring contracts when the gland is stressed in the rolling process, a pressurizing structure comprising the gland, a main screw, an auxiliary camber beam, a guide rod and a screw shaft sleeve is driven to move upwards integrally, when the screw shaft sleeve moves upwards and is close to the floating sensor, the sensor can be triggered to detect that the gland floats upwards, and a floating sensor is preferably installed; if an additional sensor is additionally arranged to detect the condition that the gland floats up greatly, the judgment precision can be improved. Because the main screw and the screw shaft sleeve are made of metal and can trigger the inductive proximity switch, namely the inductive proximity switch can be touched by mistake, the other option is to fix a detection piece at the top of the screw shaft sleeve and change the induction surface of the floating sensor to be close to the detection piece upwards; the gland is in a trigger state when not stressed, and when the gland is stressed to drive the screw shaft sleeve and the detection piece to move upwards and be away from the floating sensor, the trigger can be released, and the floating sensor can detect that the gland floats upwards.

In the scheme of the C-type double-column gantry rolling machine shown in fig. 1, the conventional A, B-type and C-type rolling machines generally determine whether the gland floats upwards by detecting the extension and retraction of the built-in buffer spring (i.e., by the movement of the screw shaft sleeve), but the installation is complicated and the false triggering is easy to occur, while the C-type double-floating gantry rolling machine can additionally and independently float because the gland itself can separately and therefore detect whether the gland floats upwards by separately installing the first floating sensor a. The specific description is as follows:

as shown in fig. 2, a floating sensor a (preferably, an inductive proximity switch or a distance sensor) is fixed on the secondary camber beam 51 through a bracket C, and a sensing end of the floating sensor a points to the gland 60, and the floating sensor a is triggered when the gland 60 is forced to float up along the optical axis 43 in the twisting process, and detects that the gland 60 floats up, at this time, the floating sensor a can acquire data and determine the current twisting pressure stage through a column of table 1 or table 2 (C-type double-column floating gland).

It should be noted that, at least two floating sensors are installed on the C-type double-column gantry kneading machine to simultaneously detect the double floating of the gland 60 and the buffer spring 42, that is, the built-in buffer spring 42 and the independent gland 60 are respectively detected, so that the judgment accuracy can be greatly improved; at this time, the first floating sensor a can judge the empty kneading and light kneading stages by detecting the floating of the individual pressing cover 60, because the damper spring 42 is almost not operated at this time; the second floating sensor B detects the floating of the built-in damper spring 42, and is used to determine the subsequent stage. However, since the rolling pressure detection only needs to distinguish light, medium and heavy stages, the first floating sensor a is preferably and independently installed on the C-type rolling machine in practical application, and most process requirements can be met.

Based on the technical scheme, the rolling pressure monitoring method has the following positive technical effects:

according to the rolling pressure monitoring method, the rolling pressure in the rolling process overcomes the dead weight of a pressurizing structure and is converted into the random floating of the gland 60, and the rolling pressure stage is judged by acquiring and calculating the floating rule of the gland 60, so that the interference of directly acquiring the rolling pressure value can be obviously overcome, and the accurate judgment can be realized particularly in the middle-low pressure stage with severe rolling pressure fluctuation.

According to the rolling pressure monitoring method of the present invention, the rolling pressure can be judged by using the floating characteristic of the gland 60 of each type of rolling machine. During operation, the accurate judgment of the rolling pressure stage can be realized even by simply fixing the floating sensor, and various rolling machines, particularly a large number of old rolling single machines existing in the industry, can be simply and quickly refitted at low cost. The floating sensor can select an inductive proximity switch, and the inductive proximity switch is non-contact detection and can be triggered only by metal, so that common dust, tea leaves and the like in a tea factory cannot cause errors, and the whole detection process is free of physical contact, abrasion and mechanical life limitation. And gather the high-low level signal of proximity switch output and only need occupy a singlechip or the general digital quantity input port of PLC, industry is kept apart and also only needs a low-speed opto-coupler, compares in pressure sensor expensive and need extra chip and circuit because of the weak signal of output millivolt level, so its effect is no matter spare part cost or transform the scheme that the installation cost all is less than current use pressure sensor far away.

For the automatic rolling control device, the technical scheme of the invention is that floating data of the gland 60 is continuously collected by installing a floating sensor, an electric control system shown in figure 3 is adopted, a main control module is used for judging the current rolling pressure stage, and then a motor driving module is used for operating the forward and reverse rotation of a lifting motor so as to adjust the pressure.

In actual operation, the set pressure curve is executed in sequence through the main control module according to different process requirements, such as air pressure for 3 minutes, light pressure for 15 minutes, medium pressure for 5 minutes, heavy pressure for 2 minutes, and medium pressure for 5 minutes. When the pressure gauge works, the data of the floating sensor is read through the main control module, and the pressure is judged. The lifting motor adopts 24V direct current for speed reduction, a pressure regulating hand wheel is reserved, the lifting motor is physically disconnected by a relay when no output exists, a remote control and communication module is arranged in the lifting motor, and the like. Meanwhile, the power supply line can be simplified, firstly, a built-in battery is adopted, secondly, a rolling working sensor is adopted, because the gland 60 can frequently float only in the rolling process, the gland 60 cannot move when the machine is stopped, and the controller can only obtain the result of air pressure or over-heavy pressure. The automatic rolling controller also controls the power supply of the rolling machine when power is supplied in a hanging mode, the problem that the power is automatically supplied to the rolling machine when rolling is started does not exist naturally, but once the controller and the power supply are hung on the rolling machine, the controller cannot know when the rolling machine is powered on through manual operation, and therefore a vibration sensor such as a vibration switch and the like is arranged in the controller and used for judging whether the rolling machine rotates or not. When the rolling machine rotates, the rolling pressure is detected, and when the rolling machine is not powered on or is manually stopped in midway, the pressure detection is automatically stopped. Thirdly, a direct current speed reducing motor is adopted. And fourthly, the upper limit and the lower limit of the gland 60 can be detected by detecting the locked rotor of the motor.

Fig. 4 is an automatic rolling method based on the gantry double-column type rolling machine with floating type gland, which specifically includes the following steps:

1. selecting a rolling curve and starting rolling;

2. the gland descends and seals the inlet of the kneading barrel for standby;

3. the rolling machine is also provided with a vibration sensor for detecting the working state of the rolling machine, so that the timing module only times when the vibration sensor monitors a vibration signal; the vibration sensor detects whether the equipment vibrates, if no vibration signal exists, the equipment is continuously standby, and if the vibration signal exists, the next step is carried out; it should be noted that the vibration sensor is optional, and is preferably used in an environment powered by a built-in battery, so that when the controller is not equipped with the vibration sensor, the step can be directly skipped;

4. starting the twisting of the Nth section of the twisting curve;

5. the floating sensor starts to continuously acquire data;

6. when the current acquisition cycle is finished, acquiring the twisting pressure stage of the current twisting machine through the data acquired by the floating sensor, comparing the current pressure of the current twisting pressure stage with the set pressure of the set twisting pressure stage, controlling the gland to rise so as to reduce the twisting pressure if the current pressure is greater than the set pressure, controlling the gland to fall so as to increase the twisting pressure if the current pressure is less than the set pressure, and entering the next step if the current pressure is equal to the set pressure; comparing the pressures, namely that overweight is larger than heavy pressure and is larger than medium pressure and light pressure and is larger than air pressure;

7. judging whether the current twisting stage is up, if not, returning to the step 5; if yes, entering the next step;

8. judging whether all the rolling stages are finished, if not, returning to the step 4 to start rolling of the next stage of the rolling curve; if yes, ending all rolling stages.

The scheme is actually measured, and practices show that the scheme can accurately detect and judge the current rolling pressure stage in real time in the rolling process, can be put into actual production and has remarkable effect.

It will, of course, be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrative embodiments, and that the present invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. Any reference sign in a claim should not be construed as limiting the claim concerned.

Furthermore, it should be understood that although the present specification describes embodiments, not every embodiment includes only a single embodiment, and such description is for clarity purposes only, and it is to be understood that all embodiments may be combined as appropriate by one of ordinary skill in the art to form other embodiments as will be apparent to those of skill in the art from the description herein.

The techniques not described in detail in the present invention are all known techniques.

Claims (10)

1. A gantry double-column type rolling machine with a floating type gland comprises a rack (10) and a gantry camber beam (70) arranged on the rack (10), wherein a pressurizing structure (40) is arranged on the gantry camber beam (70) so as to drive the gland (60) to generate vertical lifting action, and the gland (60) is arranged at the pressurizing structure (40) in a floating manner; the method is characterized in that: the kneading machine further comprises a first floating sensor (A) for monitoring a floating state of the gland (60); the first floating sensor (A) can obtain the floating time data of the gland (60) or the floating height data of the gland (60) in a designated time period, and then judge the current rolling pressure stage of the rolling machine.

2. The gantry double-column type rolling machine with floating type gland according to claim 1, characterized in that: the pressure regulating screw rod (41) is in threaded fit with a screw rod shaft sleeve (71), the screw rod shaft sleeve (71) and the gantry curved beam (70) are elastically connected with each other through a buffer spring (42), so that the force accumulation and the force release of the pressure regulating screw rod (41) along the vertical direction can be realized to move downwards, the bottom end of the pressure regulating screw rod (41) is provided with a gland (60) in a floating manner through an optical axis (43) serving as an extension section, and the pressure regulating screw rod (41) is in fixed connection fit with an auxiliary curved beam (51) which is used for guiding the movement direction of the pressure regulating screw rod (41) and is provided with a guide rod (50); the rolling machine further comprises a second floating sensor (B) for monitoring uplink data of the pressure regulating screw (41) or the screw shaft sleeve (71), wherein the uplink data comprise floating time data or floating height data of the pressure regulating screw (41) or the screw shaft sleeve (71) in a specified time period, so that the current rolling pressure stage of the rolling machine is comprehensively judged by combining the floating data of the gland (60).

3. The gantry double-column type rolling machine with floating type gland as claimed in claim 2, characterized in that: the first floating sensor (A) is arranged at the auxiliary bent beam (51) and the sensing end points to the gland (60); a support (C) is arranged at the gantry bent beam (70), a second floating sensor (B) is installed at the support (C), and the sensing end of the second floating sensor (B) points to the pressure regulating screw (41) or the screw shaft sleeve (71).

4. The gantry double column type rolling machine with floating gland as claimed in claim 1, 2 or 3, wherein: after the data of the floating time of the gland (60) or the floating height data of the gland (60) in a designated time period are obtained, the current rolling pressure stage of the rolling machine is judged by a floating time proportion method based on the data of the floating time of the gland (60) or a floating height average variance value method based on the data of the floating height of the gland (60).

5. The gantry double-column type rolling machine with floating type gland as claimed in claim 4, wherein: the floating time proportion method comprises the following substeps:

collecting the total time spent by the upward floating of the gland (60) in a specified time period, calculating the proportion eta of the total time spent in the specified time period by the following formula, and comparing the proportion eta with the set twisting pressure stage data to distinguish the twisting pressure stage:

wherein:

t is the duration of a specified time period;

t is the total time consumed by the upward floating of the gland (60);

the floating height mean variance method comprises the following substeps:

collecting the floating heights of the gland (60) in the rolling process in a specified time period, enabling the floating heights to coexist into an array, and then respectively calculating the average value and the variance value of the array; setting rolling pressure stage data, and comparing the average value of the floating heights with the rolling pressure stage data to judge the air pressure and the heavy pressure; the light pressure and the medium pressure are distinguished by comparing the variance value indicating the magnitude of the fluctuation of the pressing cover (60) with the data of the rolling pressure stage.

6. The gantry double-column type rolling machine with floating type gland as claimed in claim 5, characterized in that: after each floating sensor is installed, manually controlling pressure and rolling, separating the whole rolling process by appointed time periods, continuously acquiring floating height data of a gland (60) or floating time data of the gland (60) in the rolling process in each appointed time period, and storing the data by classification marks at the current rolling pressure stage of manually controlling pressure and rolling; then, establishing a convolutional neural network model, and putting the data stored by the classification marks into the convolutional neural network model for deep learning to obtain corresponding model parameters so as to obtain the convolutional neural network model with the corresponding model parameters; and finally, normally testing the floating height data of the gland (60) or the floating time data of the gland (60), and comparing the floating height data or the floating time data with the convolutional neural network model with the model parameters to obtain a result.

7. The gantry double-column type rolling machine with floating type gland as claimed in claim 5, characterized in that: when the floating time proportion method is adopted, the set twisting pressure stage data is as follows: the air pressure stage area is (0, 15% ], the light pressure stage area is (15%, 60% ], the medium pressure stage area is (60%, 98% ], the heavy pressure stage area is (98%, 100%), and the overweight stage area is 100%.

8. The gantry double-column type rolling machine with floating type gland as claimed in claim 5, characterized in that: when the floating height mean variance method is adopted, the set twisting pressure stage data is as follows: the average value area of the air compression stage is (0, 3), the average value area of the heavy compression stage is (20, 27), the average value area of the overweight stage is (27, 30), the variance value is not required to be compared in the above stages, when the average value falls into (3, 20), the variance value is calculated, the light compression stage is in the variance value falling into (0, 15), the medium compression stage is in the variance value larger than 15, and the units of the above numerical values are all mm.

9. The gantry double column type rolling machine with floating gland as claimed in claim 1, 2 or 3, wherein: each floating sensor is a proximity switch or a travel switch or a distance sensor.

10. An automatic rolling method of a gantry double column type rolling machine with floating type gland according to claim 1, 2 or 3, characterized by comprising the steps of:

s1, selecting a twisting curve and starting twisting;

s2, the gland (60) descends and seals the inlet of the kneading barrel (30) for standby;

s3, starting the twisting of the Nth section of the twisting curve;

s4, continuously acquiring data by each floating sensor;

s5, when the current collection period is finished, obtaining the rolling pressure stage of the current rolling machine through the data obtained by the corresponding floating sensor, comparing the current pressure of the current rolling pressure stage with the set pressure of the set rolling pressure stage, if the current pressure is greater than the set pressure, controlling the gland (60) to rise so as to reduce the rolling pressure, if the current pressure is less than the set pressure, controlling the gland (60) to fall so as to increase the rolling pressure, and if the current pressure is equal to the set pressure, entering the next step;

s6, judging whether the current twisting stage is up, if not, returning to the step S4; if yes, entering the next step;

s7, judging whether all the twisting stages are finished, if not, starting the twisting of the next stage of the twisting curve; if yes, ending all rolling stages.

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