A control system and method for the amount of tobacco shreds returned in a cigarette rolling machine.

Abstract

This invention discloses a control system for the amount of tobacco recycle in a cigarette rolling machine, comprising a human-machine interface (1), a main PLC (2), a VE part PLC (3), a servo system (4), an AC servo motor (5), a needle roller (6), a tobacco forming system (7), a leveling mechanism (8), a recycle vibration groove (9), a recycle height detector (10), a cigarette rolling process (11), and an SRM weight control system (12). This invention provides extremely stable control over the amount of tobacco recycle. The servo system allows for setting and quantifying parameters, reducing adjustment time based on experience, lowering the workload of maintenance personnel, and improving product quality. A recycle height detector is added to address fluctuations in the amount of recycle, providing fine-tuning compensation and safety warnings.

Description

Technical Field

[0001] This invention relates to the field of cigarette making machine technology in tobacco manufacturing systems, and specifically to a control system and method for the amount of tobacco shreds returned in a cigarette making machine. Background Technology

[0002] Currently, a certain factory has 21 sets of cigarette rolling machines. The ZJ17 model cigarette rolling machine is highly efficient, stable, reliable, and highly automated throughout the entire production process. However, it still has some defects. For example, the thickness of the recycled tobacco in the recycled tobacco trough 9 fluctuates greatly, causing uneven recycled tobacco quantity. This recycled tobacco is then reused and mixed into the tobacco in the storage area, causing changes in the tobacco structure ratio and resulting in unstable cigarette quality (such as empty head rate, weight SD deviation, etc.). Through technical analysis, the needle roller 6 of this model uses a DC carbon brush motor for drive, which has many hidden dangers. With wear and internal scaling, signal instability and voltage changes cause uneven speed of needle roller 6, resulting in frequent fluctuations in the recycled tobacco quantity and causing quality problems. At the same time, the original needle roller 6 was driven by a DC speed regulation system (such as...). Figure 1 As shown in the image, the following problems exist during use: 1. Outdated technology, short hardware lifespan, and low precision. The original machine's rear feed drive uses DC speed regulation technology, consisting of a DC motor, speed controller, and tachogenerator. The carbon brushes and commutator of the DC motor are easily damaged components with short lifespans; the speed controller is a custom-designed circuit board with long lead times and difficult troubleshooting; the tachogenerator has low precision. 2. Frequent malfunctions and time-consuming repairs of the original rear feed drive, all occurring after the fact—when quality defects such as unqualified weight, loose or spongy cigarettes are discovered—pose serious quality risks. 3. The system lacks intuitive quantitative data on speed, current, and load rate, forcing maintenance personnel to rely on experience for adjustments, resulting in intensive maintenance and impacting the operating efficiency and product quality of the cigarette machine.

[0003] Therefore, it is necessary to redesign a system that has a stable effect on controlling the amount of tobacco recycle, which can set and quantify parameters, shorten maintenance time, and improve product quality; it can also reduce the labor intensity of maintenance personnel, thereby improving efficiency and quality; and a recycle height detector has been added to address fluctuations in the amount of tobacco recycle, which can provide fine-tuning compensation and safety warnings. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of existing technologies and provide a control system and method for the amount of tobacco recycle in cigarette rolling machines. This invention solves the problem of maintenance personnel adjusting the amount of tobacco recycle based on experience. Through stable control of the recycle via a servo system, it improves the quality of cigarette rolling, with significant breakthroughs in improving the empty head rate and weight SD deviation of cigarettes. Simultaneously, a recycle height detector is added to address fluctuations in the amount of tobacco recycle, providing fine-tuning compensation and safety warnings. The use of the entire control system also reduces the workload of maintenance personnel, improving efficiency and effectiveness.

[0005] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0006] A control system for the amount of tobacco shreds returned in a cigarette rolling machine includes a human-machine interface (1), a main PLC (2), a VE part PLC (3), a servo system (4), an AC servo motor (5), a needle roller (6), a tobacco shred forming system (7), a leveling mechanism (8), a return shred vibration groove (9), a return shred height detector (10), a cigarette rolling process (11), and an SRM weight control system (12). The human-machine interface is electrically connected to the VE part PLC via the main PLC. The needle roller of the tobacco feeding system is used to feed tobacco shreds to the tobacco shred forming system. A leveling mechanism is set downstream of the tobacco shred forming system. A cigarette rolling process is set downstream of the leveling mechanism. The SRM weight control system is electrically connected to the leveling mechanism and the human-machine interface. Excess tobacco shreds after trimming are re-transported to the needle roller of the tobacco feeding system via the return shred vibration groove. The servo system is electrically connected to the VE part PLC and the AC servo motor respectively. The AC servo motor is used to drive the needle roller to rotate. A return shred height detector is set in the return shred vibration groove. The return shred height detector is electrically connected to the VE part PLC.

[0007] Furthermore, the return wire height detector (10) includes a potentiometer (14), a balance arm (15), a counterweight (16), and a roller (17). The return wire height detector is installed above the return wire oscillating groove. The potentiometer is installed on the pivot. One end of the pivot is connected to the roller through a first swing arm, and the other end is connected to the counterweight through a second swing arm. The counterweight is installed on the right end of the second swing arm through a waist-shaped hole and a threaded connector. The installation position of the counterweight is adjustable. The outer circumferential surface of the roller is provided with multiple array-type protrusions. The roller can rotate relative to the first swing arm, and the first swing arm and the second swing arm can rotate relative to the pivot.

[0008] Furthermore, the wire retraction height detector detects changes in the thickness of the wire retraction by varying the height of the rollers. This is converted into an electrical signal by a potentiometer and fed back to the PLC at the VE section for processing. After further calculation and processing by the PLC program at the VE section, the signal is fed back to the servo system. The encoder pulse signal is then converted by the controller, which slightly alters the speed of the AC servo motor, thereby achieving a fine-tuning compensation or correction of the wire retraction amount. Simultaneously, when the wire retraction height detector detects a signal indicating that the wire retraction exceeds 40% or 50%, it serves as a safety warning and stops the machine.

[0009] Furthermore, the tobacco shreds conveyed by the needle rollers eventually flow into the cigarette forming system. Under the action of the SRM weight control system, the leveling mechanism trims the tobacco shreds, and the trimmed tobacco shreds flow into the return trough. The return trough is driven by a separate motor, and the inertia generated by the eccentricity recovers the excess tobacco shreds after trimming, returning the tobacco shreds to the tobacco supply system for reuse. Under certain weight standard requirements, the return of tobacco shreds has a close relationship with the structural distribution of the entire rolled tobacco and the internal and external quality of the cigarette.

[0010] Furthermore, the AC servo motor provides power to the needle roller via a synchronous belt, ensuring the stability and uniformity of tobacco conveying.

[0011] Furthermore, based on the structure of different tobacco brands and the requirements of the SRM weight control system, the speed of the AC servo motor is set in the servo system's setting module to meet the requirements of weight and the internal and external quality of the cigarette. Maintenance and operation personnel make minor corrections / adjustments to the speed parameters of the AC servo motor on the human-machine interface based on the cigarette's test data and appearance quality. Under normal circumstances, the impact of the servo system's control on the fluctuation of the recycle is greatly reduced, and the recycle height detector does not need to frequently correct the recycle thickness. It only compensates or alarms and stops the machine in a timely manner when the recycle thickness fluctuates greatly or is abnormal.

[0012] This invention discloses a control system and method for the amount of tobacco shreds returned in a cigarette machine. The control effect of this invention on the amount of tobacco shreds returned is extremely stable. The servo system can set and quantify parameters, and can reduce the adjustment time for maintenance based on experience, thereby reducing the labor intensity of maintenance personnel. It also improves product quality and plays a role in improving efficiency. In response to fluctuations in the amount of tobacco shreds returned, a tobacco shred height detector is added to provide fine-tuning compensation and safety warning. Attached Figure Description

[0013] Figure 1 This is a control principle diagram of an existing technology used in a cigarette machine tobacco return quantity control system.

[0014] Figure 2 This is a control principle diagram of the tobacco return amount control system for cigarette machines according to the present invention;

[0015] Figure 3 This is a schematic diagram of the servo system control principle of the present invention;

[0016] Figure 4 This is a schematic diagram of the wire return height detector structure of the present invention.

[0017] In the diagram: 1. Human-Machine Interface, 2. Main PLC, 3. VE Part PLC, 4. Servo System, 5. AC Servo Motor, 6. Needle Roller, 7. Tobacco Shred Forming System, 8. Leveling Mechanism, 9. Recycled Cord Vibration Groove, 10. Recycled Cord Height Detector, 11. Cigarette Rolling Process, 12. SRM Weight Control System, 13. Recycled Cord, 14. Potentiometer, 15. Balance Arm, 16. Counterweight, 17. Roller. Implementation

[0018] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0019] The present invention will now be described in further detail with reference to the accompanying drawings.

[0020] like Figure 2-4 As shown, a control system for the amount of tobacco shreds returned in a cigarette rolling machine includes a human-machine interface 1, a main PLC 2, a VE section PLC 3, a servo system 4, an AC servo motor 5, a needle roller 6, a tobacco forming system 7, a leveling mechanism 8, a return shred vibration groove 9, a return shred height detector 10, a cigarette rolling process 11, and an SRM weight control system 12. The human-machine interface 1 is electrically connected to the VE section PLC 3 via the main PLC 2. The needle roller 6 of the tobacco feeding system is used to feed tobacco shreds to the tobacco forming system 7. A leveling mechanism 8 is located downstream of the tobacco forming system 7, and the cigarette rolling process 11 is located downstream of the leveling mechanism 8. The SRM weight control system 12 is electrically connected to the leveling mechanism 8 and the human-machine interface 1. Excess tobacco shreds after trimming are re-feeded to the needle roller 6 of the tobacco feeding system via the return shred vibration groove 9. The characteristic feature is that the servo system 4 is connected to the VE section PLC 6 via the return shred vibration groove 9. 3. AC servo motor 5 is electrically connected to drive needle roller 6 to rotate. The return yarn trough 9 is equipped with a return yarn height detector 10, which is electrically connected to PLC 3 at VE.

[0021] like Figure 4As shown, the wire return height detector 10 includes a potentiometer 14, a balance arm 15, a counterweight 16, and a roller 17. The wire return height detector 10 is installed above the wire return oscillating groove 9. The potentiometer 14 is installed on the pivot part. One end of the pivot part is connected to the roller 17 through a first swing arm, and the other end is connected to the counterweight 16 through a second swing arm. The counterweight 16 is installed on the right end of the second swing arm through a waist-shaped hole and a threaded connector. The installation position of the counterweight 16 is adjustable. The outer circumferential surface of the roller 17 is provided with multiple array-type protrusions. The roller 17 is rotatable relative to the first swing arm, and the first swing arm and the second swing arm are rotatable relative to the pivot part.

[0022] The rewind height detector 10 detects the thickness change of the rewind amount 13 by changing the height of the roller 17. The result is converted into an electrical signal (1.5V, 15%) by the potentiometer 14 and fed back to the PLC3 at the VE section for processing. After the signal is processed by the program of the PLC3 at the VE section, it is fed back to the servo system 4. The encoder pulse signal is then converted by the controller and slightly changes the speed of the AC servo motor 5, thereby achieving the effect of fine adjustment compensation or correction of the rewind amount (the servo system 4 performs targeted correction and compensation for the rewind amount fluctuation based on the encoder signal). At the same time, when the rewind height detector 10 detects a signal that the rewind amount exceeds 40% or 50%, it serves as a safety warning and stops the machine.

[0023] The human-machine interface (HMI) 1, main PLC 2, VE section PLC 3, needle roller 6, tobacco forming system 7, leveling mechanism 8, tobacco return trough 9, cigarette rolling process 11, and SRM weight control system 12 are the essential basic structures and functions of the cigarette rolling machine, and their design positions remain unchanged from the initial position of the equipment. The tobacco conveyed by the needle roller 6 eventually flows into the cigarette forming system 7. Under the action of the leveling mechanism 8 and the SRM weight control system 12, the leveling mechanism 8 trims the tobacco, and the trimmed tobacco flows into the tobacco return trough 9.

[0024] Servo system 4 adopts AC servo control technology. Its main function is to adjust parameters appropriately according to the tobacco structure, quantify the rotation speed of needle roller 6, and transmit power to it. The entire servo system is installed on the electrical cabinet on the lower right side of the rear of the cigarette machine. AC servo motor 5 provides power to needle roller 6 through synchronous belt, ensuring the stability and uniformity of tobacco feeding.

[0025] Based on the structure of different tobacco grades and in accordance with the requirements of the SRM weight control system 12, the speed of the AC servo motor 5 is set in the setting module of the servo system 4 to meet the requirements of weight and internal and external quality of the cigarette. Maintenance and operation personnel can make minor corrections / adjustments to the speed parameters of the AC servo motor 5 on the human-machine interface 1 based on the test data and appearance quality of the cigarette.

[0026] AC servo control technology has the following advantages: (1) Low failure rate, long service life, and maintenance-free. (2) High control precision: The servo controller uses a digital signal processor (DSP) as the control core, combined with a high-precision encoder and sine wave control drive, and the speed change is smooth, which can achieve high-precision control. (3) Easy maintenance: The servo controller has complete diagnostic functions, and with the display panel, the system operating status can be quickly diagnosed and the cause of the fault can be determined; the AC servo motor is small in size and light in weight (about 1 / 5 of the original motor), and the disassembly and assembly are more time-saving.

[0027] The tobacco return trough 9 is driven by a separate motor. It uses the inertia generated by the eccentricity to recover the excess tobacco after shearing and return the tobacco to the tobacco supply system for reuse. Under certain weight standard requirements, the tobacco return has a close relationship with the structural distribution of the entire rolled tobacco and the internal and external quality of the cigarette.

[0028] Under normal circumstances, the control of the servo system 4 significantly reduces the impact of wire return fluctuations. The wire return height detector 10 does not need to frequently correct the thickness of the wire return 13; it only compensates or alarms and stops the machine in a timely manner when the fluctuation of the wire return amount 13 is large or abnormal. The entire control system is stable, has a long service life, and has achieved a qualitative breakthrough in improving the quality of multiple products; at the same time, it reduces the labor intensity of maintenance personnel.

[0029] This invention discloses a control system and method for the amount of tobacco shreds returned in a cigarette machine. The control effect of this invention on the amount of tobacco shreds returned 13 is extremely stable. The servo system 4 can set and quantify parameters, and can reduce the adjustment time for maintenance based on experience, thereby reducing the labor intensity of maintenance personnel. It also improves product quality and plays a role in improving efficiency. In response to fluctuations in the amount of tobacco shreds returned 13, a tobacco shred height detector 10 is added to provide fine-tuning compensation and safety warning.

[0030] This invention employs a servo control system and a rewind height detection device to achieve digital quantification of the needle roller speed and stability of tobacco supply for different brands of tobacco. The detection of rewind thickness reduces fluctuations in the rolled tobacco structure and improves safety and reliability. This invention solves the problem of maintenance personnel adjusting the rewind amount of tobacco based on experience, reducing workload. It ensures the stability of cigarette rolling quality and has significant breakthrough significance in improving the empty head rate and weight SD deviation of cigarettes.

[0031] It should be noted that all directional indicators (such as up, down, left, right, front, back, horizontal, vertical, etc.) in the embodiments of the present invention are only used to explain the relative positional relationship and movement of the components in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indicator will also change accordingly. The "connection" can be a direct connection or an indirect connection. The "set", "set in", and "set at" can be a direct setting or an indirect setting.

[0032] The above embodiments are illustrative of the present invention and not intended to limit the invention. It is understood that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of the invention. The scope of protection of the present invention is defined by the appended claims and their equivalents.

Claims

1. A control system for the amount of tobacco returned to the tobacco feeder of a cigarette making machine, comprising a human-machine interface, a main machine PLC, a VE site PLC, a servo system, an AC servo motor, a needle roller, a tobacco forming system, a leveler mechanism, a returned tobacco vibration chute, a returned tobacco height detector, a cigarette wrapping process, an SRM weight control system, the human-machine interface being connected to the main machine PLC and the VE site PLC through electrical signals, the needle roller of the tobacco feeder being used to supply tobacco to the tobacco forming system, a leveler mechanism being arranged downstream of the tobacco forming system, a cigarette wrapping process being arranged downstream of the leveler mechanism, the SRM weight control system being connected to the leveler mechanism and the human-machine interface through electrical signals, the excess tobacco after trimming being re-supplied to the needle roller of the tobacco feeder through the returned tobacco vibration chute; characterized in that: The servo system is connected with the VE part PLC and the AC servo motor respectively, and the AC servo motor is used to drive the needle roller to rotate. The back yarn height detector includes a potentiometer, a balance arm, a counterweight, and a roller. The back yarn height detector is installed above the back yarn vibration tank. The potentiometer is installed on a pivot part. One end of the pivot part is connected with the roller through a first swing lever, and the other end is connected with the counterweight through a second swing lever. The counterweight is installed on the right end of the second swing lever through a waist-shaped hole and a threaded connecting piece. The installation position of the counterweight is adjustable. The outer periphery of the roller is provided with a plurality of arrayed protrusions. The roller is rotatable relative to the first swing lever. The first swing lever and the second swing lever are rotatable relative to the pivot part. The back yarn height detector detects the thickness change of the back yarn amount by changing the height position of the roller. The thickness change is converted into an electrical signal by the potentiometer, and the signal is fed back to the VE part PLC for processing. The signal is fed back to the servo system after being processed by the VE part PLC program. The encoder pulse signal is converted by the controller, and the rotation speed of the AC servo motor is slightly changed, so that the back yarn amount is slightly adjusted, compensated, or corrected. At the same time, when the back yarn height detector detects a signal that the back yarn amount exceeds 40% or 50%, a safety warning and shutdown function is realized. The tobacco delivered by the needle roller is finally collected into a cigarette forming system. The trimmer mechanism trims the tobacco under the action of the SRM weight control system, and the trimmed tobacco flows into the back yarn vibration tank. The back yarn vibration tank is driven by a separate motor, and the inertia generated by the eccentric distance is used to recycle the excess tobacco after trimming, so as to return the tobacco to the tobacco supply system for repeated use. Under certain weight standard requirements, the back yarn has a close relationship with the structure distribution of the rolled tobacco and the internal and external quality of the cigarette. The AC servo motor provides power for the needle roller through a synchronous belt, so as to ensure the stability and uniformity of the tobacco delivery. According to the structure of different brands of tobacco, the rotation speed of the AC servo motor is set in the setting module of the servo system according to the requirements of the SRM weight control system, so as to meet the requirements of weight and internal and external quality of the cigarette. Maintenance and operating personnel can slightly correct / adjust the rotation speed parameter of the AC servo motor according to the test data and appearance quality of the cigarette in the human-machine interface. Under normal circumstances, the control of the servo system greatly reduces the fluctuation of the back yarn, and the back yarn height detector does not need to frequently correct the thickness of the back yarn amount. Only in the case of large or abnormal thickness fluctuation of the back yarn amount, the back yarn height detector needs to be compensated and corrected or alarmed and stopped.

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