A method, system and computer medium for automatically controlling the blending precision of tobacco shreds

Abstract

The present invention provides a method, system and computer medium for automatically controlling the blending precision of tobacco shreds. The method comprises the following steps: S1: the system generates a work order and issues it; S2: the theoretical blending amount is generated according to the work order; S3: the theoretical blending amount of each blending node is generated according to the theoretical blending amount; S4: the system automatically produces according to the work order; S5: the difference between the current actual blending amount and the theoretical blending amount of each blending node in the production process is automatically monitored. If the difference is less than the tolerance value, step S7 is entered; if the difference is greater than the tolerance value, step S6 is entered; S6: the blending ratio is adjusted according to the tolerance value, the blending flow of each blending node is adjusted according to the adjusted blending ratio, and the difference is returned to step S5 to recalculate the difference until the difference is less than the tolerance value; S7: the system produces normally according to the work order until the production is finished. When the difference between the current real-time theoretical blending amount and the current actual blending amount is greater than the tolerance value, the present invention enters flow adjustment to control the blending precision of tobacco shreds.

Description

Technical Field

[0001] The invention relates to the field of tobacco silk making precision control, and more specifically, to a method, system and computer medium for automatic control of tobacco silk making blending precision. Background Art

[0002] In the blending process of the silk-making workshop, due to the different feed amounts and blending ratios for each brand, and the relatively long conveying distance of tobacco, expanded silk, and stem shreds, the conveying length reaches more than 100 meters. If there are abnormal situations such as empty lifting belts or blockages during the process, there will be no alarm prompts. If the abnormal situation is not handled in time, it will cause large fluctuations in accuracy, thus causing problems with blending uniformity. The feedback between the input and output of the system is only whether it has stopped due to accuracy problems, and the system cannot be adjusted according to the deviation. There is a time delay, and the deviation of the output cannot be corrected immediately or the correction amplitude is too large, which may cause the output to be in an oscillating state and the system cannot work normally.

[0003] Taking the blending of expanded silk as an example, when blending is carried out, if the flow rate of the electronic belt scale for the expanded silk blending meets the belt scale flow rate calculated by the program based on the blending ratio, it is judged to be normal operation. Since the amount of material fed in the silk blending process varies depending on the brand, the blending ratio ≠ the formula ratio, so it is common to see accuracy problems caused by the blending ratio during the production process.

[0004] The prior art discloses an online electronic belt scale calibration system and method for the tobacco silk making process. The calibration system uses the material conservation principle to establish a dry material balance mathematical model, obtains the historical value and measured value of the dry material weight through the electronic belt scale set in each section, and then obtains the dry material consumption standard value of each section, the theoretical value of the dry material weight of the electronic belt scale, and the difference between the theoretical value and the measured value through calculation based on the dry material balance mathematical model. Finally, the accuracy of the electronic belt scale is verified by data processing of the difference. This solution only verifies the accuracy of the electronic belt scale and does not involve the relevant content of precision control. Summary of the invention

[0005] The primary purpose of the present invention is to provide a method for automatically controlling the blending precision of tobacco shreds, so as to realize automatic control of the blending precision of tobacco shreds.

[0006] A further object of the present invention is to provide an automatic control system for tobacco shred blending accuracy.

[0007] A third object of the present invention is to provide a computer medium.

[0008] In order to solve the above technical problems, the technical solution of the present invention is as follows:

[0009] A method for automatically controlling the blending precision of tobacco shreds, comprising the following steps:

[0010] S1: The system generates a work order and issues it;

[0011] S2: Generate theoretical blending quantity according to the work order;

[0012] S3: generating a theoretical blending amount of each blending node according to the theoretical blending amount;

[0013] S4: The system automatically produces according to the work order;

[0014] S5: Automatically monitor the difference between the current actual blending amount and the theoretical blending amount of each blending node in the production process. If the difference is less than the tolerance value, proceed to step S7; if the difference is greater than the tolerance value, proceed to step S6;

[0015] S6: Calculate and adjust the blending ratio according to the tolerance value, adjust the blending flow of each blending node according to the adjusted blending ratio, and return to step S5 to recalculate the difference until the difference is less than the tolerance value;

[0016] S7: The system produces normally according to the work order until the production is completed.

[0017] Preferably, each blending node in step S3 includes a shredded stem blending node and a bulked silk blending node.

[0018] Preferably, the calculation formula of the theoretical blending amount of the shredded stem blending node is as follows:

[0019] The amount of shredded stems in the formula = the total amount of formula materials × the proportion of shredded stems in the formula

[0020]

[0021] Real-time theoretical amount of shredded stems = amount of shredded stems mixed in formula ÷ production time

[0022] Set the stem blending flow rate = actual main leaf electronic belt scale flow rate × standard main leaf blending ratio

[0023] Actual amount of stems blended = actual stem blending flow × production time

[0024]

[0025]

[0026] Preferably, the total amount of formula material is set by the tobacco formula, the set stem blending flow rate is calculated by the electronic belt scale through the gravity sensing area and the belt speed ratio, and the actual stem blending amount is calculated by the electronic belt scale through the flow rate and the sensitive time of the gravity sensing area.

[0027] Preferably, the calculation formula of the theoretical blending amount of the expanded fiber blending node is as follows:

[0028] The amount of fiber expansion formula = the total amount of formula materials × the proportion of fiber expansion formula

[0029]

[0030] Set the expansion wire blending flow rate = actual main blade wire scale electronic belt scale flow rate × standard expansion wire blending ratio

[0031] Actual blending amount of expanded wire = actual blending flow rate of expanded wire × production time

[0032]

[0033]

[0034] Preferably, the tolerance value in step S5 is specifically:

[0035] Tolerance value = theoretical blending amount of the formula × 1%.

[0036] Preferably, in step S5, the difference between the current actual blending amount and the theoretical blending amount of each blending node is compared at fixed intervals. If the difference is less than the tolerance value, the process proceeds to step S7; if the difference is greater than the tolerance value, the process proceeds to step S6.

[0037] Preferably, in step S6, the blending ratio is adjusted according to the tolerance value, and the specific calculation formula is as follows:

[0038] Remaining blending amount = theoretical blending amount - real-time actual blending amount Remaining main leaf silk amount = total amount of formula materials - main leaf silk feeding amount

[0039]

[0040] Adjusted blending flow rate = main blade flow rate × adjusted blending ratio.

[0041] An automatic control system for tobacco shred blending precision, comprising:

[0042] A work order issuing module, which is used to generate and issue work orders;

[0043] A theoretical blending amount generation module, wherein the theoretical blending amount generation module generates a theoretical blending amount according to a work order;

[0044] A blending node theoretical blending amount generation module, wherein the blending node theoretical blending amount generation module generates a theoretical blending amount of each blending node according to the theoretical blending amount;

[0045] A production module, which automatically produces according to the work order;

[0046] A monitoring module, wherein the monitoring module automatically monitors the difference between the current actual blending amount and the theoretical blending amount of each blending node in the production process. If the difference is less than the tolerance value, the module switches to the production end module; if the difference is greater than the tolerance value, the module switches to the adjustment module;

[0047] An adjustment module, wherein the adjustment module calculates and adjusts the blending ratio according to the tolerance value, adjusts the blending flow of each blending node according to the adjusted blending ratio, and returns to the monitoring module to recalculate the difference until the difference is less than the tolerance value;

[0048] The production end module performs normal production according to the work order until the production is completed.

[0049] A computer medium stores a computer program, and when the computer program is executed by a processor, the above-mentioned method for automatically controlling the blending accuracy of tobacco shreds is implemented.

[0050] Compared with the prior art, the technical solution of the present invention has the following beneficial effects:

[0051] The present invention compares the current real-time theoretical blending amount with the current actual blending amount. When the difference between the two is greater than the tolerance value, the flow adjustment step is entered to control the blending accuracy of the shredded tobacco. BRIEF DESCRIPTION OF THE DRAWINGS

[0052] Figure 1 It is a schematic diagram of the method flow of the present invention.

[0053] Figure 2 It is a schematic diagram of the system module of the present invention.

[0054] Figure 3 This is a schematic diagram of the device during the tobacco blending process. DETAILED DESCRIPTION

[0055] The drawings are for illustrative purposes only and should not be construed as limiting the present patent;

[0056] In order to better illustrate the present embodiment, some parts in the drawings may be omitted, enlarged or reduced, and do not represent the size of the actual product;

[0057] It is understandable to those skilled in the art that some well-known structures and their descriptions may be omitted in the drawings.

[0058] The technical solution of the present invention is further described below in conjunction with the accompanying drawings and embodiments.

[0059] Example 1

[0060] This embodiment provides a method for automatically controlling the blending precision of tobacco shreds. Figure 1 As shown, the following steps are included:

[0061] S1: The system generates a work order and issues it;

[0062] S2: Generate theoretical blending quantity according to the work order;

[0063] S3: generating a theoretical blending amount of each blending node according to the theoretical blending amount;

[0064] S4: The system automatically produces according to the work order;

[0065] S5: Automatically monitor the difference between the current actual blending amount and the theoretical blending amount of each blending node in the production process. If the difference is less than the tolerance value, proceed to step S7; if the difference is greater than the tolerance value, proceed to step S6;

[0066] S6: Calculate and adjust the blending ratio according to the tolerance value, adjust the blending flow of each blending node according to the adjusted blending ratio, and return to step S5 to recalculate the difference until the difference is less than the tolerance value;

[0067] S7: The system produces normally according to the work order until the production is completed.

[0068] The device for delayed blending in the workshop is as follows: Figure 2 As shown. The blending process history records were extracted from the database and analyzed to find that although the brands and feed amounts were different, the batch production time was the same. Therefore, based on this feature, the current real-time theoretical blending amount and the current actual blending amount were compared every 10 seconds. When the difference between the two was greater than 1% of the theoretical blending amount, the program was triggered to adjust the flow rate to control the accuracy.

[0069] In the step S3, each blending node includes a shredded stem blending node and a bulked silk blending node.

[0070] The calculation formula of the theoretical blending amount of the shredded stem blending node is as follows:

[0071] The amount of shredded stems in the formula = the total amount of formula materials × the proportion of shredded stems in the formula

[0072]

[0073] Real-time theoretical amount of shredded stems = amount of shredded stems mixed in formula ÷ production time

[0074] Set the stem blending flow rate = actual main leaf electronic belt scale flow rate × standard main leaf blending ratio

[0075] Actual amount of stems blended = actual stem blending flow × production time

[0076]

[0077]

[0078] The total amount of formula material is set by the tobacco formula, the set stem blending flow rate is calculated by the electronic belt scale through the gravity sensing area and the belt speed ratio, and the actual stem blending amount is calculated by the electronic belt scale through the flow rate and the sensitive time of the gravity sensing area.

[0079] The calculation formula of the theoretical blending amount of the expanded wire blending node is as follows:

[0080] The amount of fiber expansion formula = the total amount of formula materials × the proportion of fiber expansion formula

[0081]

[0082] Set the expansion wire blending flow rate = actual main blade wire scale electronic belt scale flow rate × standard expansion wire blending ratio. Actual expansion wire blending amount = actual expansion wire blending flow rate × production time.

[0083]

[0084]

[0085] The tolerance value in step S5 is specifically:

[0086] Tolerance value = theoretical blending amount of the formula × 1%.

[0087] In step S5, the difference between the current actual blending amount and the theoretical blending amount of each blending node is compared at fixed intervals. If the difference is less than the tolerance value, the process proceeds to step S7; if the difference is greater than the tolerance value, the process proceeds to step S6.

[0088] In step S6, the blending ratio is calculated and adjusted according to the tolerance value. The specific calculation formula is as follows:

[0089] Remaining blending amount = theoretical blending amount - real-time actual blending amount Remaining main leaf silk amount = total amount of formula materials - main leaf silk feeding amount

[0090]

[0091] Adjusted blending flow rate = main blade flow rate × adjusted blending ratio.

[0092] In a specific embodiment, one year of production data is collected to verify whether the adjustment formula is suitable for production adjustment:

[0093] For example, the formula of a certain brand of stem silk is 10%, the formula of bulked silk is 12%, and the formula of main leaf silk is 78%;

[0094] The total material quantity of the formula is 10000kg, and the production time is 80min;

[0095] To this:

[0096] The theoretical blending amount of shredded stems is 1000kg, the blending ratio is 12.821%, and the tolerance value is 10kg;

[0097] The theoretical blending amount of bulked fiber is 1200kg, the blending ratio is 15.385%, and the tolerance value is 12kg;

[0098] The main blade feeding amount is 7800kg;

[0099] When production reaches 20 minutes:

[0100] The theoretical blending amount of shredded stems is 250kg, and the actual blending amount is 239kg, with a difference of 11kg.

[0101] The theoretical real-time blending amount of the expanded fiber is 300kg, and the actual blending amount is 286kg, with a difference of 14kg.

[0102] The main blade silk has been fed with 1950kg;

[0103] At this time, the difference is greater than the tolerance value, and the system adjusts the blending ratio after judgment;

[0104] At this time, the blending ratio of stem shreds is adjusted to 13.009%. The blending ratio of bulked shreds is adjusted to 15.624%;

[0105] Compare once every 10 seconds. If the difference gradually decreases, continue to run according to the adjusted ratio for 1 minute:

[0106] The theoretical real-time blending amount of shredded stems is 262.5kg, and the actual blending amount is 251.2kg, with a difference of 10.8kg.

[0107] The theoretical real-time blending amount of the expanded fiber is 315kg, and the actual blending amount is 301.2kg, with a difference of 13.8kg.

[0108] The main leaf silk has been fed with 2047.5kg;

[0109] Run for 10 minutes:

[0110] The theoretical real-time blending amount of shredded stems is 375kg, and the actual blending amount is 366kg, with a difference of 9kg.

[0111] The theoretical real-time blending amount of the expanded fiber is 450kg, and the actual blending amount is 438.3kg, with a difference of 11.7kg.

[0112] The main leaf silk has been fed with 2925kg;

[0113] If the difference is smaller than the tolerance value, normal production will be carried out according to the adjusted ratio.

[0114] The comparison is performed every 10 seconds. If the difference gradually increases, the system will readjust the blending ratio.

[0115] Run for 1 minute:

[0116] The theoretical real-time blending amount of shredded stems is 262.5kg, and the actual blending amount is 251.2kg, with a difference of 11.3kg.

[0117] The theoretical real-time blending amount of the expanded fiber is 315kg, and the actual blending amount is 300.3kg, with a difference of 14.7kg.

[0118] The main leaf silk has been fed with 2047.5kg;

[0119] If the difference is greater than the tolerance value, the system will readjust the blending ratio;

[0120] At this time, the blending ratio of stem shreds is adjusted to 13.017%. The blending ratio of bulked shreds is adjusted to 15.640%;

[0121] Compare every 10 seconds and run for 1 minute:

[0122] The theoretical real-time blending amount of shredded stems is 275kg, and the actual blending amount is 263.9kg, with a difference of 11.1kg.

[0123] The theoretical real-time blending amount of the expanded fiber is 330kg, and the actual blending amount is 315.6kg, with a difference of 14.4kg.

[0124] The main leaf silk has been fed with 2143kg;

[0125] Run for 10 minutes:

[0126] The theoretical real-time blending amount of shredded stems is 387.5kg, and the actual blending amount is 378.2kg, with a difference of 9.3kg.

[0127] The theoretical real-time blending amount of the expanded fiber is 465kg, and the actual blending amount is 453.4kg, with a difference of 11.6kg.

[0128] The main leaf silk has been fed with 3022.5kg;

[0129] The difference is smaller than the tolerance value, and production is carried out normally according to the adjusted ratio.

[0130] Example 2

[0131] This embodiment provides a tobacco shred blending precision automatic control system, such as Figure 2 As shown, including:

[0132] A work order issuing module, which is used to generate and issue work orders;

[0133] A theoretical blending amount generation module, wherein the theoretical blending amount generation module generates a theoretical blending amount according to a work order;

[0134] A blending node theoretical blending amount generation module, wherein the blending node theoretical blending amount generation module generates a theoretical blending amount of each blending node according to the theoretical blending amount;

[0135] A production module, which automatically produces according to the work order;

[0136] A monitoring module, wherein the monitoring module automatically monitors the difference between the current actual blending amount and the theoretical blending amount of each blending node in the production process. If the difference is less than the tolerance value, the module switches to the production end module; if the difference is greater than the tolerance value, the module switches to the adjustment module;

[0137] An adjustment module, wherein the adjustment module calculates and adjusts the blending ratio according to the tolerance value, adjusts the blending flow of each blending node according to the adjusted blending ratio, and returns to the monitoring module to recalculate the difference until the difference is less than the tolerance value;

[0138] The production end module performs normal production according to the work order until the production is completed.

[0139] Each blending node in the blending node theoretical blending amount generation module includes a stem silk blending node and a bulked silk blending node.

[0140] The calculation formula of the theoretical blending amount of the shredded stem blending node is as follows:

[0141] The amount of shredded stems in the formula = the total amount of formula materials × the proportion of shredded stems in the formula

[0142]

[0143] Real-time theoretical amount of shredded stems = amount of shredded stems mixed in formula ÷ production time

[0144] Set the stem blending flow rate = actual main leaf electronic belt scale flow rate × standard main leaf blending ratio

[0145] Actual amount of stems blended = actual stem blending flow × production time

[0146]

[0147]

[0148] The total amount of formula materials is set by the tobacco formula, the set stem blending flow rate is calculated by the electronic belt scale through the gravity sensing area and the belt speed ratio, and the actual stem blending amount is calculated by the electronic belt scale through the flow rate and the sensitive time of the gravity sensing area.

[0149] The calculation formula of the theoretical blending amount of the expanded wire blending node is as follows:

[0150] The amount of fiber expansion formula = the total amount of formula materials × the proportion of fiber expansion formula

[0151]

[0152] Set the expansion wire blending flow rate = actual main blade wire scale electronic belt scale flow rate × standard expansion wire blending ratio

[0153] Actual blending amount of expanded wire = actual blending flow rate of expanded wire × production time

[0154]

[0155]

[0156] The tolerance values ​​in the step monitoring module are as follows:

[0157] Tolerance value = theoretical blending amount of the formula × 1%.

[0158] In the step monitoring module, the difference between the current actual blending amount and the theoretical blending amount of each blending node is compared at fixed intervals. If the difference is less than the tolerance value, it goes to the production end module; if the difference is greater than the tolerance value, it goes to the adjustment module.

[0159] In the step adjustment module, the blending ratio is calculated and adjusted according to the tolerance value. The specific calculation formula is as follows:

[0160] Remaining blending amount = theoretical blending amount - real-time actual blending amount

[0161] The remaining amount of main leaf silk = the total amount of formula materials - the amount of main leaf silk input

[0162]

[0163] Adjust the blending flow rate = main blade flow rate × adjust the blending ratio

[0164] Example 3

[0165] This embodiment provides a computer medium, which stores a computer program. When the computer program is executed by a processor, the method for automatically controlling the blending accuracy of tobacco shreds described in Example 1 is implemented.

[0166] The same or similar reference numerals correspond to the same or similar components;

[0167] The terms used in the drawings to describe positional relationships are only used for illustrative purposes and should not be construed as limiting this patent;

[0168] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the embodiments of the present invention. For those skilled in the art, other different forms of changes or modifications can be made based on the above description. It is not necessary and impossible to list all the embodiments here. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the protection scope of the claims of the present invention.

Claims

1. A method for automatically controlling the blending precision of tobacco shreds, characterized in that: The following steps are involved: S1: The system generates a work order and issues it; S2: Generate theoretical blending quantity according to the work order; S3: generating a theoretical blending amount of each blending node according to the theoretical blending amount; S4: The system automatically produces according to the work order; S5: Automatically monitor the difference between the current actual blending amount and the theoretical blending amount of each blending node in the production process. If the difference is less than the tolerance value, proceed to step S7; if the difference is greater than the tolerance value, proceed to step S6; S6: Calculate and adjust the blending ratio according to the tolerance value, adjust the blending flow of each blending node according to the adjusted blending ratio, and return to step S5 to recalculate the difference until the difference is less than the tolerance value; S7: The system produces normally according to the work order until the production is completed; In step S3, each blending node includes a stem silk blending node and a bulked silk blending node; The calculation formula of the theoretical blending amount of the shredded stem blending node is as follows: The amount of shredded stems in the formula = the total amount of formula materials × the proportion of shredded stems in the formula Real-time theoretical amount of stem shreds blended = amount of stem shreds blended in formula ÷ production time setting stem shreds blending flow = actual main leaf shreds electronic belt scale flow × standard main leaf shreds blending ratio Actual amount of stems blended = actual stem blending flow × production time The calculation formula of the theoretical blending amount of the expanded wire blending node is as follows: The amount of fiber expansion formula = the total amount of formula materials × the proportion of fiber expansion formula Set the expansion wire blending flow rate = actual main blade wire scale electronic belt scale flow rate × standard expansion wire blending ratio Actual blending amount of expanded wire = actual blending flow rate of expanded wire × production time In step S6, the blending ratio is calculated and adjusted according to the tolerance value. The specific calculation formula is as follows: Remaining blending amount = theoretical blending amount - real-time actual blending amount The remaining amount of main leaf silk = the total amount of formula materials - the amount of main leaf silk input Adjust the blending flow rate = main blade flow rate × adjust the blending ratio.

2. The method for automatically controlling the blending precision of tobacco shreds according to claim 1, characterized in that: The total amount of formula material is set by the tobacco formula, the set stem blending flow rate is calculated by the electronic belt scale through the gravity sensing area and the belt speed ratio, and the actual stem blending amount is calculated by the electronic belt scale through the flow rate and the sensitive time of the gravity sensing area.

3. The method for automatically controlling the blending precision of tobacco shreds according to claim 2, characterized in that: The tolerance value in step S5 is specifically: Tolerance value = theoretical blending amount of the formula × 1%.

4. The method for automatically controlling the blending precision of tobacco shreds according to claim 3, characterized in that: In step S5, the difference between the current actual blending amount and the theoretical blending amount of each blending node is compared at fixed intervals. If the difference is less than the tolerance value, the process proceeds to step S7; if the difference is greater than the tolerance value, the process proceeds to step S6.

5. An automatic control system for tobacco shred blending precision, characterized in that: The system applies the method for automatically controlling the blending precision of tobacco shreds according to any one of claims 1 to 4, comprising: A work order issuing module, which is used to generate and issue work orders; A theoretical blending amount generation module, wherein the theoretical blending amount generation module generates a theoretical blending amount according to a work order; A blending node theoretical blending amount generation module, wherein the blending node theoretical blending amount generation module generates a theoretical blending amount of each blending node according to the theoretical blending amount; A production module, which automatically produces according to the work order; A monitoring module, wherein the monitoring module automatically monitors the difference between the current actual blending amount and the theoretical blending amount of each blending node in the production process. If the difference is less than the tolerance value, the module switches to the production end module; if the difference is greater than the tolerance value, the module switches to the adjustment module; An adjustment module, wherein the adjustment module calculates and adjusts the blending ratio according to the tolerance value, adjusts the blending flow of each blending node according to the adjusted blending ratio, and returns to the monitoring module to recalculate the difference until the difference is less than the tolerance value; The production end module performs normal production according to the work order until the production is completed.

6. A computer medium, characterized in that The computer medium stores a computer program, and when the computer program is executed by a processor, the method for automatically controlling the tobacco shred blending accuracy according to any one of claims 1 to 4 is implemented.

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