A method and system for intelligent control of a ribbon box feeder lift

Abstract

This invention discloses an intelligent control method and system for the lifting belt of a feeding machine for making ribbon boxes. The method includes the following steps: S1: The belt scale starts running; S2: The instantaneous flow rate of the belt scale is detected in real time to see if it is within the set range. If the instantaneous flow rate of the belt scale is not within the set range, proceed to step S3; if the instantaneous flow rate of the belt scale is within the set range, proceed to step S4; S3: The speed of the lifting belt motor is controlled using a constant speed control mode, and proceed to step S5; S4: The speed of the lifting belt motor is controlled using a self-adjusting speed control mode; S5: Steps S2 to S4 are repeated until the belt scale stops running. This invention achieves stepless speed regulation control of the feeding machine lifting belt according to the material flow rate during production through intelligent control, ensuring continuous operation as much as possible during production. It effectively solves the problem of frequent start-stop of the feeding machine lifting belt during production, improves the stability of the electronic scale flow rate, and ensures process indicators such as the coefficient of variation.

Description

Technical Field

[0001] This invention relates to the field of feeder lifting belt control technology, and more specifically, to an intelligent control method and system for the lifting belt of a ribbon feeding machine. Background Technology

[0002] In silk refining workshops, production lines typically use electronic belt scales to control flow rate, and the stability (coefficient of variation) of these scales is a crucial quality control indicator. To ensure stable control by the electronic belt scales, a quantitative tube, a lifting belt, and a box feeder are usually installed at the inlet. The original control system uses a photoelectric switch on the quantitative tube to control the lifting belt of the box feeder, which is a staged control system.

[0003] Because each production line produces a full range of products from multiple brands, and different brands require different flow rates, the quantitative tube graded control of the conveyor belt often results in insufficient material supply or frequent start-ups and shutdowns of the conveyor belt. This leads to material blockages, flow interruptions, equipment malfunctions, and downtime, reducing equipment lifespan and affecting product quality. According to the manufacturer's requirements, production must achieve zero flow interruptions. Therefore, graded control using photoelectric switches is no longer sufficient to meet the demands for high-precision control and zero flow interruptions, and this problem urgently needs to be solved.

[0004] Taking the leaf feeder as an example, the current main control mode of the feeder's lifting belt is based on the combination of material height detection by three pairs of photoelectric tubes installed on the metering tube to control the lifting belt speed accordingly. When no photoelectric switch on the metering tube detects material, the lifting belt motor runs at high speed; when the photoelectric switches at the bottom and middle of the metering tube detect material, but the top photoelectric switch does not, the lifting belt motor runs at constant speed; when the photoelectric switches at the bottom, middle, and top of the metering tube simultaneously detect material, the lifting belt motor stops after a delay.

[0005] In this control mode, control is relatively simple and easy to implement, with fixed setpoints for the constant and high speeds of the conveyor belt. However, it also has several drawbacks: due to the nature of the incoming material, it is difficult to adjust to the optimal speed control setpoint. A setpoint that is too low will cause the electronic scale to disconnect, while a setpoint that is too high will cause frequent motor starts and stops, reducing motor lifespan and increasing the failure rate. Therefore, the existing constant frequency conveyor belt control mode for feeders is not conducive to stable control of the electronic scale's flow rate, affecting the flow rate variation coefficient and also impacting the accuracy of auxiliary material blending and flavoring addition; for example... Figure 3 The current control mode is used. The start-stop trend chart of the motor of the lifting belt in a single batch of the blade feeding cabinet shows that the lifting belt started and stopped 194 times during the production process.

[0006] The existing technology relates to a method for controlling the lifting belt of a tobacco conveying device, which involves: a feeder conveying tobacco to the lifting belt, the tobacco being lifted by the lifting belt and then passing through a belt scale, and the weight of tobacco shreds x per unit time of the feeder and m per unit time of the belt scale being measured; the output power of the lifting belt is calculated as m / y, where y = 0.2879x + 152.73. Through research on the operating law of the lifting belt, the operating law of the lifting belt is derived by summarizing the tobacco shred weights from the feeder and belt scale; experimental results show that this scheme can effectively avoid frequent start-stop of the lifting belt, keeping the speed (i.e., output power) of the lifting belt within a smooth and stable range, thus better protecting the lifting belt. However, this scheme still involves a relatively high number of lifting belt cycles. Summary of the Invention

[0007] The primary objective of this invention is to provide an intelligent control method for the lifting belt of a ribbon feeding machine, which adjusts the lifting belt frequency in real time to match the flow rate of the electronic scale and the material conveying capacity of the lifting belt.

[0008] A further objective of this invention is to provide an intelligent control system for the lifting belt of a ribbon feeding machine.

[0009] To solve the above-mentioned technical problems, the technical solution of the present invention is as follows:

[0010] A method for intelligent control of the lifting belt of a ribbon feeding machine includes the following steps:

[0011] S1: The belt scale starts running;

[0012] S2: Real-time detection of whether the instantaneous flow rate of the belt scale is within the set range. If the instantaneous flow rate of the belt scale is not within the set range, proceed to step S4; if the instantaneous flow rate of the belt scale is within the set range, proceed to step S3.

[0013] S3: Use constant speed control mode to control the speed of the belt motor, and proceed to step S5;

[0014] S4: Use self-adjusting speed control mode to control the speed of the booster motor;

[0015] S5: Repeat steps S2 to S4 until the belt scale stops running.

[0016] Preferably, whether the instantaneous flow rate of the belt scale in step S2 is within the set range is specifically as follows:

[0017] WB_FlowSP×(1-K_Range)≤ WB_FlowPV ≤WB_FlowSP×(1+K_Range)

[0018] In the formula, WB_FlowPV is the instantaneous flow rate of the belt scale, WB_FlowSP is the set flow rate of the belt scale, and K_Range is the set fluctuation range coefficient.

[0019] Preferably, the constant speed control mode described in step S3 specifically refers to:

[0020] Set the frequency of the lifting belt inverter to a fixed frequency to keep the speed of the lifting belt motor constant.

[0021] Preferably, the self-speed control mode described in step S4 is specifically:

[0022] Detect the material level occupancy in the metering tube;

[0023] If the material level in the metering tube is high or low, calculate the material inventory coefficient N, calculate the adjustment coefficient K_PV based on the material inventory coefficient N, calculate the real-time setting frequency Fre_SP of the lifting belt based on the adjustment coefficient K_PV, and set the frequency of the lifting belt inverter to the real-time setting frequency Fre_SP of the lifting belt.

[0024] If the material level in the metering tube is at a suitable level, then maintain the current boost frequency of the frequency converter.

[0025] Preferably, the material level occupancy in the detection and metering tube is as follows:

[0026] Phototubes are installed at the bottom, middle and top of the metering tube, respectively, and the phototubes are used to detect the height of the material inside the metering tube;

[0027] When the photocells at the bottom and middle of the metering tube detect material at the same time, after a delay, the material level occupancy level of the metering tube is determined to be a high level.

[0028] If the photocells at the bottom and middle of the metering tube do not detect any material at the same time, after a delay, the material level occupancy level of the metering tube is determined to be a low level.

[0029] When the phototube at the bottom of the metering tube detects material but the phototube in the middle of the metering tube does not detect material, the material level occupancy level of the metering tube is judged to be appropriate.

[0030] Preferably, the calculation of the material inventory coefficient N specifically involves:

[0031] When the material level occupancy level of the metering tube is at a high level, the material inventory coefficient N is reduced by 1; when the material level occupancy level of the metering tube is at a low level, the material inventory coefficient N is increased by 0.8, until the material inventory of the metering tube is between the bottom photoelectric tube and the middle photoelectric tube.

[0032] Preferably, the step of calculating the adjustment coefficient K_PV based on the material inventory coefficient N specifically involves:

[0033] K_PV = K + (C × N)

[0034] In the formula, K is the initial adjustment coefficient for boosting the frequency, and the coefficient C is the average initial value obtained by statistically analyzing big data from previous production.

[0035] Preferably, the step of calculating the real-time set frequency Fre_SP of the boost band based on the adjustment coefficient K_PV specifically involves:

[0036] Fre_SP = WB_Speed ​​× K_PV

[0037] In the formula, WB_Speed ​​is the instantaneous speed of the belt scale.

[0038] Preferably, the method further includes step S6:

[0039] Once it is determined that the material level in the metering tube is appropriate and has remained stable for a period of time, the actual adjustment coefficient K_PV of the current lifting belt frequency is adjusted accordingly. Save data in tiers based on the current production flow rate.

[0040] A smart control system for the lifting belt of a ribbon box feeder, the system applying the aforementioned smart control method for the lifting belt of a ribbon box feeder, comprising:

[0041] The operation module is used to start the belt scale.

[0042] The detection module is used to detect in real time whether the instantaneous flow rate of the belt scale is within the set range. If the instantaneous flow rate of the belt scale is not within the set range, it enters the self-adjusting speed control module; if the instantaneous flow rate of the belt scale is within the set range, it enters the constant speed control module.

[0043] A constant speed control module, which uses a constant speed control mode to control the speed of the lifting belt motor and enter the cycle module;

[0044] The self-speed control module uses a self-speed control mode to control the speed of the booster motor.

[0045] The circulation module is used to cycle the operation of the detection module, constant speed control module, and self-adjusting speed control module until the belt scale stops running.

[0046] Compared with the prior art, the beneficial effects of the technical solution of the present invention are:

[0047] This invention achieves stepless speed regulation of the feeder conveyor belt based on material flow rate through intelligent control, ensuring continuous operation as much as possible during production. It effectively solves the problem of frequent start-stop cycles during feeder conveyor belt operation, improves the stability of the electronic scale flow rate, and guarantees process parameters such as the coefficient of variation. This invention can be extended to the control of feeder conveyor belts in all feeders in a workshop. Attached Figure Description

[0048] Figure 1 This is a schematic diagram of the method flow of the present invention.

[0049] Figure 2 This is a schematic diagram of the system modules of the present invention.

[0050] Figure 3 This is a chart showing the start-stop trend of the motor in a single batch of the existing blade feeder.

[0051] Figure 4 The following is a trend chart of the start-stop of the motor of the single-batch lifting belt in the feeder after using the method of the present invention, provided as an example. Detailed Implementation

[0052] The accompanying drawings are for illustrative purposes only and should not be construed as limiting the scope of this patent.

[0053] To better illustrate this embodiment, some parts in the accompanying drawings may be omitted, enlarged, or reduced, and do not represent the actual product dimensions;

[0054] It will be understood by those skilled in the art that certain well-known structures and their descriptions may be omitted in the accompanying drawings.

[0055] The technical solution of the present invention will be further described below with reference to the accompanying drawings and embodiments.

[0056] Example 1

[0057] This embodiment provides an intelligent control method for the lifting belt of a ribbon feeding machine, such as... Figure 1 As shown, it includes the following steps:

[0058] S1: The belt scale starts running;

[0059] S2: Real-time detection of whether the instantaneous flow rate of the belt scale is within the set range. If the instantaneous flow rate of the belt scale is not within the set range, proceed to step S4; if the instantaneous flow rate of the belt scale is within the set range, proceed to step S3.

[0060] S3: Use constant speed control mode to control the speed of the belt motor, and proceed to step S5;

[0061] S4: Use self-adjusting speed control mode to control the speed of the booster motor;

[0062] S5: Repeat steps S2 to S4 until the belt scale stops running.

[0063] Example 2

[0064] This embodiment provides an intelligent control method for the lifting belt of a ribbon feeding machine, such as... Figure 1 As shown, it includes the following steps:

[0065] S1: The belt scale starts running;

[0066] S2: Real-time detection of whether the instantaneous flow rate of the belt scale is within the set range. If the instantaneous flow rate of the belt scale is not within the set range, proceed to step S4; if the instantaneous flow rate of the belt scale is within the set range, proceed to step S3.

[0067] S3: Use constant speed control mode to control the speed of the belt motor, and proceed to step S5;

[0068] S4: Use self-adjusting speed control mode to control the speed of the booster motor;

[0069] S5: Repeat steps S2 to S4 until the belt scale stops running.

[0070] In step S2, to determine whether the instantaneous flow rate of the belt scale is within the set range, a fluctuation range coefficient K_Range is first set for the real-time instantaneous flow rate of the belt scale during the production process. When the actual instantaneous flow rate WB_FlowPV of the belt scale is within the set fluctuation range of the belt scale's set flow rate WB_FlowSP, the following formula applies:

[0071] WB_FlowSP×(1-K_Range)≤ WB_FlowPV ≤WB_FlowSP×(1+K_Range)

[0072] In the formula, WB_FlowPV is the instantaneous flow rate of the belt scale, WB_FlowSP is the set flow rate of the belt scale, and K_Range is the set fluctuation range coefficient.

[0073] When the instantaneous flow rate of the belt scale meets the above formula, it is determined that the flow rate is in a stable state, and the scale's flow rate stability flag is triggered. At this time, the belt frequency is constant. When the instantaneous flow rate of the belt scale does not meet the above formula, it is determined that the flow rate has not entered a stable state, and the scale's flow rate stability flag is reset. At this time, the control system begins to adjust the belt frequency.

[0074] The constant speed control mode described in step S3 is specifically as follows:

[0075] Set the frequency of the lifting belt inverter to a fixed frequency to keep the speed of the lifting belt motor constant.

[0076] The self-speed control mode described in step S4 is specifically as follows:

[0077] Detect the material level occupancy in the metering tube;

[0078] If the material level in the metering tube is high or low, calculate the material inventory coefficient N, calculate the adjustment coefficient K_PV based on the material inventory coefficient N, calculate the real-time setting frequency Fre_SP of the lifting belt based on the adjustment coefficient K_PV, and set the frequency of the lifting belt inverter to the real-time setting frequency Fre_SP of the lifting belt.

[0079] If the material level in the metering tube is at a suitable level, then maintain the current boost frequency of the frequency converter.

[0080] The level of material occupancy in the detection and metering tube is specifically as follows:

[0081] Phototubes are installed at the bottom, middle and top of the metering tube, respectively, and the phototubes are used to detect the height of the material inside the metering tube;

[0082] When the photocells at the bottom and middle of the metering tube detect material at the same time, after a delay, the material level occupancy level of the metering tube is determined to be a high level.

[0083] If the photocells at the bottom and middle of the metering tube do not detect any material at the same time, after a delay, the material level occupancy level of the metering tube is determined to be a low level.

[0084] When the phototube at the bottom of the metering tube detects material but the phototube in the middle of the metering tube does not detect material, the material level occupancy level of the metering tube is judged to be appropriate.

[0085] To maintain the material level in the metering tube within a suitable range, it is envisioned that the belt conveyor frequency be matched to the actual flow rate of the belt scale through real-time calculation. This would ensure that the material level in the metering tube is between the bottom and middle photoelectric switches, which is considered an ideal level. Based on this control principle, when both the bottom and middle photoelectric switches in the metering tube detect material simultaneously, after a delay, it is determined that the material level in the metering tube is high, and the belt conveyor frequency needs to be appropriately reduced. Conversely, when neither the bottom nor middle photoelectric switches detect material simultaneously, after a delay, it is determined that the material level in the metering tube is low, and the belt conveyor frequency needs to be appropriately increased.

[0086] The calculation of the material inventory coefficient N is specifically as follows:

[0087] When the material level occupancy level of the metering tube is at a high level, the material inventory coefficient N is reduced by 1; when the material level occupancy level of the metering tube is at a low level, the material inventory coefficient N is increased by 0.8, until the material inventory of the metering tube is between the bottom photoelectric tube and the middle photoelectric tube.

[0088] The calculation of the adjustment coefficient K_PV based on the material inventory coefficient N is specifically as follows:

[0089] K_PV = K + (C × N)

[0090] In the formula, K is the initial adjustment coefficient for boosting the frequency, and the coefficient C is the average initial value obtained by statistically analyzing big data from previous production.

[0091] The calculation of the real-time set frequency Fre_SP for the boost band based on the adjustment coefficient K_PV is specifically as follows:

[0092] Fre_SP = WB_Speed ​​× K_PV

[0093] In the formula, WB_Speed ​​is the instantaneous speed of the belt scale.

[0094] It also includes step S6:

[0095] Once it is determined that the material level in the metering tube is appropriate and has remained stable for a period of time, the actual adjustment coefficient K_PV of the current lifting belt frequency is adjusted accordingly. The flow rate of the belt scale is classified and saved according to the current production flow rate level. The flow rate classification of the belt scale is based on the different flow rate settings of the belt scale for each production batch. When producing the next batch of the same flow rate level, the saved adjustment coefficient K_PV can be used as the initial value of the coefficient K. This can greatly reduce the time for the belt scale flow rate to reach a stable state and realize graded control of different flow rates.

[0096] like Figure 4 As shown in this embodiment, by employing the method, intelligent control enables stepless speed regulation of the feeder's conveyor belt during production based on material flow rate, ensuring continuous operation as much as possible. The conveyor belt motor only started and stopped twice in this batch, reducing the number of starts and stops by over 90%, and ensuring stable tobacco flow rate on the electronic scale throughout the entire batch production process. Using the intelligent conveyor belt control system effectively solves the problem of frequent starts and stops during feeder conveyor belt production, improves the stability of the electronic scale flow rate, and ensures process parameters such as the coefficient of variation. This invention can be extended to the conveyor belt control of all feeders in the workshop.

[0097] Example 3

[0098] A smart control system for the lifting belt of a ribbon box feeder, such as Figure 2 As shown, the system applies the intelligent control method for the lifting belt of the ribbon feeding machine described in Embodiment 1 or Embodiment 2, including:

[0099] The operation module is used to start the belt scale.

[0100] The detection module is used to detect in real time whether the instantaneous flow rate of the belt scale is within the set range. If the instantaneous flow rate of the belt scale is not within the set range, it enters the self-adjusting speed control module; if the instantaneous flow rate of the belt scale is within the set range, it enters the constant speed control module.

[0101] A constant speed control module, which uses a constant speed control mode to control the speed of the lifting belt motor and enter the cycle module;

[0102] The self-speed control module uses a self-speed control mode to control the speed of the booster motor.

[0103] The circulation module is used to cycle the operation of the detection module, constant speed control module, and self-adjusting speed control module until the belt scale stops running.

[0104] The same or similar labels correspond to the same or similar parts;

[0105] The terms used to describe positional relationships in the accompanying drawings are for illustrative purposes only and should not be construed as limiting this patent.

[0106] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the implementation of the present invention. Those skilled in the art can make other variations or modifications based on the above description. It is neither necessary nor possible to exhaustively describe all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the claims of the present invention.

Claims

1. A method for intelligent control of the lifting belt of a ribbon box feeder, characterized in that, Includes the following steps: S1: The belt scale starts running; S2: Real-time detection of whether the instantaneous flow rate of the belt scale is within the set range. If the instantaneous flow rate of the belt scale is not within the set range, proceed to step S4; if the instantaneous flow rate of the belt scale is within the set range, proceed to step S3. S3: Use constant speed control mode to control the speed of the belt motor, and proceed to step S5; S4: Use self-adjusting speed control mode to control the speed of the booster motor; S5: Repeat steps S2 to S4 until the belt scale stops running; The self-speed control mode described in step S4 is specifically as follows: Detect the material level occupancy in the metering tube; If the material level in the metering tube is high or low, calculate the material inventory coefficient N, calculate the adjustment coefficient K_PV based on the material inventory coefficient N, calculate the real-time setting frequency Fre_SP of the lifting belt based on the adjustment coefficient K_PV, and set the frequency of the lifting belt inverter to the real-time setting frequency Fre_SP of the lifting belt. If the material level in the metering tube is at a suitable level, then maintain the current booster frequency. The calculation of the adjustment coefficient K_PV based on the material inventory coefficient N is specifically as follows: K_PV = K + (C × N) In the formula, K is the initial adjustment coefficient for boosting the frequency, and coefficient C is the average initial value obtained by statistically analyzing big data from previous production. The calculation of the material inventory coefficient N is specifically as follows: When the material level of the metering tube is at a high level, the material inventory coefficient N is reduced by 1; when the material level of the metering tube is at a low level, the material inventory coefficient N is increased by 0.8, until the material inventory of the metering tube is between the bottom photoelectric tube and the middle photoelectric tube. The calculation of the real-time set frequency Fre_SP for the boost band based on the adjustment coefficient K_PV is specifically as follows: Fre_SP = WB_Speed ​​× K_PV In the formula, WB_Speed ​​is the instantaneous speed of the belt scale; It also includes step S6: Once it is determined that the material level in the metering tube is appropriate and has remained stable for a period of time, the actual adjustment coefficient K_PV of the current lifting belt frequency is adjusted accordingly. Save data in tiers based on the current production flow rate.

2. The intelligent control method for the lifting belt of the ribbon feeding machine according to claim 1, characterized in that, In step S2, whether the instantaneous flow rate of the belt scale is within the set range is specifically as follows: WB_FlowSP×(1-K_Range)≤ WB_FlowPV ≤WB_FlowSP×(1+K_Range) In the formula, WB_FlowPV is the instantaneous flow rate of the belt scale, WB_FlowSP is the set flow rate of the belt scale, and K_Range is the set fluctuation range coefficient.

3. The intelligent control method for the lifting belt of the ribbon feeding machine according to claim 1, characterized in that, The constant speed control mode described in step S3 is specifically as follows: Set the frequency of the lifting belt inverter to a fixed frequency to keep the speed of the lifting belt motor constant.

4. The intelligent control method for the lifting belt of the ribbon feeding machine according to claim 1, characterized in that, The level of material occupancy in the detection and metering tube is specifically as follows: Phototubes are installed at the bottom, middle and top of the metering tube, respectively, and the phototubes are used to detect the height of the material inside the metering tube; When the photocells at the bottom and middle of the metering tube detect material at the same time, after a delay, the material level occupancy level of the metering tube is determined to be a high level. If the photocells at the bottom and middle of the metering tube do not detect any material at the same time, after a delay, the material level occupancy level of the metering tube is determined to be a low level. When the phototube at the bottom of the metering tube detects material but the phototube in the middle of the metering tube does not detect material, the material level occupancy level of the metering tube is judged to be appropriate.

5. A smart control system for the lifting belt of a ribbon box feeder, characterized in that, The system employs the intelligent control method for the lifting belt of the ribbon feeding machine according to any one of claims 1 to 4, including: The operation module is used to start the belt scale. The detection module is used to detect in real time whether the instantaneous flow rate of the belt scale is within the set range. If the instantaneous flow rate of the belt scale is not within the set range, it enters the self-adjusting speed control module; if the instantaneous flow rate of the belt scale is within the set range, it enters the constant speed control module. A constant speed control module, which uses a constant speed control mode to control the speed of the lifting belt motor and enter the cycle module; The self-speed control module uses a self-speed control mode to control the speed of the booster motor. The circulation module is used to cycle the operation of the detection module, constant speed control module, and self-adjusting speed control module until the belt scale stops running.

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