How to change the paper tray in an automatic paper changer for a range hood

Abstract

This invention relates to a reel-changing method for an automatic cigarette paper changing machine, comprising: calculating the unwinding speed of the A reel unwinding shaft; calculating the tension swing PID of the A and B reel unwinding shafts; the process of the upper rejection roller cutting the unwound paper strips from the A reel unwinding shaft; and the paper strip splicing process: the smooth roller starts in advance to achieve a uniform speed; the pattern roller accelerates from a standstill at the acceleration position, and its speed must be exactly the same as the smooth roller and the linear speed of the paper roll before reaching the splicing position; the pattern roller and the smooth roller instantly bond the unwound paper strips from the A and B reel unwinding shafts; and the lower rejection roller cuts the unwound paper strips from the B reel unwinding shaft. This invention achieves dynamic online real-time monitoring and real-time action, as well as the mutual coordination between actions, realizing automatic reel changing and glue-free paper strip bonding, overcoming industry problems and truly achieving mechanical automation.

Description

Technical Field

[0001] This invention relates to a method for changing the paper tray of an automatic paper tray changer for a tobacco machine, belonging to the technical field of equipment coordination methods. Background Technology

[0002] With the development of mechanical automation, many industrial operations are now completed by machines, and the effective coordination between machines allows for continuous operation without downtime. The most challenging aspect of controlling cigarette machine paper reel feed is the automatic replacement of the reel after it has finished feeding. When replacing the reel with a new one, precise alignment, accurate glue-free splicing, and perfectly consistent dynamic speed are required, achieving a relative speed of zero at the moment of bonding. This involves controlling numerous variables and coordinating their transitions, making paper reel replacement extremely difficult. How to achieve this in a programming framework remains an unsolved problem. Summary of the Invention

[0003] To solve the above-mentioned technical problems, the present invention provides a method for changing the paper tray of an automatic paper changing machine for a cigarette machine, the specific technical solution of which is as follows:

[0004] A method for changing the paper rolls of an automatic cigarette machine paper roll changing machine is disclosed. The method controls the operation of the automatic paper roll changing machine. The automatic paper roll changing machine includes an A-roll unwinding shaft and a B-roll unwinding shaft, an upper rejecting roller and a lower rejecting roller, and a patterned roller and a smooth roller between the upper and lower rejecting rollers. Both the A-roll unwinding shaft and the B-roll unwinding shaft are fitted with paper rolls. The paper strips released from the paper rolls on the A-roll unwinding shaft pass through the upper rejecting roller and are fed between the patterned roller and the smooth roller. In the paper feeding stage, the paper strips released from the rolls on the B reel pass between the pattern roller and the smooth roller and connect to the lower rejection roller. When the rolls on the A reel are almost empty, the paper is fed from the rolls on the B reel. At this time, the upper rejection roller cuts the paper strips released from the rolls on the A reel, and the lower rejection roller cuts the paper strips released from the rolls on the B reel. The pattern roller and the smooth roller come into contact and stick the paper strips released from the rolls on the A and B reels together.

[0005] Includes the following steps:

[0006] Step 1: First, calculate the unwinding speed of the A disk unwinding reel: Based on the total length, maximum diameter, and minimum diameter of the paper roll, calculate the thickness of each sheet using the FB_UnwindCalc function block.

[0007] (1)

[0008] in: The thickness of each sheet of paper is given; MaxDia is the maximum diameter of the paper roll; MinDia is the minimum diameter of the paper roll; TotalLenth is the total length of the paper roll; PI is π.

[0009] The thickness of each sheet of paper is calculated using the formula (1) above, and then the actual number of rolls of paper unwound is calculated using the formula (2) below:

[0010] (2)

[0011] Where: AmoveTurns is the number of revolutions of disk A, AactPos is the current position of disk A, and AstartPos is the starting position of disk A. Finally, the current diameter of disk A is calculated using formula (3):

[0012] (3)

[0013] Based on the current diameter of disk A, the required rotational speed of the servo motor of disk A can be calculated.

[0014] Step 2: Calculate the tension pendulum PID of unwinding shafts A and B: Use the system-integrated PID method function block to collect the feedback voltage VoltActual of the tension pendulum to adjust the unwinding speed of unwinding shafts A and B, and stabilize the tension pendulum in a horizontal position.

[0015] Step 3: The process of the upper rejection roller cutting the unwinding paper strip of the A-disc unwinding shaft: The upper rejection shaft adopts the variable speed ratio gear coupling MC_GearInDyn method, which is coupled to the encoder main shaft. The direction of movement is opposite to that of the blank roller and the pattern roller. Before the pattern roller and the blank roller are separated from contact, the movement is accelerated in advance, and a speed difference is generated before they are completely separated, which tears the old paper end.

[0016] Step 4: Paper strip splicing process: The smooth roller starts in advance to reach a constant speed. The pattern roller accelerates from a standstill at the acceleration position. Before reaching the splicing position, the speed must be exactly the same as the smooth roller and the paper roll line speed. The pattern roller and the smooth roller will instantly stick and connect the unwound paper strips of the A reel and the B reel.

[0017] Step 5: The process of the lower rejection roller cutting the unwound paper strip from the B-disc unwinding shaft: The lower rejection roller is coupled to multiple main shafts using a multi-axis coupling method. The MC_GearInMultiMaster is coupled to the unwinding shaft and the encoder main shaft respectively. First, the lower rejection roller is coupled to the new paper roll and accelerates from a stationary state to the same speed as the blank roll and the pattern roll for splicing. Second, after the blank roll and the pattern roll come into contact, the lower rejection roller is coupled to the encoder shaft and accelerates again to create a speed difference relative to the blank roll and the pattern roll, thus tearing the new paper strip.

[0018] Furthermore, in step 3, the core splicing method uses the FlyingSaw function. Before the smooth roller and the pattern roller make mechanical contact, the FlyingSaw speed mode is used to accelerate the speed of the pattern roller to the speed of the smooth roller at maximum acceleration, so that the speeds of the smooth roller, the pattern roller, and the unwinding line are completely synchronized before the smooth roller and the pattern roller make contact.

[0019] Furthermore, the variable gear ratio gear coupling MC_GearInDyn is specifically described as dynamic coupling. The gear ratio GearRatio is given in real number form and dynamically modified while Execute is True. If Execute changes from True to False, the axis remains coupled, but the gear ratio remains at its value before False until MC_GearOut is used to decouple it. There will be acceleration or deceleration phases during gear coupling. After the speed of the master and slave axes reaches the set gear ratio, the output status bit Ingear is set. If the coupling was canceled for some reason, the output status bit CommandAborted is set. Acceleration, Deceleration, and Jerk refer to acceleration, deceleration, and jitter, which can be filled in or left blank. If left blank, the function block will use the parameters set in the Dynamic page of the axis in System Manager to accelerate or decelerate.

[0020] Furthermore, the MC_GearInMultiMaster method of coupling to multiple spindles specifically allows a maximum of one slave axis to be coupled to four spindles. The rising edge of Enable will trigger gear coupling, but GearRatio can only be modified when Enable remains True. The type of each speed ratio is a real number. Although this function block is used for speed synthesis of multi-axis motion, the inconvenience is that even if only two axes are used for synthesis, Master3 and Master4 must be specified, otherwise a compilation error will occur. Therefore, when using it, multiple virtual axes should be created as spare spindles, and then the corresponding GearRatio should be specified as 0.

[0021] Furthermore, the FlyingSaw function specifically refers to the slave axis synchronizing with the moving spindle and running with the spindle to complete a processing cycle. This synchronization with the spindle means that the workpiece is processed during transmission. After the flying saw is started, the slave axis can couple to the moving spindle whether it is stationary or in motion. The slave axis catches up with the spindle (e.g., the moving axis that transmits the material) and maintains speed synchronization with the material for a period of time in order to process the material. After processing is completed, the synchronous operation phase ends, and the flying saw moves in the opposite direction from the slave axis back to the starting point to prepare for the next cycle.

[0022] The beneficial effects of this invention are:

[0023] This invention achieves online data acquisition and real-time calculation through a series of dynamic data collections. It can dynamically monitor the remaining paper on the A-disc unwinding shaft and the real-time rotation speed of the A-disc unwinding shaft. Because the linear velocity of the unwinding paper is fixed, the real-time rotation speed of the A-disc unwinding shaft changes dynamically in real time, thus realizing the instantaneous acquisition and control of online dynamic data.

[0024] When splicing paper strips, the upper and lower rejection rollers are activated instantly to cut the unwound paper strips on the A and B unwound shafts (by relying on instantaneous acceleration for cutting). In addition, the instantaneous contact speed of the pattern roller and the smooth roller is the same, so as to achieve adhesive bonding.

[0025] This invention fully considers the coordination and cooperation between multiple actions, and realizes instantaneous coordination between multiple operations, with precise calculations and seamless cooperation. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the automatic paper changing machine for cigarette machines according to the present invention.

[0027] Figure 2 This is a speed curve diagram of the pattern roller and the smooth roller during the splicing process of this invention.

[0028] Figure 3 This is a speed curve diagram of the upper / lower rejection rollers cutting paper strips according to the present invention.

[0029] In the diagram: 1—Reel A unloads the roll, 2—Reel B unloads the roll, 3—Reel A unloads the roll of paper on the roll, 4—Reel B unloads the roll of paper on the roll, 5—Reel A unloads the paper strip, 6—Reel B unloads the paper strip, 7—Pattern roller, 8—Smooth roller, 9—Upper rejection roller, 10—Lower rejection roller. Detailed Implementation

[0030] The present invention will now be described in further detail with reference to the accompanying drawings. These drawings are simplified schematic diagrams, illustrating only the basic structure of the invention, and therefore only show the components relevant to the invention.

[0031] like Figure 1As shown, the structure of the automatic paper changing machine for cigarette machines controlled by the method of the present invention is first introduced. The automatic paper changing machine for cigarette machines includes an A-disc unwinding shaft 1 and a B-disc unwinding shaft 2, an upper rejecting roller 9 and a lower rejecting roller 10, and a patterned roller 7 and a smooth roller 8 between the upper rejecting roller 9 and the lower rejecting roller 10. Both the A-disc unwinding shaft 1 and the B-disc unwinding shaft 2 are fitted with paper discs. The paper strips released from the paper discs on the A-disc unwinding shaft 1 pass through the upper rejecting roller 9, and are fed into the paper supply between the patterned roller 7 and the smooth roller 8. In this process, the paper strips released from the unwinding roller 2 of reel B pass between the pattern roller 7 and the smooth roller 8, and connect to the lower rejection roller 10. When the paper strips 3 on the unwinding roller 1 of reel A are almost finished, the paper strips 4 on the unwinding roller 2 of reel B are switched on. At this time, the upper rejection roller 9 cuts the paper strips 5 released from the unwinding roller 1 of reel A, and the lower rejection roller 10 cuts the paper strips 6 released from the unwinding roller 2 of reel B. The pattern roller 7 and the smooth roller 8 come into contact, sticking the paper strips released from the unwinding rollers 1 and 2 of reel A together. When reel A is used up and rewinding roller B is in operation, after the diameter of the paper on reel B reaches the set value, it rotates 180° clockwise, waiting for the next cycle.

[0032] The control method of the automatic paper changing machine for tobacco machines according to the present invention is as follows:

[0033] 1. Paper roll unwinding algorithm

[0034] The thickness of each sheet of paper is calculated using the FB_UnwindCalc function block based on the total length, maximum diameter, and minimum diameter of the roll.

[0035]

[0036] in: The thickness of each sheet of paper; MaxDia is the maximum diameter of the paper roll; MinDia is the minimum diameter of the paper roll; TotalLenth is the total length of the paper roll; PI is π.

[0037] The thickness of each sheet of paper is calculated using the formula above. Then, the actual number of rolls of paper unwound is calculated using the formula below:

[0038]

[0039] Where: AmoveTurns is the number of revolutions of disk A, AactPos is the current position of disk A, and AstartPos is the starting position of disk A. Finally, the current diameter of disk A is calculated using the following formula:

[0040]

[0041] The required speed of the servo motor of disk A can be calculated based on the current diameter of disk A.

[0042] 2. PID calculation of tension pendulum

[0043] The tension pendulum PID algorithm uses a pre-integrated PID algorithm function block to collect the feedback voltage VoltActual of the tension pendulum, thereby adjusting the unwinding speed of disks A and B to stabilize the tension pendulum in a horizontal position.

[0044] On the one hand, the tension swing is set to a horizontal position, and due to gravity, it generates a certain tension on the unwinding of the paper. On the other hand, the PID controller adjusts the tension swing position in real time, which plays a certain role in buffering the tension.

[0045] 3. The splicing algorithm is as follows: Figure 2

[0046] The splicing process involves: the smooth roller starting early to achieve a constant speed; the pattern roller accelerating from a standstill at the acceleration position, ensuring its speed matches that of the smooth roller and the paper winding line before reaching the splicing position, otherwise the paper will break. The entire splicing process is completed within 15ms, which is very fast.

[0047] In this solution, the core splicing algorithm uses the FlyingSaw function. Before the smooth roller and the patterned roller make mechanical contact, the FlyingSaw speed mode is used to accelerate the speed of the patterned roller to the speed of the smooth roller with maximum acceleration, so that the speeds of the smooth roller, the patterned roller and the unwinding line are completely synchronized before the smooth roller and the patterned roller make contact.

[0048] 4. Top and bottom removal algorithm, refer to Figure 3

[0049] The upper rejection axis is coupled to the main axis using the MC_GearInDyn method; the lower rejection axis is coupled to both the main axis and the unwind axis using the MC_GearInMultiMaster method.

[0050] (1) The lower rejection roller is coupled to the unwinding shaft and the encoder spindle in a multi-axis coupling manner (MC_GearInMultiMaster). First, the lower rejection roller is coupled to the new paper roll and accelerates from a stationary state to the same speed as the blank roll and the pattern roll for splicing. Second, after the blank roll and the pattern roll come into contact, the lower rejection roller is coupled to the encoder shaft and accelerates again to create a speed difference relative to the blank roll and the pattern roll, thus tearing the new paper end.

[0051] (2) The upper rejection roller algorithm is relatively simple. It adopts the MC_GearInDyn method and is coupled to the encoder spindle. The direction of motion is opposite to that of the blank roller and the pattern roller. Before the pattern roller and the blank roller are separated from contact, the motion is accelerated in advance, and a speed difference is generated before they are completely separated, which tears the old paper ends.

[0052] Based on the above-described preferred embodiments of the present invention, and through the foregoing description, those skilled in the art can make various changes and modifications without departing from the inventive concept. The technical scope of this invention is not limited to the contents of the specification, but must be determined according to the scope of the claims.

Claims

1. A method for changing the paper rolls of an automatic paper roll changing machine for a cigarette machine, the method controlling the operation of the automatic paper roll changing machine, the automatic paper roll changing machine including an A-roll unwinding shaft and a B-roll unwinding shaft, an upper rejection roller and a lower rejection roller, and a patterned roller and a smooth roller between the upper rejection roller and the lower rejection roller, both the A-roll unwinding shaft and the B-roll unwinding shaft are fitted with paper rolls, the paper strips released from the paper rolls on the A-roll unwinding shaft pass through the upper rejection roller, and are fed between the patterned roller and the smooth roller. In the paper feeding stage, the paper strips released from the rolls on the B reel pass between the pattern roller and the smooth roller and connect to the lower rejection roller. When the rolls on the A reel are almost empty, the paper is switched to the rolls on the B reel. At this time, the upper rejection roller cuts the paper strips released from the rolls on the A reel, and the lower rejection roller cuts the paper strips released from the rolls on the B reel. The pattern roller and the smooth roller come into contact and stick the paper strips released from the rolls on the A and B reels together. Its features are: Includes the following steps: Step 1: First, calculate the unwinding speed of the A disk unwinding reel: Based on the total length, maximum diameter, and minimum diameter of the paper roll, calculate the thickness of each sheet using the FB_UnwindCalc function block. （1） in: The thickness of each sheet of paper is given; MaxDia is the maximum diameter of the paper roll; MinDia is the minimum diameter of the paper roll; TotalLenth is the total length of the paper roll; PI is π. The thickness of each sheet of paper is calculated using the formula (1) above, and then the actual number of rolls of paper unwound is calculated using the formula (2) below: （2） Where: AmoveTurns is the number of revolutions of disk A, AactPos is the current position of disk A, AstartPos is the starting position of disk A, and finally, the current diameter of disk A is calculated using formula (3): （3） Based on the current diameter of disk A, the required rotational speed of the servo motor of disk A can be calculated. Step 2: Calculate the tension pendulum PID of unwinding shafts A and B: Use the system-integrated PID method function block to collect the feedback voltage VoltActual of the tension pendulum to adjust the unwinding speed of unwinding shafts A and B, and stabilize the tension pendulum in a horizontal position. Step 3: The process of the upper rejection roller cutting the unwinding paper strip of the A-disk unwinding shaft: The upper rejection shaft adopts the variable speed ratio gear coupling MC_GearInDyn method, which is coupled to the encoder main shaft. The direction of movement is opposite to that of the light roller and the pattern roller. Before the pattern roller and the light roller are separated from contact, the movement is accelerated in advance, and a speed difference is generated before they are completely separated, which tears the old paper end. In step 3, the core splicing method uses the FlyingSaw function. Before the smooth roller and the patterned roller make mechanical contact, the FlyingSaw speed mode is used to accelerate the speed of the patterned roller to the speed of the smooth roller with maximum acceleration. Before the smooth roller and the patterned roller make contact, the speeds of the smooth roller, the patterned roller and the unwinding line are completely synchronized. Step 4: Paper strip splicing process: The light roller starts in advance to reach a constant speed, and the pattern roller accelerates from a standstill at the acceleration position. Before reaching the splicing position, the speed must be exactly the same as the speed of the light roller and the paper roll line speed. The pattern roller and the light roller will instantly stick and connect the unwound paper strips of the A reel and the B reel. Step 5: The process of the lower rejection roller cutting the unwound paper strip from the B reel unwinding shaft: The lower rejection roller is coupled to the unwinding shaft and the encoder main shaft in a multi-axis coupling manner. First, the lower rejection roller is coupled to the new paper roll and accelerates from a stationary state to the same speed as the smooth roller and the patterned roller for splicing. Second, after the smooth roller and the patterned roller come into contact, the lower rejection roller is coupled to the encoder shaft and accelerates again to create a speed difference relative to the smooth roller and the patterned roller, thus tearing the new paper strip.

2. The paper changing method of the automatic paper changing machine for tobacco machines according to claim 1, characterized in that: The variable gear ratio gear coupling MC_GearInDyn mode is specifically as follows: dynamic coupling. The gear ratio GearRatio is given in real number form. While Execute is True, it is dynamically modified. If Execute changes from True to False, the shaft remains coupled, but the gear ratio remains at its value before False until MC_GearOut is used to decouple it. There will be acceleration or deceleration phases during gear coupling. After the speed of the master and slave shafts reaches the set gear ratio, the output status bit Ingear is set. If the coupling was canceled for some reason beforehand, the output status bit CommandAborted is set. Acceleration, Deceleration, and Jerk refer to acceleration, deceleration, and jitter, respectively.

3. The paper changing method of the automatic paper changing machine for tobacco machines according to claim 1, characterized in that: The FlyingSaw function specifically refers to the slave axis synchronizing with the moving spindle and running with the spindle to complete a processing cycle. This synchronization with the spindle means that the workpiece is processed during the transfer process. After the flying saw is started, the slave axis can couple to the moving spindle whether it is stationary or in motion. The slave axis catches up with the spindle and maintains speed synchronization with the material for a period of time in order to process the material. After the processing is completed, the synchronous operation phase ends, and the flying saw moves in the opposite direction from the slave axis back to the starting point to prepare for the next cycle.

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