Punching blade shape control process based on punching guidance technology

Abstract

The present invention provides a leaf shape control process method based on punching guidance technology, which helps to improve the middle piece rate and helps to effectively control the shape of the punched tobacco leaves. The specific method of the present invention is to set a leaf punching process before the leaf beating process. A series of holes are punched on the flattened tobacco leaves using a punching device to form patterns of several specific shapes, such as triangles, quadrilaterals, pentagons, hexagons, etc., or combinations thereof. The shapes, sizes, and combinations of these patterns are adjustable and controllable, or determined according to the requirements of customers (i.e., cigarette companies). The pre-punched tobacco leaves are transported to the leaf beating process. In the leaf beating process, due to the guiding effect of the weak strength lines formed by the punching, the position where the tobacco leaves are torn will tend to be along a predetermined line, thereby achieving the purpose of controlling the leaf shape and improving the middle piece rate.

Description

Technical Field

[0001] The invention belongs to the technical field of tobacco processing technology, and in particular relates to a sheet shape control process in a leaf threshing and re-roasting process. Background Art

[0002] The raw materials used by modern cigarette industry enterprises have been improved from whole tobacco to sheet tobacco. The so-called sheet tobacco is the main product processed by the redrying enterprises after the tobacco leaves are purchased, and then processed through the process of beating and redrying. The beating and redrying process determines the quality of the sheet tobacco, which in turn affects the quality of the tobacco shreds of the cigarette enterprises. The overlong or overshort tobacco shreds cut from the overlarge or undersized sheet tobacco are likely to cause serious quality problems in the rolled cigarettes.

[0003] The shape of tobacco leaves is determined by the processing process, mainly the threshing process. Threshing refers to the process of cutting off the petiole and tip of the tobacco leaves, removing the veins and forming tobacco leaves. In this process, the tobacco leaves are torn at high speed in a special threshing frame to form leaves of various shapes and sizes. These leaves of different shapes and sizes are re-baked to remove some of the moisture, and then packaged to become threshed and re-baked products, which are supplied to cigarette companies for shredding and cigarette making.

[0004] In order to produce high-quality products, cigarette companies have certain requirements on the shape of incoming tobacco slices, generally requiring as many medium slices as possible, and as few large slices, small slices and fragments as possible. Summary of the invention

[0005] In order to solve the problems in the prior art that the sheet shape cannot be controlled, the middle sheet rate is low, and it is difficult to adapt to the needs of cigarette silk production, the present invention provides a processing process for tobacco leaves before threshing, which helps to improve the middle sheet rate and help to effectively control the shape of the threshed tobacco sheets.

[0006] To achieve the above purpose, the technical solution adopted by the present invention is as follows:

[0007] A tobacco leaf shape control process based on punching guidance technology, the specific method is to set a leaf punching process after the pre-punching process (receiving, selecting and preparing raw tobacco, vacuum rehumidification, laying and cutting leaves, etc.), and further process the punched tobacco leaves after the punching process (leaf moistening, leaf punching and stem removal, re-roasting and packaging, etc.). In the tobacco leaf punching process, a series of holes are punched on the flattened tobacco leaves using a punching device, and these holes form specific weak strength lines, and these weak strength lines form several specific shapes of patterns, such as triangles, quadrilaterals, pentagons, hexagons, etc., or combinations thereof. The shape, size, and combination of these patterns are adjustable and controllable, or determined according to the requirements of customers (i.e., cigarette companies).

[0008] The process flow diagram is shown in Figure 1The solid line process is the existing process; the dotted line process is the process added by the present invention, that is, the "leaf punching" process point is added after the "leaf laying and cutting" of the original process.

[0009] Further, preferably, the patterns formed by the weak strength lines are all regular hexagons, and all sides are L (L is a value between 0.785 cm and 2.502 cm), preferably 1.5 cm; these regular hexagons are arranged in a honeycomb shape, for example, with a side length of 0.785 cm or 2.502 cm.

[0010] Furthermore, preferably, the diameter of a single hole in the series of holes is between 0.05 and 0.5 cm.

[0011] Furthermore, preferably, the hole spacing of the series of holes is between 0.1 and 0.8 cm.

[0012] Beneficial Effects

[0013] However, in the existing leaf threshing and redrying process, there is a large gap between the sheet structure and the requirements of cigarette companies, which is manifested as: there are fewer medium-sized sheets, more large sheets, small sheets and fragments, and the appearance of the tobacco sheets is difficult to control, and most of them are irregular shapes. The length uniformity of the tobacco cut from irregular-shaped tobacco sheets is poor. For example, under the same area, thin and long strips of tobacco sheets will cut more super-long and super-short filaments. After research, it is found that this can further cause a series of problems such as "bamboo cigarettes", "empty cigarettes", "burning cone turning", and "end drop filaments" in the finished cigarettes; while nearly square or nearly round tobacco sheets will cut more medium-long filaments, and almost no super-long and super-short filaments will be cut, and the uniformity is better.

[0014] The contradiction between the supply of leaf threshing and redrying and the demand for cigarette thread making is a problem that needs to be solved in the current leaf threshing and redrying technology.

[0015] In the previous technology, the evaluation of leaf threshing effect only considered the area density distribution of the tobacco leaves, but did not consider the influence of the appearance of the tobacco leaves on the quality of shredded tobacco. In fact, after research, it was found that:

[0016] 1. Simply controlling the area distribution of tobacco leaves cannot make the quality of shredded tobacco and finished cigarettes reach a more ideal state, such as the problems of super long and super short filaments.

[0017] 2. When controlling the area distribution, the shape of the tobacco sheet is also controlled, and the distribution function of its shredded length will also be completely controlled. In this way, in the leaf beating process, due to the guiding effect of the weak strength line formed by the punching, the position where the tobacco leaf is torn will tend to be along the predetermined line, thereby achieving the purpose of controlling the sheet shape, and the length distribution of the cut tobacco shreds will be more uniform, and the quality control level of the finished cigarettes will be greatly improved, which will effectively prevent a series of serious quality accidents such as "bamboo-jointed cigarettes", "empty cigarettes", "burning cone turning", and "end falling shreds". Therefore, the present invention proposes to apply the punching guidance technology to the tobacco leaf processing process before leaf beating based on the punching guidance technology, which will effectively solve the above-mentioned "bamboo-jointed cigarettes", "empty cigarettes", "burning cone turning", "end falling shreds" and other problems. The principle of the present invention is to add a leaf punching process to the existing process. The tobacco leaves are pre-punched before threshing to form a series of pores of specific shapes, forming specific weak strength lines on the tobacco leaves, so that the tobacco leaves tend to be torn along the lines during threshing to form the desired tobacco sheet shape, thereby achieving the purpose of controlling the sheet shape. If the shape of the tobacco sheet is controlled, the distribution function of the shredded length will also be fully controlled, effectively solving the problems of "bamboo-jointed tobacco", "empty tobacco", "burning cone turning around", "shredded tobacco at the end" and so on. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 The process flow chart of the punching guide sheet shape control of the present invention;

[0019] Figure 2 A schematic diagram of the structure of the punching device of the present invention;

[0020] Figure 3 The punching effect diagram of the present invention. DETAILED DESCRIPTION

[0021] Embodiment 1,

[0022] The punching blade shape control process method based on the punching guide technology includes the following steps:

[0023] Step (1), pre-punching process: preliminary purification of the received raw tobacco; rehumidification and loosening of the raw tobacco according to its moisture content, the temperature of the tobacco leaves after rehumidification shall not be higher than 75°C, and the moisture content shall be greater than 16%; then the tobacco leaves adjusted to the appropriate moisture content are laid flat, and the binding bands or tobacco handles are cut off;

[0024] Step (2), leaf punching process: punching a series of holes on the flat tobacco leaves, wherein the diameter of the series of holes is between 0.05-0.5 cm, and the hole spacing is between 0.1 cm-0.8 cm;

[0025] Step (3), post-punching process: the moisture and temperature of the punched tobacco leaves are further adjusted once or twice, and the adjusted temperature reaches 50°C-70°C, the moisture reaches 17%-20%, and the looseness reaches more than 95%; then the leaves are threshed and the stems are removed to separate the tobacco leaves and the stems; the area of ​​the tobacco leaves after threshing and stem removal is greater than 6.45cm 2 The large piece rate shall not exceed 45%, and the area shall be less than 0.0557cm 2 The fragmentation rate shall not be greater than 0.5%; the separated tobacco sheets, tobacco stems and fragments shall be redried respectively, and the moisture content of tobacco sheets, tobacco stems and fragments after redrying shall reach 11%-13.5%, 10%-13% and 11%-13% respectively; after the tobacco sheets, tobacco stems and fragments are packaged separately, they shall be put into storage after the temperature of the tobacco sheet core is lower than 35℃ and the temperature of the tobacco stem and fragment core is lower than 45℃.

[0026] A method for regulating tobacco leaf shape based on the punching guide technology utilizes a punching device to punch a series of holes on a flattened tobacco leaf. The series of holes form specific weak strength lines, which present patterns of several specific shapes, such as triangles, quadrilaterals, pentagons, hexagons, or combinations thereof. The shapes, sizes, and combinations of these patterns are adjustable and controllable, or determined according to the requirements of cigarette companies. The pre-punched tobacco leaves are transported to the threshing and stemming process.

[0027] Embodiment 2,

[0028] Between the pre-punching process and the post-punching process, a blade punching process is set. The specific punching method can be mechanical punching, electrostatic punching, or laser punching. This example uses a mechanical punching device, a punching device used in the punching blade shape control process method based on the punching guide technology, and the device is provided with a nail plate 1, which is densely covered with many punching nails 2. These punching nails are arranged to form Figure 2The series of regular hexagonal honeycomb patterns shown in the figure have a side length of 1.24 cm, a nail length of 5 cm, a diameter of 0.1 cm, and a spacing of 0.31 cm. The nail tips of the nail plate face downward and can be exposed through the corresponding holes 5 on the auxiliary plate 3. The nail plate and the auxiliary plate are driven by their own drive systems and can move synchronously or independently up and down. Below the nail plate is a conveyor belt 4 for conveying tobacco leaves. The conveyor belt is reserved with holes corresponding to the nail plate pattern (that is, the holes 5 arranged in a regular hexagon) and is precisely controlled by the drive system. When the conveyor belt is controlled to pause, its holes are precisely aligned with the nails on the nail plate. When the nail plate is driven to move downward, the nail body is exposed through the corresponding holes on the auxiliary plate 3, which can just pierce the tobacco leaves 6 to form a series of holes 5 arranged in a regular hexagon. After the punching is completed, the nail plate returns, and the auxiliary plate does not move to prevent the tobacco leaves from being taken away from the conveyor belt by the nail plate. After the nail plate returns, the auxiliary plate returns. At this time, the conveyor belt restarts and can transport the tobacco leaves downstream. A punching cycle is completed. In the beating process, due to the guidance of the weak strength line, the position where the tobacco leaves are torn will tend to be along the predetermined line, thereby achieving the purpose of controlling the leaf shape. Figure 3 The right half is the effect after punching. The auxiliary plate 3 has the function of flattening the tobacco leaves and preventing the tobacco leaves from being taken away from the conveyor belt by the nail plate, so as to achieve the flat force balance of the tobacco leaves, effectively prevent the punching nail 2 from tilting when punching downward, and make the punching more accurate.

[0029] Embodiment 3,

[0030] During production, the conveyor belt stops after conveying the tobacco leaves to the nail plate position, and the nail plate moves downward to punch holes in the tobacco leaves. After the action is completed, it returns to its original position, and the auxiliary plate temporarily does not move to prevent the tobacco leaves from being taken away. After the nail plate returns, the auxiliary plate returns, the conveyor belt restarts, and the tobacco leaves are conveyed downstream, completing a punching cycle.

[0031] The invention has reasonable design, simple process and remarkable effect. The shape and size of the produced tobacco sheets can be controlled, which solves the difficulty of cigarette enterprises in regulating the length of cut tobacco sheets, thereby preventing a series of serious quality problems such as "bamboo cigarettes", "empty cigarettes", "burning cone turning", "end falling tobacco sheets" and the like. The invention is simple to operate and has low investment cost. It does not change the original process route and is easy to implement in factories.

[0032] Embodiment 4,

[0033] The punching blade shape control process method based on the punching guide technology, the punching equipment is made by mechanical, electrostatic, laser and other principles. Among them, the mechanical punching equipment can be composed of a conveyor belt (with mesh), a nail plate, and an auxiliary plate.

[0034] The accessible area of ​​a single punch of the punching equipment shall not be less than 70×20cm; in the mechanical punching equipment, the single-sided size of the conveyor belt shall not be less than 80cm×20cm, the size of the nail plate shall not be less than 70×20cm, and the size of the auxiliary plate shall be in between the two; in the mechanical punching equipment, the diameter of the nails on the nail plate shall be 0.05-0.5cm, and the length shall not be less than 2cm.

[0035] The above shows and describes the basic principles, main features, advantages, and implementation examples of the present invention in specific cases. It should be understood by those skilled in the art that the present invention is not limited to the above embodiments, and the above embodiments and descriptions are only for explaining the principles of the present invention. Without departing from the spirit and scope of the present invention, the present invention may have various changes and improvements, and these changes and improvements fall within the scope of the present invention to be protected. The scope of protection of the present invention is defined by the attached claims and their equivalents.

Claims

1. A method for controlling blade shape based on punching guidance technology, characterized in that: The following steps are involved: Step (1), pre-punching process: preliminary purification of the received raw tobacco; rehumidification and loosening according to the moisture content of the raw tobacco, the temperature of the tobacco leaves after rehumidification shall not be higher than 75°C, and the moisture content shall be greater than 16%; then the tobacco leaves adjusted to the appropriate moisture content are laid flat, and the binding belt or tobacco handle is cut off; step (2), leaf punching process: a series of holes are punched on the laid tobacco leaves, the diameter of the series of holes is between 0.05-0.5cm, and the hole spacing is between 0.1cm-0.8cm; step (3), post-punching process: the moisture content and temperature of the punched tobacco leaves are further adjusted once or twice, and the adjusted temperature reaches 50°C-70°C, the moisture content reaches 17%-20%, and the looseness reaches more than 95%; then the leaves are threshed and stems are removed, and the tobacco leaves and stems are separated; in the tobacco leaves after threshing and stem removal, the area greater than 6.45cm 2 The percentage of large pieces should not exceed 45%, and the area should be less than 0.0557 cm 2 The fragmentation rate shall not be greater than 0.5%; the separated tobacco slices, tobacco stems and fragments are re-roasted respectively, and the moisture content of the tobacco slices, tobacco stems and fragments after re-roasting shall reach 11%-13.5%, 10%-13% and 11%-13% respectively; after the tobacco slices, tobacco stems and fragments are packaged separately, they shall be put into storage after the temperature of the tobacco slice core package is lower than 35°C and the temperature of the tobacco stem and fragment core package is lower than 45°C; the punching equipment used in the punching blade shape control process method based on the punching guide technology comprises a nail plate, the nail plate is densely covered with many punching nails, the punching nails are arranged to form a pattern of several shapes, the length of the punching nails is 5 cm, the diameter is 0.1 cm, the spacing is 0.31 cm, the tips of the punching nails of the nail plate face downwards, and the nail bodies are exposed after passing through the corresponding holes on the auxiliary plate, the nail plate and the auxiliary plate are driven by their respective driving systems, and can move synchronously It can move independently up and down. Below the nail plate is a conveyor belt for conveying tobacco leaves. The conveyor belt is reserved with holes corresponding to the nail plate pattern and is controlled by the drive system. When the conveyor belt is controlled to pause, its holes are precisely aligned with the punching nails on the nail plate; when the nail plate is driven to move downward, the nail body is exposed after passing through the corresponding holes on the auxiliary plate, which can pierce the tobacco leaves to cause holes. After the punching is completed, the nail plate returns, and the auxiliary plate does not move to prevent the tobacco leaves from being taken away from the conveyor belt by the nail plate. After the nail plate returns, the auxiliary plate returns. At this time, the conveyor belt restarts and can transport the tobacco leaves to the downstream, and a punching cycle is completed; in the leaf beating process, a series of holes are punched on the flattened tobacco leaves using a punching device. The series of holes form weak strength lines. Due to the guiding effect of the weak strength lines, the position where the tobacco leaves are torn will tend to be along the predetermined line, thereby achieving the purpose of controlling the sheet shape.

2. The punching blade shape control process method based on punching guide technology according to claim 1 is characterized in that: The weak strength lines present patterns of several shapes, and the patterns are selected from triangles, quadrilaterals, pentagons, hexagons, or combinations thereof; the pre-punched tobacco leaves are conveyed to the threshing and stemming process.

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