CN115349657B - Abnormality early warning system and method for online moisture meter of wire making key process - Google Patents
Abnormality early warning system and method for online moisture meter of wire making key process Download PDFInfo
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- CN115349657B CN115349657B CN202211036394.7A CN202211036394A CN115349657B CN 115349657 B CN115349657 B CN 115349657B CN 202211036394 A CN202211036394 A CN 202211036394A CN 115349657 B CN115349657 B CN 115349657B
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- 238000000034 method Methods 0.000 title claims abstract description 53
- 230000008569 process Effects 0.000 title claims abstract description 25
- 230000005856 abnormality Effects 0.000 title claims abstract description 12
- 239000000463 material Substances 0.000 claims abstract description 83
- 238000001514 detection method Methods 0.000 claims abstract description 38
- 230000007246 mechanism Effects 0.000 claims abstract description 31
- 238000004519 manufacturing process Methods 0.000 claims abstract description 22
- 230000002159 abnormal effect Effects 0.000 claims abstract description 17
- 230000001960 triggered effect Effects 0.000 claims abstract description 11
- 238000013500 data storage Methods 0.000 claims description 7
- 238000012795 verification Methods 0.000 abstract description 6
- 238000001035 drying Methods 0.000 abstract description 4
- 238000005265 energy consumption Methods 0.000 abstract description 3
- 235000019504 cigarettes Nutrition 0.000 description 9
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 6
- 241000208125 Nicotiana Species 0.000 description 5
- 235000002637 Nicotiana tabacum Nutrition 0.000 description 5
- 238000013461 design Methods 0.000 description 3
- 230000000694 effects Effects 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 238000007689 inspection Methods 0.000 description 2
- 238000012423 maintenance Methods 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 230000001953 sensory effect Effects 0.000 description 2
- 230000000391 smoking effect Effects 0.000 description 2
- 238000012935 Averaging Methods 0.000 description 1
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- 238000010276 construction Methods 0.000 description 1
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- 239000000428 dust Substances 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012544 monitoring process Methods 0.000 description 1
- 230000001151 other effect Effects 0.000 description 1
- 238000000643 oven drying Methods 0.000 description 1
- 238000004806 packaging method and process Methods 0.000 description 1
- 238000003908 quality control method Methods 0.000 description 1
- 230000008439 repair process Effects 0.000 description 1
- 239000000779 smoke Substances 0.000 description 1
Classifications
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- A—HUMAN NECESSITIES
- A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
- A24B—MANUFACTURE OR PREPARATION OF TOBACCO FOR SMOKING OR CHEWING; TOBACCO; SNUFF
- A24B9/00—Control of the moisture content of tobacco products, e.g. cigars, cigarettes, pipe tobacco
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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
- A24C5/39—Tobacco feeding devices
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N33/00—Investigating or analysing materials by specific methods not covered by groups G01N1/00 - G01N31/00
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
- G05B19/41875—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by quality surveillance of production
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Abstract
The invention discloses an abnormality early warning system and method for an online moisture meter of a wire making key process, which are mainly designed in that two online moisture meters are used for carrying out online detection and combining the two online moisture meters to set positions, distances and delay time, and moisture detection results of the two online moisture meters for the same material are synchronously collected, so that whether the online moisture meters to be detected are abnormal or not can be timely found in a normal production stage, an early warning signal can be triggered and output when the abnormal condition is detected by a nuclear, and a conveying mechanism corresponding to the production process can be controlled to stop running in a specific production stage, thereby saving the energy consumption of workshops. The invention can conveniently carry out functional stability verification on the online moisture meter when key procedures such as a flavoring machine, a charging machine, sheet drying and the like are in a production state.
Description
Technical Field
The invention relates to the field of cigarette manufacturing, in particular to an on-line moisture meter abnormality early warning system and method for a key cut tobacco manufacturing process.
Background
The key control indexes of the process quality of the cigarette cut-tobacco making link are the water content and the temperature of materials, and for the water content, the online infrared moisture meter can realize non-contact continuous rapid measurement of the water content of the materials, so that the online infrared moisture meter is widely applied to the control points of each key process of the cigarette cut-tobacco making production line (the key process is defined by actual production scenes) so as to realize real-time monitoring and feedback of the water content of the materials. The water content of cut tobacco is used as an important index in tobacco processing, such as the water content of outlets of a cut tobacco drier, a feeder and a flavoring machine, and the processing intensity of the next procedure is related, so that the indexes of cigarette quality, circumference, suction resistance, hardness, dust content, blank and the like of a cigarette in a cigarette packaging machine link are finally influenced, and the smoking quality and smoke release amount of the cigarette are also influenced to a certain extent.
Therefore, how to ensure that the online moisture meter can truly, objectively and accurately reflect the moisture of materials is a key concern for process quality control.
At present, an oven method is mainly used for checking an online moisture meter regularly, an infrared moisture meter for a microwave moisture meter and an infralab710 laboratory, a convection oven drying MT-CA and the like are used for auxiliary checking, and manual judgment is carried out according to a certain checking standard.
However, due to the influences of temperature and humidity changes of workshops, different absorption characteristics of materials, maintenance level of online moisture meter manufacturers, manual verification links and the like, deviation of online moisture meters and true values of the materials can occur; furthermore, as the cut tobacco manufacturing workshop belongs to the assembly line operation, the sensory quality smoking link and the moisture inspection of the finished cigarette products have hysteresis for the inspection work of the corresponding batches, and the deviation of the online moisture meter is combined, the sensory difference among the corresponding batches is likely to be obvious, and the process is very unfavorable for the averaging work of the cigarette products.
Disclosure of Invention
In view of the above, the present invention aims to provide an on-line moisture meter abnormality pre-warning system and method for a wire making key process, so as to solve the above-mentioned technical problems.
The technical scheme adopted by the invention is as follows:
in a first aspect, an abnormality pre-warning system for an online moisture meter for a critical process of wire making, comprising: the device comprises an online moisture meter to be tested, a standby online moisture meter, a material conveying mechanism, a timer, an alarm and a data storage module, wherein an input port and an output port of the material conveying mechanism are respectively connected with a feed roller of a previous process and equipment of a subsequent process;
the standby online moisture meter is arranged above the material conveying mechanism, and is positioned in front of or behind the online moisture meter to be tested according to the running direction of the material conveying mechanism; wherein a preset interval is reserved between the to-be-detected online moisture meter and the standby online moisture meter;
the data storage module is used for storing detection data of the to-be-detected online moisture meter or the standby online moisture meter;
the timer is used for setting the data delay reading time length;
the original machine controller is connected with the material conveying mechanism and the alarm through electric signals and is used for sending a stop signal to the material conveying mechanism and sending a trigger signal to the alarm, so that the alarm outputs early warning information.
In at least one possible implementation manner, the early warning system further comprises: and the roller rotating speed detection unit is electrically connected with the original machine controller and is used for detecting the rotating speed of the feeding roller in the previous working procedure.
In at least one possible embodiment, a first fill level detector and a second fill level detector are each provided above the inlet and outlet of the material conveying means.
In at least one possible implementation, the first level detector and the second level detector are both infrared rangefinders.
In at least one possible implementation manner, the timer is any one of the following: electronic timer, clock module, delay relay.
In at least one possible implementation manner, the early warning system further comprises a trigger button electrically connected with the original machine controller and used for providing an on-off signal of the abnormal early warning function.
In a second aspect, an abnormality pre-warning method for an online moisture meter for a critical process of wire making, comprising:
after detecting that the early warning function starting condition is triggered, acquiring the rotating speed of the roller;
judging the current production state according to the rotating speed of the roller:
when judging that the material is in a normal conveying state currently according to the rotating speed of the roller, collecting and storing detection data of an online moisture meter to be detected or a standby online moisture meter;
synchronously reading the moisture detection value of the online moisture meter to be detected and the standby online moisture meter for the same material based on the preset data delay reading time;
judging whether the online moisture meter to be tested is abnormal or not according to the comparison result of the moisture detection values of the two moisture meters;
if the detected signal is abnormal, outputting an early warning signal;
when the drum is judged to be in a standby state or a material pouring state according to the rotating speed of the drum, acquiring a material level signal of a material conveying inlet and/or a material conveying outlet;
and triggering material conveying shutdown according to the relation between the material level signal and a preset material level threshold value.
In at least one possible implementation manner, the method further includes: after triggering material conveying and stopping, if fluctuation of the indication value of the online moisture meter to be detected is detected, outputting an early warning signal.
The main design concept of the invention is that the two online moisture meters are used for online detection and setting positions, distances and delay time lengths in combination, and the moisture detection results of the two online moisture meters for the same material are synchronously collected, so that whether the online moisture meters to be detected are abnormal or not can be timely found in a normal production stage, when the abnormal condition is detected by a nuclear detection, an early warning signal can be triggered and output, and the conveying mechanism corresponding to the production process can be controlled to stop running in a specific production stage, thereby saving the energy consumption of workshops. The invention can conveniently carry out functional stability verification on the online moisture meter when key procedures such as a flavoring machine, a charging machine, sheet drying and the like are in a production state.
Drawings
For the purpose of making the objects, technical solutions and advantages of the present invention more apparent, the present invention will be further described with reference to the accompanying drawings, in which:
FIG. 1 is a schematic diagram of an architecture of an abnormality pre-warning system of an online moisture meter for a wire making key process provided by an embodiment of the invention;
fig. 2 is a flowchart of an abnormality early warning method of an online moisture meter for a wire making key process according to an embodiment of the present invention.
Detailed Description
Embodiments of the present invention are described in detail below, examples of which are illustrated in the accompanying drawings, wherein like or similar reference numerals refer to like or similar elements or elements having like or similar functions throughout. The embodiments described below by referring to the drawings are illustrative only and are not to be construed as limiting the invention.
The invention provides an embodiment of an abnormality early warning system of an online moisture meter for a wire making key process, specifically, as shown in fig. 1, the system comprises: the device comprises an online moisture meter 1 to be tested, a standby online moisture meter 2, a material conveying mechanism 3 (a belt or a vibrating conveyor according to different working procedures), a timer, an alarm and a data storage module, wherein an input port and an output port of the material conveying mechanism 3 are respectively connected with a previous working procedure feeding roller 100 and a subsequent working procedure device 200;
the online moisture meter 1 to be tested is arranged above the material conveying mechanism 3 and is used for participating in control feedback of the original wire making process;
the standby online moisture meter 2 is arranged above the material conveying mechanism 3 and is positioned before or after the online moisture meter 1 to be tested according to the running direction of the material conveying mechanism 3 (an example positioned behind the online moisture meter to be tested is shown); wherein, a preset interval is arranged between the online moisture meter 1 to be tested and the standby online moisture meter 2;
the data storage module is used for storing detection data (according to the sequence positions of the two detection data) of the online moisture meter 1 to be detected or the standby online moisture meter 2;
in order to synchronize the detection data of the online moisture meter 1 to be detected and the detection data of the standby online moisture meter 2, the timer can set a data delay reading time length, that is, according to the set time length, the detection data of the two detection data read by the original machine controller are for the same material, and it can be understood that the setting of the data delay reading time length is related to the preset interval and the running speed of the material conveying mechanism 3. In actual operation, the timer may be implemented in a manner such as an electronic timer, a clock module, a delay relay, etc.
Continuing the foregoing, it can be understood that, besides being electrically connected with the online moisture meter 1 to be tested, the standby online moisture meter 2, the timer and the data storage module, the original machine controller is also electrically connected with the material conveying mechanism 3 and the alarm respectively, and is used for sending a shutdown signal to the material conveying mechanism 3 and sending a trigger signal to the alarm, so that the alarm outputs early warning information.
In the stage of normal material conveying in the two processes, the online moisture meter 1 to be tested collects the material moisture which needs to participate in the conventional control of the production process, and the standby moisture meter 2 is used as a reference source of moisture detection values, and it can be understood that the two moisture meters are of the same type and are set to be identical, and the moisture values detected by the two moisture meters aiming at the same material object are compared, so that the online check can be performed on whether the online moisture meter 1 to be tested is abnormal or not.
The comparison method of the two to be tested and the standby belongs to the mature technology, for example, but not limited to, the relation between the numerical deviation of the two to be tested and the preset upper deviation threshold and the preset lower deviation threshold can be directly compared (the corresponding required threshold can be calculated according to the history data of different brands in advance), and the relation between the abnormal deviation frequency and the preset times (for example, 5 times, the times can be realized by a counting module connected with an original machine controller) is combined, so that an early warning signal can be sent out through an alarm to prompt an online operator to pay attention to and check in time. The method for checking by adopting two meters with the same specification belongs to the mature technology, the invention is not limited, and the other effect of designing the standby online moisture meter is that if the online moisture meter to be tested is abnormal, the standby online moisture meter can be started to take over the work of the original online moisture meter to be tested, thereby providing a convenient condition for online production without stopping.
Further, the early warning system may further include a drum rotation speed detecting unit electrically connected to the original machine controller, where the drum rotation speed detecting unit is configured to detect a rotation speed of the feeding drum 100 in a previous process, and the rotation speed signal may assist in characterizing the aforementioned "stage of normal material conveying in two processes", for example, detect that the rotation speed of the drum is increased (for example, the normal state of the sheet drying process is 9 r/min), at this time, the material conveying mechanism is triggered to operate, and the material is conveyed to a next process, at this time, the moisture data may be collected and verified by the moisture meter. On the basis of the concept, a first material level detector 4 and a second material level detector 5 (preferably infrared distance measuring instruments) can be arranged above the input port and the output port of the material conveying mechanism 3 so as to trigger the material conveying mechanism to stop in a non-moisture instrument verification stage in combination with the roller state. The following examples are given herein by reference:
the detection signal of the roller rotating speed detection unit indicates that the roller rotating speed is relatively low (such as at or below 6 r/min), at the moment, the first material level detector and the second material level detector detect that the material height is at a certain set limit value or the height change does not exceed a certain set specified value, and at the moment, the original machine controller can trigger the material conveying mechanism to stop running; or, the detection signal of the drum rotation speed detection unit indicates that the drum is in a 'dumping' state, namely, the drum rotation speed is relatively too fast (such as at or above 15 r/min), and at the moment, the height of the material detected by the second material level detector reaches a low limit, so that conveying is triggered to stop.
It should be noted that, considering triggering the material conveying to stop, not only energy is saved, but also the on-line moisture meter to be tested can be checked from another angle, namely, once the material conveying mechanism is triggered to stop, if fluctuation of the indication value of the on-line moisture meter to be tested is detected at this stage, the abnormal operation of the moisture meter is also indicated, and an alarm can be triggered to prompt related personnel to pay attention.
Finally, in some preferred embodiments, the early warning system further includes a trigger button electrically connected to the original machine controller, which can be used as a trigger mechanism for starting and stopping the functions of the system, for example, the system is in a maintenance or repair state in a workshop, and is not suitable for checking the online moisture meter, and the early warning system may be triggered by mistake to output an early warning signal, so that the trigger button can be operated to cut off the corresponding detection early warning function; otherwise, when the online check moisture meter is needed, the trigger button can be operated to start the functions.
In combination with the foregoing embodiments, a preferred embodiment of a complete early warning method is provided herein, as shown in fig. 2, including:
step S1, after detecting that an early warning function starting condition is triggered, acquiring the rotating speed of a roller;
step S2, judging the current production state according to the rotating speed of the roller:
step S31, collecting and storing detection data of an on-line moisture meter to be detected or a standby on-line moisture meter when judging that the material is in a normal conveying state according to the rotating speed of the roller;
step S310, synchronously reading moisture detection values of an online moisture meter to be detected or a standby online moisture meter on the same material based on preset data delay reading time;
step S311, judging whether the online moisture meter to be tested is abnormal or not according to the comparison result of the moisture detection values of the two moisture meters;
if so, executing step S312, and outputting an early warning signal;
step S32, when the drum is judged to be in a standby state or a material pouring state according to the rotating speed of the drum, acquiring a material level signal of a material conveying inlet and/or a material conveying outlet;
and step 320, triggering material conveying shutdown according to the relation between the material level signal and a preset material level threshold value.
Further, the early warning method further comprises: after triggering material conveying and stopping, if fluctuation of the indication value of the online moisture meter to be detected is detected, outputting an early warning signal.
With respect to the foregoing mechanism for storing detection data, specific examples are given herein for illustration: according to the installation positions of the online moisture meter to be detected and the standby online moisture meter relative to the material conveying direction, only detection data with the front relative position can be stored. For example, only the detection data of the moisture meter at the front position is needed to be stored, and after the moisture meter at the rear position detects the data, the detection data of the moisture meter at the front position is read from the storage module according to the set delay reading time length and is compared with the current detection data of the moisture meter at the rear position to finish verification.
In summary, the main design concept of the invention is that the two online moisture meters are used for online detection and combining the two online moisture meters to set positions, distances and delay time, so that the moisture detection results of the two online moisture meters for the same material are synchronously collected, whether the online moisture meters to be detected are abnormal or not can be timely found in a normal production stage, when the abnormal condition is detected by a nuclear detection, an early warning signal can be triggered and output, and the conveying mechanism corresponding to the production process can be controlled to stop running in a specific production stage, so that the energy consumption of workshops is saved. The invention can conveniently carry out functional stability verification on the online moisture meter when key procedures such as a flavoring machine, a charging machine, sheet drying and the like are in a production state.
In the embodiments of the present invention, "at least one" means one or more, and "a plurality" means two or more. "and/or", describes an association relation of association objects, and indicates that there may be three kinds of relations, for example, a and/or B, and may indicate that a alone exists, a and B together, and B alone exists. Wherein A, B may be singular or plural. The character "/" generally indicates that the context-dependent object is an "or" relationship. "at least one of the following" and the like means any combination of these items, including any combination of single or plural items. For example, at least one of a, b and c may represent: a, b, c, a and b, a and c, b and c or a and b and c, wherein a, b and c can be single or multiple.
The construction, features and effects of the present invention are described in detail according to the embodiments shown in the drawings, but the above is only a preferred embodiment of the present invention, and it should be understood that the technical features of the above embodiment and the preferred mode thereof can be reasonably combined and matched into various equivalent schemes by those skilled in the art without departing from or changing the design concept and technical effects of the present invention; therefore, the invention is not limited to the embodiments shown in the drawings, but is intended to be within the scope of the invention as long as changes made in the concept of the invention or modifications to the equivalent embodiments do not depart from the spirit of the invention as covered by the specification and drawings.
Claims (5)
1. An early warning method for an abnormality early warning system of an online moisture meter for a wire making key process is characterized in that the abnormality early warning system of the online moisture meter for the wire making key process comprises the following steps: the device comprises an online moisture meter to be tested, a standby online moisture meter, a material conveying mechanism, a timer, an alarm and a data storage module, wherein an input port and an output port of the material conveying mechanism are respectively connected with a feed roller of a previous process and equipment of a subsequent process;
the standby online moisture meter is arranged above the material conveying mechanism, and is positioned in front of or behind the online moisture meter to be tested according to the running direction of the material conveying mechanism; wherein a preset interval is reserved between the to-be-detected online moisture meter and the standby online moisture meter;
the data storage module is used for storing detection data of the to-be-detected online moisture meter or the standby online moisture meter;
the timer is used for setting the data delay reading time length;
the original machine controller is in electrical signal connection with the material conveying mechanism and the alarm, and is used for sending a stop signal to the material conveying mechanism and sending a trigger signal to the alarm so that the alarm outputs early warning information;
the early warning system further comprises: the rotary speed detection unit of the rotary drum is electrically connected with the original machine controller and is used for detecting the rotary speed of the feeding rotary drum in the previous working procedure, and a first material level detector and a second material level detector are respectively arranged above an input port and an output port of the material conveying mechanism;
the early warning method comprises the following steps:
after detecting that the early warning function starting condition is triggered, acquiring the rotating speed of the roller;
judging the current production state according to the rotating speed of the roller:
when judging that the material is in a normal conveying state currently according to the rotating speed of the roller, collecting and storing detection data of an online moisture meter to be detected or a standby online moisture meter;
synchronously reading the moisture detection value of the online moisture meter to be detected and the standby online moisture meter for the same material based on the preset data delay reading time;
judging whether the online moisture meter to be tested is abnormal or not according to the comparison result of the moisture detection values of the two moisture meters;
if the detected signal is abnormal, outputting an early warning signal;
when the drum is judged to be in a standby state or a material pouring state according to the rotating speed of the drum, acquiring a material level signal of a material conveying inlet and/or a material conveying outlet;
and triggering material conveying shutdown according to the relation between the material level signal and a preset material level threshold value.
2. The method of claim 1, further comprising: after triggering material conveying and stopping, if fluctuation of the indication value of the online moisture meter to be detected is detected, outputting an early warning signal.
3. The method of claim 1 or 2, wherein the first level detector and the second level detector are both infrared rangefinders.
4. The method of claim 1 or 2, wherein the timer is any one of the following: electronic timer, clock module, delay relay.
5. The early warning method according to claim 1 or 2, wherein the early warning system further comprises a trigger button electrically connected with the original machine controller, and the trigger button is used for providing an on-off signal of an abnormal early warning function.
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