A Status Diagnosis System and Method for the Cigarette Packet Group Input Unit of a FOCKE Packing Machine

Abstract

A status diagnosis system and method for the cigarette packet group input unit of a FOCKE packaging machine, device: The PLC controller is respectively connected to a computer, a digital input module, an analog input module, an ELAU servo drive system and 413 packaging machines; The digital input module is respectively connected to a zero position sensor one, a zero position sensor two and a zero position sensor three; The analog input module is connected to the main encoder. Method: Start and detect whether the inlet system of the 413 packaging machines works normally. After an abnormality, start the diagnosis process; Compare the mechanical zero position with the zero position electrical angle and adjust them to be consistent; Detect the status of the missing packet detector and ensure its normal status; Detect whether the tipping station motor controller, the cigarette packet extractor motor controller, the cigarette packet conveyor motor controller and the cigarette group conveyor motor controller are synchronized, and synchronize them when they are not synchronized. The device and method can quickly and effectively detect faults in the cigarette packet input unit of the FOCKE 413 packaging machines.

Description

Technical Field

[0001] The present invention belongs to the technical field of cigarette-making equipment, and particularly relates to a status diagnosis system and method for the cigarette packet input unit of a FOCKE packaging machine. Background Art

[0002] The FOCKE 413 carton-packaging machine completes the functions of carton and carton transparent paper packaging for the FXS packaging unit. Its inlet unit has a relatively complex structure. It extracts qualified cigarette packets from the upstream machine, flips and combines them into a cigarette packet group of two layers with 10 boxes each, and then conveys them to the subsequent workstations. During the process from a single cigarette packet to the formation of a cigarette packet group, four servo motors drive belts and mechanical components to complete various functions, namely the tipping station motor, the cigarette packet extractor motor, the cigarette packet conveyor belt motor, and the cigarette packet group conveyor belt motor. The entire cigarette packet input system works synchronously and coordinately. However, during the operation of the equipment, due to various factors, it is easy to cause disharmony in the cigarette packet group input unit, resulting in frequent servo drive failures of the input device, faultless rejection of cigarette packet groups, and faults such as detection of carton trademark paper and self-checking at subsequent workstations in the 413 inlet part, causing disorder in the cigarette packet input system and seriously affecting the equipment efficiency. However, tiny misalignments are not obvious mechanically, and it is also very difficult to reflect in the parameter settings of the electrical cam. This has led to a wide range of troubleshooting for such faults, great difficulty in handling, long time consumption, and even difficulty in fundamentally solving such faults. Summary of the Invention

[0003] In view of the problems existing in the above-mentioned prior art, the present invention provides a status diagnosis system and method for the cigarette packet input unit of a FOCKE packaging machine. The device and method can quickly and effectively detect faults in the cigarette packet input unit of the FOCKE 413 carton-packaging machine; the method steps are simple and can efficiently and accurately detect faults in the cigarette packet input unit of the FOCKE 413 carton-packaging machine.

[0004] The present invention provides a status diagnosis system for the cigarette packet input unit of a FOCKE packaging machine, including a PLC controller, a computer, a digital input module, an analog input module, an ELAU servo drive system, a zero position sensor one, a zero position sensor two, and a zero position sensor three;

[0005] The PLC controller is respectively connected to the computer, the digital input module, the analog input module, the ELAU servo drive system, and the 413 carton-packaging machine;

[0006] The zero position sensor one is fixedly installed on one side above the cigarette packet group conveyor belt, and a plurality of metal blocks one cooperating with the zero position sensor one are evenly installed on the cigarette packet group conveyor belt;

[0007] The zero position sensor two is fixedly installed on one side above the tipping station, and a plurality of metal blocks two cooperating with the zero position sensor two are evenly installed on the tipping station;

[0008] The zero position sensor three is fixedly installed on one side below the cigarette packet extractor, and a plurality of metal blocks three which are matched with the zero position sensor two are evenly installed on the cigarette packet extractor;

[0009] The digital quantity input module is respectively connected with the zero position sensor one, the zero position sensor two, the zero position sensor three and the missing packet detector of the 413-packaging machine;

[0010] The analog quantity input module is connected with the main encoder on the 413-packaging machine;

[0011] The ELAU servo drive system is respectively connected with the tipping station motor controller, the cigarette packet extractor motor controller, the cigarette packet conveyor motor controller and the cigarette group conveyor motor controller.

[0012] As a preference, the zero position sensor one, the zero position sensor two and the zero position sensor three are all non-contact zero position sensors.

[0013] The structure of the present invention is simple. By adding the zero position sensors one, two and three, the mechanical zero positions one, two and three of the cigarette group conveyor belt, the tipping station and the cigarette packet extractor can be respectively obtained in real time. Furthermore, it is beneficial to respectively compare the mechanical zero positions one, two and three with the zero position electrical angles in real time, and when they are inconsistent, the deviation data can be displayed through the PLC controller. Furthermore, it is beneficial to diagnose whether the fault is related to the mechanical zero position. Connecting the missing packet detector with the PLC controller through the digital quantity input module can conveniently obtain the running state of the missing packet detector, and thus it is beneficial to diagnose whether the fault is related to the missing packet detector; connecting the PLC controller with the tipping station motor controller, the cigarette packet extractor motor controller, the cigarette packet conveyor motor controller and the cigarette group conveyor motor controller through the ELAU servo drive system can not only conveniently control the connection of the tipping station motor controller, the cigarette packet extractor motor controller, the cigarette packet conveyor motor controller and the cigarette group conveyor motor controller, but also conveniently enable the PLC controller to obtain the running parameters of the connection of the tipping station motor controller, the cigarette packet extractor motor controller, the cigarette packet conveyor motor controller and the cigarette group conveyor motor controller, so that it can conveniently diagnose whether the fault is related to the running state of the connection of the tipping station motor controller, the cigarette packet extractor motor controller, the cigarette packet conveyor motor controller and the cigarette group conveyor motor controller. This system is beneficial to conveniently and quickly diagnose the source of the fault, can effectively solve the maintenance problem, and helps to improve the maintenance efficiency.

[0014] The present invention also provides a method for diagnosing the state of the cigarette packet group input unit of a FOCKE packaging machine, including the following steps:

[0015] Step 1: Control the start of the 413-packaging machine through the PLC controller;

[0016] Step 2: Detect whether the 413-packaging machine inlet system is working properly. When it is normal, keep the 413-packaging machine running normally. When it is abnormal, control the 413-packaging machine to stop and execute Step 3;

[0017] Step 3: Conduct the first-level diagnosis; obtain the mechanical zero position 1 of the cigarette group conveyor belt, the mechanical zero position 2 of the tipping station, and the mechanical zero position 3 of the cigarette pack extractor through the zero position electrical signal 1, zero position electrical signal 2, and zero position electrical signal 3, and obtain the zero position electrical angle of the 413-packaging machine through the main encoder; compare the mechanical zero position 1 with the zero position electrical angle, compare the mechanical zero position 2 with the zero position electrical angle, and compare the mechanical zero position with the zero position electrical angle 3. If they are all consistent, execute Step 4; if the mechanical zero position 1 is inconsistent with the zero position electrical angle, control the cigarette group conveyor belt motor through the ELAU servo drive system to perform mechanical position calibration and adjustment until the mechanical zero position 1 is consistent with the zero position electrical angle. If the mechanical zero position 2 is inconsistent with the zero position electrical angle 2, control the tipping station motor through the ELAU servo drive system to perform mechanical position calibration and adjustment until the mechanical zero position 2 is consistent with the zero position electrical angle. If the mechanical zero position 3 is inconsistent with the zero position electrical angle 3, control the cigarette pack extractor motor through the ELAU servo drive system to perform mechanical position calibration and adjustment until the mechanical zero position 3 is consistent with the zero position electrical angle. After they are all consistent, execute Step 4;

[0018] Step 4: Conduct the second-level diagnosis; within the set detection range, check whether the working status of the cigarette pack group missing pack detector is normal. If the status is normal, directly execute Step 5. If the status is abnormal, adjust the missing pack detector to make its working status normal. After the working status of the missing pack detector is normal, execute Step 5;

[0019] Step 5: Conduct the third-level diagnosis; collect the operating parameters of the tipping station motor, cigarette pack extractor motor, cigarette pack conveyor motor, and cigarette group conveyor motor through the ELAU servo drive system, and judge whether the operation of the tipping station motor, cigarette pack extractor motor, cigarette pack conveyor motor, and cigarette group conveyor motor is synchronized. If the operation is synchronized, save the current operating parameters and end the diagnosis process; when it is not synchronized, the PLC controller issues the deviation data of non-synchronization, and the ELAU servo drive system repeatedly adjusts according to the received deviation data until the operation is synchronized, saves the current operating parameters and ends the diagnosis process.

[0020] Furthermore, for convenient real-time observation, in Step 5, the operating parameters of the tipping station motor, cigarette pack extractor motor, cigarette pack conveyor motor, and cigarette group conveyor motor are displayed in real time through a computer.

[0021] The steps of the present invention are simple. By adding a zero-point sensor and electrical angle, it can achieve rapid diagnosis of faults in the cigarette packet group input unit. This method can achieve rapid and accurate diagnosis of faults in the cigarette packet group inlet system of 413 packaging machines through step-by-step hierarchical diagnosis without affecting the original control functions of the machine, effectively solving the maintenance problem and greatly improving the maintenance efficiency. Description of the Drawings

[0022] Figure 1 is the circuit principle block diagram of the present invention;

[0023] Figure 2 is the schematic diagram of the cooperation between the cigarette group conveyor belt and the zero-position electrical signal one in the present invention;

[0024] Figure 3 is the schematic diagram of the cooperation between the tipping station and the zero-position electrical signal two in the present invention;

[0025] Figure 4 is the schematic diagram of the cooperation between the cigarette packet extractor and the zero-position electrical signal three in the present invention;

[0026] Figure 5 is the flowchart of the diagnostic method in the present invention.

[0027] In the figure: 1. Cigarette group conveyor belt, 2. Tipping station, 3. Cigarette packet extractor, 4. Zero-position sensor one, 5. Zero-position sensor two, 6. Zero-position sensor three. Detailed Embodiment

[0028] The present invention will be further described below with reference to the accompanying drawings.

[0029] As Figures 1 to 4 shown, a state diagnostic system for the cigarette packet group input unit of a FOCKE packaging machine includes a PLC controller, a computer, a digital input module, an analog input module, an ELAU servo drive system, a zero-position sensor one, a zero-position sensor two, and a zero-position sensor three;

[0030] The PLC controller is respectively connected to the computer, the digital input module, the analog input module, the ELAU servo drive system, and the 413 packaging machines;

[0031] The zero-position sensor one is fixedly installed on one side above the cigarette group conveyor belt, and a plurality of metal blocks one cooperating with the zero-position sensor one are evenly installed on the cigarette group conveyor belt. The zero-position sensor one is used to send a zero-position electrical signal one to the digital input module when detecting that any one of the metal blocks one runs directly below;

[0032] The second zero - position sensor is fixedly installed on one side above the tipping station. A plurality of second metal blocks, which cooperate with the second zero - position sensor, are evenly installed on the tipping station. The second zero - position sensor is used to send a second zero - position electrical signal to the digital input module when it detects that any one of the second metal blocks runs directly below it;

[0033] The third zero - position sensor is fixedly installed on one side below the cigarette packet extractor. A plurality of third metal blocks, which cooperate with the second zero - position sensor, are evenly installed on the cigarette packet extractor. The third zero - position sensor is used to send a third zero - position electrical signal to the digital input module when it detects that any one of the third metal blocks runs directly below it;

[0034] The digital input module is respectively connected to the first zero - position sensor, the second zero - position sensor, the third zero - position sensor and the missing - packet detector of the 413 - type packaging machine. The digital input module is respectively used to send the received first zero - position electrical signal, second zero - position electrical signal, third zero - position electrical signal and the working - state signal sent by the missing - packet detector to the PLC controller;

[0035] The analog input module is connected to the main encoder on the 413 - type packaging machine, and is used to receive the main encoding signal collected by the main encoder and send the received third main encoding signal to the PLC controller;

[0036] The ELAU servo drive system is respectively connected to the tipping - station motor controller, cigarette - packet extractor motor controller, cigarette - packet conveyor motor controller and cigarette - group conveyor motor controller. It is used to respectively collect the running parameters of the tipping - station motor, cigarette - packet extractor motor, cigarette - packet conveyor motor and cigarette - group conveyor motor, and is used to judge whether the running of the tipping - station motor, cigarette - packet extractor motor, cigarette - packet conveyor motor and cigarette - group conveyor motor is synchronous. When they are not synchronous, it sends out deviation data of non - synchronization through the PLC controller. The ELAU servo drive system repeatedly adjusts according to the received deviation data until the running is synchronous. At the same time, it is used to send the collected running parameters of the tipping - station motor, extractor motor, cigarette - packet conveyor motor and cigarette - group conveyor motor to the PLC controller, and is used to control the tipping - station motor, extractor motor, cigarette - packet conveyor motor and cigarette - group conveyor motor according to the control of the PLC controller;

[0037] The PLC controller is used to obtain the mechanical zero position one of the cigarette group conveyor belt, the mechanical zero position two of the tipping station, and the mechanical zero position three of the cigarette pack extractor according to the received zero position electrical signal one, zero position electrical signal two, and zero position electrical signal three; to obtain the zero position electrical angle of the 413-packaging machine according to the received main coding signal; to compare the mechanical zero position one with the zero position electrical angle, and when the mechanical zero position one is inconsistent with the zero position electrical angle, control the cigarette group conveyor belt motor through the ELAU servo drive system to perform mechanical position calibration adjustment until the mechanical zero position one is consistent with the zero position electrical angle; to compare the mechanical zero position two with the zero position electrical angle, and when the mechanical zero position two is inconsistent with the zero position electrical angle, control the tipping station motor through the ELAU servo drive system to perform mechanical position calibration adjustment until the mechanical zero position two is consistent with the zero position electrical angle; to compare the mechanical zero position three with the zero position electrical angle, and when the mechanical zero position three is inconsistent with the zero position electrical angle, control the cigarette pack extractor motor through the ELAU servo drive system to perform mechanical position calibration adjustment until the mechanical zero position three is consistent with the zero position electrical angle; to control the start and stop of the 413-packaging machine, and to collect the operation status signals of the 413-packaging machine; to receive the signals collected by the ELAU servo drive system, and to send control signals to the ELAU servo drive system.

[0038] As a preference, the zero position sensor one, zero position sensor two, and zero position sensor three are all non-contact zero position sensors.

[0039] By adding external zero position sensors 1, 2, and 3, the mechanical zero positions 1, 2, and 3 of the cigarette group conveyor belt, tipping station, and cigarette pack extractor can be obtained in real time respectively. Furthermore, it is beneficial to compare the mechanical zero positions 1, 2, and 3 with the zero position electrical angles in real time, and when they are inconsistent, the corresponding motors can be adjusted through the ELAU servo drive system to make the mechanical zero position consistent with the zero position electrical angle, which is conducive to diagnosing whether the fault is related to the mechanical zero position. Connect the missing pack detector to the PLC controller through the digital input module, and the operating status of the missing pack detector can be easily obtained, which is conducive to diagnosing whether the fault is related to the missing pack detector; connect the PLC controller to the tipping station motor controller, cigarette pack extractor motor controller, cigarette pack conveyor motor controller, and cigarette group conveyor motor controller through the ELAU servo drive system. This can not only facilitate the control of the connection of the tipping station motor controller, cigarette pack extractor motor controller, cigarette pack conveyor motor controller, and cigarette group conveyor motor controller, but also enable the PLC controller to obtain the operating parameters of the connection of the tipping station motor controller, cigarette pack extractor motor controller, cigarette pack conveyor motor controller, and cigarette group conveyor motor controller, so as to easily diagnose whether the fault is related to the operating status of the connection of the tipping station motor controller, cigarette pack extractor motor controller, cigarette pack conveyor motor controller, and cigarette group conveyor motor controller. This system is conducive to quickly diagnosing the source of the fault, effectively solving the maintenance problem, and helping to improve the maintenance efficiency.

[0040] The main factors causing faults in the cigarette pack input unit of the FOCKE 413 cartoner are as follows: (1) The working state of the missing pack detector is abnormal, such as the detector itself being in an abnormal state or the electrical cam being set improperly. (2) The four servo motors do not work in a coordinated manner, and the mechanical and zero position electrical angles are inconsistent. There are many influencing factors in this regard, and small mechanical misalignments cannot be clearly reflected during the operation of the equipment. In the past, traditional methods had no reference standards and could not accurately detect faults.

[0041] To solve the above problems, as Figure 5 shown, the present invention also provides a method for diagnosing the state of the cigarette pack group input unit of a FOCKE cartoner, including the following steps:

[0042] Step 1: Control the start of the 413 cartoner through the PLC controller;

[0043] Step 2: Detect whether the inlet system of the 413 cartoner is working properly. When it is normal, keep the 413 cartoner running normally. When it is abnormal, control the 413 cartoner to stop and execute Step 3;

[0044] Step 3: Conduct the first-level diagnosis; obtain the mechanical zero position 1 of the cigarette group conveyor belt, the mechanical zero position 2 of the tipping station, and the mechanical zero position 3 of the cigarette pack extractor through zero position electrical signal 1, zero position electrical signal 2, and zero position electrical signal 3, and obtain the zero position electrical angle of the 413-packaging machine through the main encoder; compare the mechanical zero position 1 with the zero position electrical angle, compare the mechanical zero position 2 with the zero position electrical angle, and compare the mechanical zero position 3 with the zero position electrical angle. If they are all consistent, execute Step 4; if the mechanical zero position 1 is inconsistent with the zero position electrical angle, control the cigarette group conveyor belt motor through the ELAU servo drive system to perform mechanical position calibration and adjustment until the mechanical zero position 1 is consistent with the zero position electrical angle. If the mechanical zero position 2 is inconsistent with the zero position electrical angle 2, control the tipping station motor through the ELAU servo drive system to perform mechanical position calibration and adjustment until the mechanical zero position 2 is consistent with the zero position electrical angle. If the mechanical zero position 3 is inconsistent with the zero position electrical angle 3, control the cigarette pack extractor motor through the ELAU servo drive system to perform mechanical position calibration and adjustment until the mechanical zero position 3 is consistent with the zero position electrical angle. After they are all consistent, execute Step 4;

[0045] Step 4: Conduct the second-level diagnosis; within the set detection range, check whether the working state of the cigarette pack group missing pack detector is normal. If the state is normal, directly execute Step 5. If the state is abnormal, adjust the missing pack detector to make its working state normal. After the working state of the missing pack detector is normal, execute Step 5;

[0046] Step 5: Conduct the third-level diagnosis; collect the operating parameters of the tipping station motor, cigarette pack extractor motor, cigarette pack conveyor motor, and cigarette group conveyor motor through the ELAU servo drive system, and judge whether the operation of the tipping station motor, cigarette pack extractor motor, cigarette pack conveyor motor, and cigarette group conveyor motor is synchronous. If the operation is synchronous, save the current operating parameters and end the diagnosis process; when it is not synchronous, send out the deviation data of non-synchronization through the PLC controller, and the ELAU servo drive system repeatedly adjusts according to the received deviation data until the operation is synchronous, save the current operating parameters and end the diagnosis process.

[0047] For convenient real-time observation, in Step 5, the operating parameters of the tipping station motor, cigarette pack extractor motor, cigarette pack conveyor motor, and cigarette group conveyor motor are displayed in real time through the computer.

[0048] The steps of the present invention are simple. By adding an external zero-point sensor and electrical angle, it can achieve rapid diagnosis of faults in the cigarette pack group input unit. This method can realize rapid and accurate diagnosis of faults in the cigarette pack group inlet system of the 413-packaging machine through a step-by-step hierarchical diagnosis method without affecting the various control functions of the original machine, effectively solving the maintenance problem and greatly improving the maintenance efficiency.

Claims

1. A method for diagnosing the state of the cigarette pack group input unit of a FOCKE packaging machine, characterized in that, it includes the following steps: Step 1: Control the start of the 413-packaging machine through the PLC controller; Step 2: Detect whether the inlet system of the 413-packaging machine is working properly. When it is normal, keep the 413-packaging machine running normally. When it is abnormal, control the 413-packaging machine to stop and execute Step 3; Step 3: Conduct the first-level diagnosis; obtain the mechanical zero position 1 of the cigarette group conveyor belt, the mechanical zero position 2 of the tipping station, and the mechanical zero position 3 of the cigarette pack extractor through the zero position electrical signal 1, zero position electrical signal 2, and zero position electrical signal 3, and obtain the zero position electrical angle of the 413-packaging machine through the main encoder; compare the mechanical zero position 1 with the zero position electrical angle, compare the mechanical zero position 2 with the zero position electrical angle, and compare the mechanical zero position 3 with the zero position electrical angle. If they are all consistent, execute Step 4; if the mechanical zero position 1 is inconsistent with the zero position electrical angle, control the cigarette group conveyor belt motor through the ELAU servo drive system to perform mechanical position calibration and adjustment until the mechanical zero position 1 is consistent with the zero position electrical angle. If the mechanical zero position 2 is inconsistent with the zero position electrical angle, control the tipping station motor through the ELAU servo drive system to perform mechanical position calibration and adjustment until the mechanical zero position 2 is consistent with the zero position electrical angle. If the mechanical zero position 3 is inconsistent with the zero position electrical angle, control the cigarette pack extractor motor through the ELAU servo drive system to perform mechanical position calibration and adjustment until the mechanical zero position 3 is consistent with the zero position electrical angle. After they are all consistent, execute Step 4; Step 4: Conduct the second-level diagnosis; within the set detection range, check whether the working state of the cigarette pack group missing pack detector is normal. If the state is normal, directly execute Step 5. If the state is abnormal, adjust the missing pack detector to make its working state normal. After the working state of the missing pack detector is normal, execute Step 5; Step 5: Conduct the third-level diagnosis; collect the operating parameters of the tipping station motor, cigarette pack extractor motor, cigarette pack conveyor motor, and cigarette group conveyor motor through the ELAU servo drive system, and judge whether the operation of the tipping station motor, cigarette pack extractor motor, cigarette pack conveyor motor, and cigarette group conveyor motor is synchronized. If the operation is synchronized, save the current operating parameters and end the diagnosis process; when it is not synchronized, the PLC controller issues the deviation data of non-synchronization, and the ELAU servo drive system repeatedly adjusts according to the received deviation data until the operation is synchronized, saves the current operating parameters and ends the diagnosis process.

2. A method for diagnosing the state of the cigarette pack group input unit of a FOCKE packaging machine according to claim 1, characterized in that, in Step 5, the operating parameters of the tipping station motor, cigarette pack extractor motor, cigarette pack conveyor motor, and cigarette group conveyor motor are displayed in real time through a computer.

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