An early warning system for each process of cigarette making before entering the production process

Abstract

The present invention provides an early warning system before each process of cigarette shred production enters the production process, wherein the early warning system stores the set values ​​of various index parameters required for preheating or prefilling and the production process; the early warning system includes multiple sensors for real-time detection of the actual values ​​of various parameters; the early warning system includes: a parameter verification stage before preheating or prefilling, a self-checking stage during preheating or prefilling, and a parameter verification stage before the production process; wherein, in the parameter verification stage before preheating or prefilling, the system compares the preheating or prefilling parameter set value with the matching parameter; in the self-checking stage during preheating or prefilling, the system compares the preheating or prefilling set value with the actual value of the required parameter; in the parameter verification stage before the production process, the system obtains the stored parameter set value and MES standard required for production, and compares the parameter set value required for production with the MES standard. When the deviation exceeds the deviation threshold, an early warning is issued through an alarm device.

Description

Technical Field

[0001] The invention belongs to the technical field of tobacco shred production, and in particular relates to an early warning system before each process of cigarette shred production enters a production process. Background Art

[0002] The manufacturing process of cigarette silk mainly includes: super loosening, leaf moistening and feeding, thin plate drying, blending, and flavoring. Each process is usually divided into multiple stages, for example: 1. The super loosening process and leaf moistening and feeding process are divided into the pre-preheating stage, preheating stage, pre-production stage after preheating, mid-production stage, and post-production stage; 2. The drying process is divided into the pre-preheating stage, preheating stage, pre-production stage after preheating, and mid-production stage; 3. The blending process and flavoring process are divided into the pre-prefilling stage, pre-filling stage, pre-production stage after prefilling, mid-production stage, and post-production stage.

[0003] Before the above processes officially enter the production process, it is generally necessary to manually confirm whether the preheating or pre-filling parameter standards are consistent with the winCC (Windows Control Center) equipment matching parameters, and whether the production parameter standards are consistent with the MES (Manufacturing Execution System) workshop standards. From the start of the work order to the end of production, each stage needs to ensure that each parameter is accurate in order to ensure the final quality of the cigarettes.

[0004] Manual confirmation may result in misreading parameters, which may lead to people thinking that the parameters are "matched normally", but in fact they are not. This "mismatch" will affect the quality of cigarettes. In addition, there are many parameters involved in cigarette silk manufacturing, and manual confirmation is time-consuming and laborious. Once the parameter confirmation time is too long, it will affect the subsequent production time.

[0005] The patent application with publication number CN113837608A discloses a tobacco silk control and early warning platform based on big data analysis, which is divided into four modules, including a cleaning system, an operating terminal, a control system, and an early warning platform. In the early warning process, the tobacco silk control and early warning platform method only uses the highest and lowest points of historical data as the early warning standard for real-time data, without considering that there may be abnormal batches in the historical data, and there are inaccurate early warnings. At the same time, there is no verification of the set values ​​of various parameters before the production process. That is, only early warnings are issued for indicators in the production process, without considering that the inconsistency of parameters before the production process will also affect the quality of cigarettes. Summary of the invention

[0006] The present invention proposes an early warning system before each process of cigarette making enters the production process. By verifying the parameters before each process officially enters the production process, the problem in the prior art that manual comparison and verification is required to determine whether the preheating or pre-filling parameter standards and the production parameter standards match the WinCC equipment standards and the MES workshop standards can be solved. It can determine in real time whether various parameters have deviated too much and issue an early warning based on the deviation.

[0007] An early warning system before each process of cigarette shred production enters the production process, wherein the early warning system stores the set values ​​of various index parameters required for preheating or prefilling and production process; the early warning system includes multiple sensors for real-time detection of the actual values ​​of various parameters;

[0008] The early warning system includes multiple stage checks that are run before entering each process: a parameter check stage before preheating or prefilling, a self-check stage during preheating or prefilling, and a parameter check stage before the production process;

[0009] In the parameter verification stage before preheating or prefilling, the system obtains the stored preheating or prefilling parameter setting values ​​and the matching parameters of the WinCC device, and then compares the preheating or prefilling parameter setting values ​​with the matching parameters. When the deviation exceeds the deviation threshold, an alarm device is used to issue an early warning;

[0010] During the self-checking stage of the preheating or prefilling process, the system obtains the actual value of the required parameters through a variety of sensors, and compares the preheating or prefilling set value with the actual value of the required parameters. When the deviation exceeds the deviation threshold, an alarm device is used to issue an early warning;

[0011] During the parameter verification phase before the production process, the system obtains the stored parameter setting values ​​required for production and the MES standard, and compares the parameter setting values ​​required for production with the MES standard. When the deviation exceeds the deviation threshold, an early warning is issued through the alarm device.

[0012] Preferably, the early warning system also includes a general check that is run before entering the production process:

[0013] After the system obtains the stored preheating or prefilling parameter setting values ​​of each process and the matching parameters of the winCC equipment, it compares the preheating or prefilling parameter setting values ​​with the matching parameters. When the deviation exceeds the deviation threshold, an alarm device is used to issue an early warning.

[0014] The system obtains the actual values ​​of the required parameters of each process through a variety of sensors, and compares the preheated or pre-filled set values ​​with the actual values ​​of the required parameters. When the deviation exceeds the deviation threshold, an alarm device will issue an early warning;

[0015] The system obtains the stored parameter setting values ​​and MES standards for each process, and compares the parameter setting values ​​for production with the MES standards. When the deviation exceeds the deviation threshold, an alarm device is used to issue an early warning.

[0016] Preferably, the actual values ​​of the parameters include: the working status of various valves and moisture meters, the leaf storage time, and the discharge information.

[0017] Preferably, the parameter verification before preheating or prefilling includes: parameter verification before preheating and parameter verification before prefilling, wherein the parameter verification stage before preheating exists in the three processes of ultra-loosening, leaf moistening and feeding, and thin plate drying, and the parameter verification stage before prefilling exists in the two processes of blending and flavoring.

[0018] More preferably, when the preheating parameter verification is applied to the super-return loosening process, the system obtains the stored preheating parameter setting values ​​including: the preheating inlet material flow setting value, the preheating sheet blending flow setting value, and the preheating inlet moisture meter zero point setting value;

[0019] When the preheating parameter verification is applied to the leaf moistening and feeding process, the system obtains the stored preheating parameter setting values ​​including: preheating inlet material flow setting value, preheating inlet moisture meter zero point setting value, preheating circulation hot air temperature setting value;

[0020] When the preheating parameter verification is applied to the thin plate wire drying process, the system obtains the stored preheating parameter setting values ​​including: the preheating inlet material flow setting value, the preheating expansion unit thrower speed setting value, and the preheating hot air initial temperature setting value;

[0021] When the pre-filling parameter verification is applied to the blending process, the system obtains the stored pre-filling parameter setting values ​​including: pre-filling shredded silk moisture setting value, pre-filling expanded silk moisture setting value, and pre-filling shredded silk instantaneous blending ratio setting value;

[0022] When the pre-filling parameter verification is applied to the flavoring process, the system obtains the stored pre-filling parameter setting values ​​including: pre-filling inlet material flow setting value, pre-filling recycled silk blending ratio setting value, and pre-filling recycled silk blending flow setting value.

[0023] Preferably, the preheating or prefilling process self-inspection includes: preheating process self-inspection and prefilling process self-inspection, wherein the preheating process self-inspection stage exists in the three processes of ultra-loosening, leaf moistening and adding materials, and thin plate drying, and the prefilling process self-inspection stage exists in the two processes of blending and flavoring.

[0024] More preferably, when the preheating process self-check is applied to the super-return loosening process, the actual values ​​of the parameters required by the system include: steam injection ratio, hot cycle wind angle actuator status, valve island compressed air supply pressure;

[0025] When the preheating process self-check is applied to the leaf moistening and feeding process, the actual values ​​of the parameters required by the system include: pre-filling flow rate, feeding forward predicted inlet moisture, and feed liquid weight;

[0026] When the preheating process self-check is applied to the thin plate drying process, the actual values ​​of the parameters required by the system include: the expansion unit forward predicted inlet moisture, the expansion unit steam flow, the drying machine barrel motor frequency, and the drying machine drum support wheel temperature;

[0027] When the pre-filling process self-check is applied to the blending process, the actual values ​​of the parameters required by the system include: the compressed air supply pressure of the valve island;

[0028] When the pre-filling process self-check is applied to the flavoring process, the actual values ​​of the parameters required by the system include: compressed air supply pressure of the atomizing flavor cold air valve island, flavoring forward predicted outlet moisture, and barrel temperature.

[0029] Preferably, the parameter verification before the production process includes: parameter verification before the production process after preheating, and parameter verification before the production process after prefilling, wherein the parameter verification stage before the production process after preheating exists in the three processes of ultra-loosening, leaf moistening and adding materials, and thin plate drying, and the parameter verification stage before the production process after prefilling exists in the two processes of blending and flavoring.

[0030] More preferably, when the preheating and pre-production process parameter verification is applied to the super-return loosening process, the actual values ​​of the parameters required by the system include: outlet setting value, drum speed setting value, steam ratio setting value;

[0031] When the preheating and pre-production process parameter verification is applied to the leaf moistening and feeding process, the actual values ​​of the parameters required by the system include: hot air temperature setting value, instantaneous flow setting value, and dehumidification wind speed setting value;

[0032] When the preheating and pre-production process parameter verification is applied to the thin-plate silk drying process, the actual values ​​of the parameters required by the system include: the set value of the outlet weight, the set value of the wall temperature of the silk drying machine, and the set value of the moisture content of the pure silk;

[0033] When the pre-filled post-production process parameter verification is applied to the blending process, the actual values ​​of the parameters required by the system include: the set value of the moisture content of the shredded stems, the set value of the moisture content of the expanded silk, and the set value of the instantaneous blending ratio of the shredded stems;

[0034] When the pre-filling and pre-production process parameter verification is applied to the flavoring process, the actual values ​​of the parameters required by the system include: material flow setting value, recycled silk blending ratio setting value, and outlet moisture setting value.

[0035] Preferably, the alarm device is a buzzer for emitting sound and / or light alarms.

[0036] The early warning system disclosed in the present invention is mainly divided into three stages: parameter verification before preheating or prefilling, self-checking during preheating or prefilling, and parameter verification before the production process. The parameter verification before preheating or prefilling and the parameter verification before the production process are mainly matched by the program automatically. When the parameter matching fails, an alarm message is issued on the system interface and the buzzer sounds an alarm. In this way, workers can modify the parameters in a targeted manner through the alarm message, which greatly shortens the time spent before officially entering production, and effectively avoids the production quality defects caused by the existence of extremely individual parameter mismatches. The self-check during preheating or prefilling is to determine whether the actual parameters in the preheating or prefilling process exceed the allowable error range through the program. If it exceeds the allowable error range, an early warning is issued on the system interface. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] Figure 1 This is a functional stage diagram of the early warning system of the present invention before each process of cigarette making enters the production process.

[0038] Figure 2 A pre-production warning flow chart of a pre-production warning system for each process of cigarette making before entering the production process according to the processing sequence of the present invention

[0039] Figure 3 Flow chart of another example of an early warning system before each process of cigarette making enters the production process of the present invention DETAILED DESCRIPTION

[0040] To make the purpose, technical solution and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific implementation methods described herein are only used to explain the present invention and do not limit the scope of protection of the present invention.

[0041] like Figure 1 As shown, an early warning system before each process of cigarette making enters the production process stores the set values ​​of various indicator parameters required for preheating or prefilling and the production process; includes multiple sensors for real-time detection of the actual value of each parameter; the early warning stage includes three stages: parameter verification stage before preheating / prefilling, self-check stage during preheating / prefilling, and parameter verification stage before the production process.

[0042] The early warning system of the present invention can be applied to multiple processes of the cigarette shred process, and multiple stage checks are performed before entering each process, such as: super-loosening process, leaf moistening and feeding process, thin plate drying process, blending process, and flavoring process. The early warning system of the present invention pre-stores the preheating / pre-filling standard parameters and production standard parameters of each brand batch of materials. The system is also equipped with multiple sensors for real-time detection of the actual values ​​of each parameter.

[0043] like Figure 2 As shown, in the super-return loosening process, after the early warning system obtains the stored preheating parameter setting value and the matching parameters of the winCC device, it determines whether the stored preheating parameter standard is consistent with the winCC device standard. If it is inconsistent, a pop-up window alarm and a buzzer alarm are issued; if it is consistent, it enters the next stage;

[0044] The system obtains the actual values ​​of the required parameters through a variety of sensors, and compares the preheated or pre-filled set values ​​with the actual values ​​of the required parameters: the early warning system obtains the actual values ​​of the parameters of various valves through a variety of sensors, and determines the status of various valves in real time. When the valve is in an abnormal state, a pop-up warning is issued; the early warning system will also compare the actual values ​​of the parameters sent back by the sensor with the equipment standards, calculate the difference, and determine in real time whether the difference is within the tolerance range. If it exceeds the tolerance range, a pop-up warning will be issued; the early warning system obtains the parameters of the moisture meter. When the parameters of the moisture meter remain unchanged within the preset time or the parameters of the moisture meter suddenly drop to 0, the moisture meter is judged to have crashed and a pop-up warning is issued; if there is no such situation, enter the next stage.

[0045] During the parameter verification phase before production after preheating, the early warning system obtains the stored production parameter setting values ​​and MES standards, and compares the production parameter setting values ​​with the MES standards. When the deviation exceeds the deviation threshold or the parameter standard is inconsistent, a pop-up window alarm and a buzzer alarm sound, otherwise, the production process is entered. After the production is completed, the leaf moistening and feeding process begins.

[0046] In the leaf moistening and feeding process, the early warning system first determines whether the stored preheating parameter standard is consistent with the winCC equipment standard. If it is inconsistent, a pop-up window alarm and a buzzer alarm sound. If it is consistent, it enters the preheating stage.

[0047] Then the early warning system determines in real time whether various valves are working normally. When the valve is in abnormal operation, a pop-up warning will be issued. It will also determine in real time whether various index parameters are within the tolerance range. Here, the system calculates the difference between the actual value of the parameter sent back by the sensor and the equipment standard, and compares the difference with the tolerance. When the difference exceeds the tolerance, a pop-up warning will be issued. At the same time, it also determines in real time whether the moisture meter is dead. When the moisture meter parameters remain unchanged for a certain period of time or the moisture meter parameters suddenly drop to 0, it is determined that the moisture meter is dead and a pop-up warning will be issued. It is also necessary to determine whether the pre-allocated leaf storage time exceeds the maximum storage time. When the time exceeds the maximum storage time, a pop-up warning will be issued. It is also necessary to determine whether the material is in the wrong cabinet. When the brand batch of the material leaving the cabinet does not match the brand batch of the material to be added, a pop-up alarm will be issued. When the above situation does not occur, the parameter verification stage before production after preheating is entered.

[0048] During this stage, the early warning system compares the production parameter standards with the MES workshop standards. When the parameter standards are inconsistent, a pop-up alarm and a buzzer alarm sound. When they are consistent, the production process begins.

[0049] After the super-loosening process is completed, the thin plate wire drying process begins.

[0050] In the thin-plate drying process, the early warning system first determines whether the stored preheating parameter standard is consistent with the WinCC equipment standard. If it is inconsistent, a pop-up window alarm and a buzzer alarm sound. If it is consistent, it enters the preheating stage.

[0051] Then the early warning system determines in real time whether various valves are working normally. When the valve is in abnormal operation, a pop-up warning will be issued. It will also determine in real time whether various index parameters are within the tolerance range. Here, the system calculates the difference between the actual value of the parameter sent back by the sensor and the equipment standard, and compares the difference with the tolerance. When the difference exceeds the tolerance, a pop-up warning will be issued. At the same time, it also determines in real time whether the moisture meter is dead. When the moisture meter parameters remain unchanged for a certain period of time or the moisture meter parameters suddenly drop to 0, it is determined that the moisture meter is dead and a pop-up warning will be issued. It is also necessary to determine whether the leaf storage time exceeds the maximum storage time. When the time exceeds the maximum storage time, a pop-up warning will be issued. It is also necessary to determine whether the material is in the wrong cabinet. When the brand batch of the material leaving the cabinet does not match the brand batch of the material to be added, a pop-up alarm will be issued. When the above situation does not occur, the parameter verification stage before production after preheating is entered.

[0052] In this stage, the early warning system compares the production parameter standards with the MES workshop standards. When the parameter standards are inconsistent, a pop-up alarm and a buzzer sound an alarm. When they are consistent, the production process begins. After the production is completed, the blending process begins.

[0053] In the blending process, the early warning system first determines whether the stored preheating parameter standard is consistent with the winCC equipment standard. If it is inconsistent, a pop-up window alarm and a buzzer alarm sound. If it is consistent, it enters the pre-filling stage.

[0054] Then the early warning system determines in real time whether various valves are working normally. When the valve is in abnormal working state, a pop-up window warning is issued. At the same time, it also determines in real time whether the moisture meter is dead. When the moisture meter parameters remain unchanged for a certain period of time or the moisture meter parameters suddenly drop to 0, it is determined that the moisture meter is dead and a pop-up window warning is issued. The early warning system also needs to determine whether the pre-filling is started normally. If the pre-filling is not started, a pop-up window warning is issued. The early warning system also needs to determine whether the pre-filling is in place. If the pre-filling photoelectric tube is still not in the pre-filling state after the specified time, a pop-up window alarm is issued. If there is no such situation, the parameter verification stage before production after pre-filling is entered.

[0055] During this stage, the early warning system compares the production parameter standards with the MES workshop standards. When the parameter standards are inconsistent, a pop-up alarm and a buzzer alarm sound. When they are consistent, the production process begins.

[0056] After the production is completed, the fragrance adding process begins.

[0057] In the aroma-adding process, after the early warning system obtains the stored preheating parameter setting values ​​and the matching parameters of the winCC device, it determines whether the stored preheating parameter standards are consistent with the winCC device standards. If they are inconsistent, a pop-up window alarm and a buzzer alarm will sound; if they are consistent, it enters the next stage;

[0058] The system obtains the actual values ​​of the required parameters through a variety of sensors, and compares the preheated or pre-filled set values ​​with the actual values ​​of the required parameters: the early warning system obtains the actual values ​​of the parameters of various valves through a variety of sensors, and judges the status of various valves in real time. When the valve is in an abnormal state, a pop-up warning is issued; the early warning system will also compare the actual values ​​of the parameters sent back by the sensor with the equipment standards, calculate the difference, and judge in real time whether the difference is within the tolerance range. If it exceeds the tolerance range, a pop-up warning will be issued; the early warning system obtains the parameters of the moisture meter. When the parameters of the moisture meter remain unchanged within the preset time or the parameters of the moisture meter suddenly drop to 0, it is judged that the moisture meter is dead and a pop-up warning is issued; the early warning system also needs to determine whether the temporary storage time of the mixed yarn exceeds the preset maximum storage time, and a pop-up warning will be issued when the maximum storage time is exceeded; the early warning system also needs to determine whether the material is in the wrong cabinet, and a pop-up alarm will be issued when the brand batch of the material leaving the cabinet does not match the brand batch of the material to be added; if there is no such situation, the parameter verification stage before production after preheating is entered;

[0059] During the parameter verification phase before production after preheating, the early warning system obtains the stored production parameter setting values ​​and MES standards, and compares the production parameter setting values ​​with the MES standards. When the deviation exceeds the deviation threshold or the parameter standard is inconsistent, a pop-up alarm and a buzzer sound an alarm. Otherwise, the production process is entered. At this point, the cigarette wire production is completed.

[0060] The present invention provides an early warning system before each process of cigarette making enters the production process. The self-checking stage of the preheating or prefilling process can be divided into the following abnormal diagnosis types: threshold judgment, whether the valve is open, moisture meter crash phenomenon, whether the leaf storage time is too long, and material discharge situation. Among them, the threshold judgment indicates that the difference between the actual value or predicted value of the preheating or prefilling parameter and the preheating or prefilling parameter setting value exceeds the tolerance range; whether the valve is open indicates whether the status of various valves is normally opened; the moisture meter crash phenomenon indicates that the moisture meter does not change for a long time or suddenly becomes 0; the leaf storage time indicates whether the length of time the material stays in the leaf storage cabinet exceeds the normal time; the material discharge situation indicates whether the wrong material is discharged.

[0061] When the sensor collects the device status of various valves in real time, 0 means not open and 1 means open. At this stage, if the device status of the valve is still not 0 after x1 seconds, it is determined that the valve is in an abnormal state, and the early warning system issues an early warning message to remind workers that a valve or several valves are abnormal.

[0062] When the sensor collects the actual parameter values ​​of the moisture meter in real time, the system uses an algorithm to determine whether the value of the moisture meter remains unchanged for x2 seconds or the value of the moisture meter drops sharply to 0. The early warning system then issues an early warning message to inform workers that the moisture meter is in an abnormal state.

[0063] The warning logic of the leaf storage time is to first compare the brand of the material to be put into the cabinet with the brand of the material to be stored in the leaf storage cabinet. If the brand is inconsistent, the system will issue a warning to inform the worker that the material is about to be put into the wrong leaf storage cabinet. If the brand is consistent, the time starts from the moment the material enters the leaf storage cabinet. If the material is stored in the leaf storage cabinet for more than x2 hours, the system will issue a warning to inform the worker that the storage time of this batch of materials is too long.

[0064] The early warning logic for the discharge situation is to compare whether the batch number and brand number stored in the discharge cabinet are consistent with the batch number and brand number to be produced. If they are inconsistent, the system will issue an early warning to inform the workers that the batch of materials belongs to the wrong cabinet.

[0065] like Figure 3 As shown, the early warning system of the present invention can also be set up with a total check before entering the production process. During the total check, the system obtains the stored preheating or prefilling parameter setting values ​​of each process and the matching parameters of the winCC device, and then compares the preheating or prefilling parameter setting values ​​with the matching parameters. When the deviation exceeds the deviation threshold, an early warning is issued through the alarm device;

[0066] The system obtains the actual value of the required parameters of each process through various sensors installed in each process, compares the preheated or pre-filled set value with the actual value of the required parameter, and issues an early warning through the alarm device when the deviation exceeds the deviation threshold;

[0067] The system obtains the stored parameter setting values ​​and MES standards for each process, and compares the parameter setting values ​​for production with the MES standards. When the deviation exceeds the deviation threshold, an alarm device is used to issue an early warning.

[0068] Subsequent process and Figure 2 The embodiments shown are consistent.

[0069] Figure 3 In the embodiment shown, the parameters of each process are first checked (i.e., initially determined) before entering the production process. Since some parameters will change in real time as each process is completed after entering the production process, before entering each process, Figure 2The embodiment shown in the figure also performs stage verification. This improved method makes the error detection rate in the subsequent stage more accurate, providing production personnel with correction time and more accurate reference data.

[0070] The present invention provides an early warning system for each process of cigarette making before entering the production process, which essentially divides the production parameters into standard parameters and dynamic parameters. The standard parameters are parameters with preset values ​​or preset threshold characteristics, and the dynamic parameters are parameters that need to obtain values ​​in real time. By analyzing the stored production parameters, the standard parameters are compared with the set values ​​of the corresponding processes required by the process. For the dynamic parameters, the system provides a hypothetical range based on the existing production data.

[0071] The present invention discloses an early warning system before each process of cigarette silk making enters the production process. The pre-stored parameters and real-time parameters are first obtained before the cigarette silk making process enters the production process, and the system automatically verifies whether the preheating or pre-filled relevant parameter standards match the set values ​​of the WinCC device, which reduces the time and error rate compared with manual verification. The present invention can automatically detect in real time whether each valve device is in a normal working state, and can also detect whether the actual value of the parameter deviates too much from the set value. It saves time to a great extent, improves the work efficiency of workers, and is beneficial to ensuring the quality of cigarette production. The present invention can automatically verify whether the production-related parameter standards in the system match the MES workshop standards, saves labor and time, and can effectively avoid cigarette production quality defects caused by parameter mismatch.

[0072] The present invention provides an early warning system for each process of cigarette making before entering the production process. Before officially entering the production process, there are also a preheating or pre-filling stage, a preheating or pre-filling process stage, and a pre-production stage after preheating or pre-filling. These three stages require verification of various indicator parameters to ensure that the parameters are set correctly. At the same time, it is also necessary to determine whether various types of equipment are in normal working condition.

[0073] At present, parameter verification before preheating or prefilling and before the production process is usually confirmed manually. Manual confirmation is time-consuming and laborious, and there is also the possibility of parameter "mismatch". Once parameter "mismatch" occurs and the production is started directly, the cigarettes produced subsequently may have quality defects. The present invention can automatically verify the parameters in real time through the algorithm in the system, which can effectively save time and avoid quality defects in cigarette production. It is necessary to detect the status of various valve equipment during the preheating or prefilling stage. Only when each valve is in normal working condition can the subsequent production be guaranteed to be problem-free. Omissions are inevitable when manually checking the valve status. The present invention can solve the omission problem and ensure that various types of equipment are in normal working condition. At the same time, manual inspection may also result in the valve being in normal working condition during inspection, but sudden abnormalities occur during the preheating or prefilling process. This requires real-time detection of the equipment. The present invention can monitor the equipment in real time and immediately issue an early warning once an abnormality occurs during the process.

[0074] The implementation case adopted by the present invention is to verify the preheating or prefilling parameter standards stored in the system proposed by the present invention with the winCC equipment standards, and to verify the production parameters stored in the system proposed by the present invention with the MES workshop standards. However, the embodiments of the present invention are not limited to the above cases, but are also applicable to verifying the parameters of the work order with the winCC equipment standards and the MES workshop standards. The real-time early warning system for parameters before the production process of the present invention can also be applied to parameter early warnings before entering the production process in other industries, and it is only necessary to replace the work order parameters and standard parameters used in production with those of other industries.

[0075] The specific implementation methods described above are only preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, supplements and equivalent substitutions made within the scope of the principles of the present invention should be included in the protection scope of the present invention.

Claims

1. An early warning system before each process of cigarette making enters the production process, characterized in that: The early warning system stores the set values ​​of various index parameters required for preheating or prefilling and production processes; the early warning system includes a variety of sensors for real-time detection of the actual values ​​of various parameters; The early warning system includes multiple stage checks before entering each process: preheating or pre-filling parameter check stage, preheating or pre-filling process self-check stage, and pre-production process parameter check stage; wherein, In the parameter verification stage before preheating or prefilling, the system obtains the stored preheating or prefilling parameter setting values ​​and the matching parameters of the WinCC device, and then compares the preheating or prefilling parameter setting values ​​with the matching parameters. When the deviation exceeds the deviation threshold, an alarm device is used to issue an early warning; During the self-checking stage of the preheating or prefilling process, the system obtains the actual value of the required parameters through a variety of sensors, and compares the preheating or prefilling set value with the actual value of the required parameters. When the deviation exceeds the deviation threshold, an alarm device will issue an early warning; In the parameter verification stage before the production process, the system obtains the stored parameter setting values ​​and MES standards required for production, and compares the parameter setting values ​​required for production with the MES standards. When the deviation exceeds the deviation threshold, an alarm device will issue an early warning; The pre-preheating or pre-filling parameter verification includes: pre-preheating parameter verification and pre-pre-filling parameter verification, wherein the pre-preheating parameter verification stage exists in the three processes of super-return loosening, leaf moistening and feeding, and thin plate drying, and the pre-pre-filling parameter verification stage exists in the two processes of blending and flavoring; When the preheating parameter verification is applied to the super-return loosening process, the system obtains the stored preheating parameter setting values ​​including: preheating inlet material flow setting value, preheating slice blending flow setting value, and preheating inlet moisture meter zero point setting value; When the preheating parameter verification is applied to the leaf moistening and feeding process, the system obtains the stored preheating parameter setting values ​​including: preheating inlet material flow setting value, preheating inlet moisture meter zero point setting value, preheating circulation hot air temperature setting value; When the preheating parameter verification is applied to the thin plate wire drying process, the system obtains the stored preheating parameter setting values ​​including: the preheating inlet material flow setting value, the preheating expansion unit thrower speed setting value, and the preheating hot air initial temperature setting value; When the pre-filling parameter verification is applied to the blending process, the system obtains the stored pre-filling parameter setting values ​​including: pre-filling shredded silk moisture setting value, pre-filling expanded silk moisture setting value, and pre-filling shredded silk instantaneous blending ratio setting value; When the pre-filling parameter verification is applied to the flavoring process, the system obtains the stored pre-filling parameter setting values ​​including: pre-filling inlet material flow setting value, pre-filling recycled silk blending ratio setting value, and pre-filling recycled silk blending flow setting value.

2. The early warning system for each process of cigarette making before entering the production process as claimed in claim 1, characterized in that: The actual values ​​of the parameters include: the working status of various valves and moisture meters, the leaf storage time, and the discharge information.

3. The early warning system for each process of cigarette making before entering the production process as claimed in claim 1, characterized in that: The preheating or prefilling process self-inspection includes: preheating process self-inspection and prefilling process self-inspection, wherein the preheating process self-inspection stage exists in the three processes of ultra-loosening, leaf moistening and adding materials, and thin plate drying, and the prefilling process self-inspection stage exists in the two processes of blending and flavoring.

4. The early warning system for each process of cigarette making before entering the production process as claimed in claim 3, characterized in that: When the preheating process self-check is applied to the super-return loosening process, the actual values ​​of the parameters required by the system include: steam injection ratio, hot cycle wind angle actuator status, and valve island compressed air supply pressure; When the preheating process self-check is applied to the leaf moistening and feeding process, the actual values ​​of the parameters required by the system include: pre-filling flow rate, feeding forward predicted inlet moisture, and feed liquid weight; When the preheating process self-check is applied to the thin plate drying process, the actual values ​​of the parameters required by the system include: the expansion unit forward predicted inlet moisture, the expansion unit steam flow, the drying machine barrel motor frequency, and the drying machine drum support wheel temperature; When the pre-filling process self-check is applied to the blending process, the actual values ​​of the parameters required by the system include: the compressed air supply pressure of the valve island; When the pre-filling process self-check is applied to the flavoring process, the actual values ​​of the parameters required by the system include: compressed air supply pressure of the atomizing flavor cold air valve island, flavoring forward predicted outlet moisture, and barrel temperature.

5. The early warning system for each process of cigarette making before entering the production process as claimed in claim 1, characterized in that: The parameter verification before the production process includes: parameter verification before the production process after preheating and parameter verification before the production process after prefilling, wherein the parameter verification stage before the production process after preheating exists in the three processes of ultra-loosening, leaf moistening and feeding, and thin plate drying, and the parameter verification stage before the production process after prefilling exists in the two processes of blending and flavoring.

6. The early warning system for each process of cigarette making before entering the production process as claimed in claim 5, characterized in that: When the preheating production process pre-parameter verification is applied to the super-return loosening process, the actual values ​​of the parameters required by the system include: outlet setting value, drum speed setting value, steam ratio setting value; When the preheating and pre-production process parameter verification is applied to the leaf moistening and feeding process, the actual values ​​of the parameters required by the system include: hot air temperature setting value, instantaneous flow setting value, and dehumidification wind speed setting value; When the preheating and pre-production process parameter verification is applied to the thin-plate silk drying process, the actual values ​​of the parameters required by the system include: the set value of the outlet weight, the set value of the wall temperature of the silk drying machine, and the set value of the moisture content of the pure silk; When the pre-filled post-production process parameter verification is applied to the blending process, the actual values ​​of the parameters required by the system include: the set value of the moisture content of the shredded stems, the set value of the moisture content of the expanded silk, and the set value of the instantaneous blending ratio of the shredded stems; When the pre-filling and pre-production process parameter verification is applied to the flavoring process, the actual values ​​of the parameters required by the system include: material flow setting value, recycled silk blending ratio setting value, and outlet moisture setting value.

7. The early warning system for each process of cigarette making before entering the production process as claimed in claim 1, characterized in that: The alarm device is a buzzer, which is used to emit sound and / or light alarms.

8. An early warning system for each process of cigarette making before entering the production process as claimed in any one of claims 1 to 7, characterized in that: The early warning system also includes a general check before entering the production process: After the system obtains the stored preheating or prefilling parameter setting values ​​of each process and the matching parameters of the winCC equipment, it compares the preheating or prefilling parameter setting values ​​with the matching parameters. When the deviation exceeds the deviation threshold, an alarm device is used to issue an early warning. The system obtains the actual values ​​of the required parameters of each process through a variety of sensors, compares the preheated or pre-filled set values ​​with the actual values ​​of the required parameters, and issues an early warning through the alarm device when the deviation exceeds the deviation threshold; The system obtains the stored parameter setting values ​​and MES standards for each process, and compares the parameter setting values ​​for production with the MES standards. When the deviation exceeds the deviation threshold, an alarm device is used to issue an early warning.

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