Loose conditioning moisture addition ratio setting method

Abstract

The application discloses a loose moisture regaining water adding proportion setting method, and the main design concept is that overall design is carried out based on feedforward prediction, feedback correction and grouping processing, various elements influencing the moisture at the outlet of the low-temperature moisture regaining machine are completely represented, and accurate setting of the water adding proportion of the loose moisture regaining machine is realized, specifically, a water adding contribution rate coefficient is introduced on the theoretical water adding proportion, and the relationship between the moisture at the outlet of the loose moisture regaining machine and the water adding proportion is completely represented; then, the results of historical batches of production are fully utilized to guide current production, a correction coefficient is formed based on the pre-calibrated water adding deviation of each bale of tobacco leaves, and the problem caused by the difference of tobacco water absorption is solved by means of a differential correction strategy, and a feedback hierarchical correction mechanism serving as a bias compensation further solves the problem of inaccurate feedback control caused by the high time delay characteristics of the moisture regaining system, and it can be seen that the application provides a better water adding setting scheme for the tobacco industry to replace the existing mode.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of cigarette manufacturing, in particular to a loose conditioning water proportion setting method. BACKGROUND

[0002] At present, the loose conditioning machine is used for conditioning the bales of cut tobacco in the production process of cigarette production enterprises. The loose conditioning machine only has hot air temperature control and water flow control, and does not have outlet moisture control function. The outlet moisture control is a function developed by the user. In the industry, two methods of constant water addition and manual control are generally used. Due to the influence of factors such as incoming material moisture, tobacco water absorption characteristics, and environmental temperature and humidity, the control effect is not ideal.

[0003] In summary, the existing methods are as follows: manual control is too dependent on the experience of operators, and the set water proportion needs to be continuously adjusted and corrected to achieve the required outlet moisture; the method of controlling outlet moisture based on grouping processing is adopted, that is, different water proportions are given to all bales in a batch; generally, it takes 186 seconds for the material to pass from the inlet to the outlet, and PID feedback control often causes violent oscillation; in addition, most manufacturers use the process of secondary water supplementing after the moisture balance of the bales in the tank after constant water addition loose conditioning. This process has the disadvantages of poor conditioning and complex processing.

[0004] It can be seen that the existing technology is affected by multiple factors such as operating experience, incoming material moisture, tobacco water absorption characteristics, and environmental temperature and humidity, resulting in large fluctuations in the outlet moisture of the conditioning and feeding process, which exceeds the outlet moisture standard requirements. SUMMARY

[0005] In view of the above, the present application aims to provide a loose conditioning water proportion setting method to solve the problem of large fluctuations in the outlet moisture of the low-temperature conditioning and feeding process.

[0006] The technical solution adopted by the present application is as follows:

[0007] The present application provides a loose conditioning water proportion setting method, which comprises the following steps:

[0008] Real-time acquisition of the outlet moisture of loose conditioning, incoming material moisture, steam flow, tobacco flow, and pre-set target moisture;

[0009] Using the outlet moisture and the incoming material moisture, the theoretical water addition proportion is obtained;

[0010] Using the steam flow, the tobacco flow, and the theoretical water addition proportion, the water addition contribution rate coefficient is obtained, which is used to represent the influence of steam in the water addition process;

[0011] Combining the water addition contribution rate coefficient with the theoretical water addition proportion, the first optimized water addition proportion prediction value is obtained;

[0012] obtaining a pre-stored incoming material characteristic coefficient corresponding to the current production material, the incoming material characteristic coefficient being used to characterize the water absorption characteristic of the tobacco leaf;

[0013] combining the incoming material characteristic coefficient with the first water addition ratio prediction value to obtain a second water addition ratio prediction value;

[0014] obtaining a feedback correction value corresponding to the current deviation between the outlet moisture and the target moisture based on the current deviation and in combination with pre-set different deviation levels;

[0015] correcting the second water addition ratio prediction value by using the feedback correction value to obtain a final prediction value for setting the water addition ratio.

[0016] In at least one possible implementation manner, the water addition contribution rate coefficient is obtained according to the following formula:

[0017] Water addition contribution rate coefficient = (1-steam flow / (theoretical water addition ratio*tobacco leaf flow))×loss coefficient; wherein the loss coefficient is a pre-set constant value.

[0018] In at least one possible implementation manner, the incoming material characteristic coefficient is calculated according to the following formula: Incoming material characteristic coefficient = (outlet moisture-target moisture) / target moisture.

[0019] In at least one possible implementation manner, the water addition ratio setting method further comprises:

[0020] calculating the incoming material characteristic coefficient of each package of material in the formula according to the historical production cumulative amount, and recording in the historical database;

[0021] correspondingly taking out the incoming material characteristic coefficient of each package of material from the historical database based on the current production cumulative amount.

[0022] In at least one possible implementation manner, the water addition ratio setting method further comprises:

[0023] pre-setting several deviation interval ranges between the set outlet moisture and the target moisture;

[0024] correspondingly setting feedback correction values of different levels for each of the deviation interval ranges.

[0025] In at least one possible implementation manner, the theoretical water addition ratio is obtained according to the following formula: Theoretical water addition ratio = (outlet moisture-incoming moisture) / (100-outlet moisture).

[0026] Compared with the prior art, the main design concept of the present application is that, based on feedforward prediction, feedback correction and grouping processing, the three links are overall designed, and each element affecting the moisture at the outlet of the low-temperature conditioning is fully characterized, so that the accurate setting of the water addition ratio of the loose conditioning machine is realized. Specifically, a water addition contribution rate coefficient is introduced on the theoretical water addition ratio, and the relationship between the moisture at the outlet of the loose conditioning machine and the water addition ratio is fully characterized. Then, the results of the historical batches of production are fully utilized to guide the current production, a correction coefficient is formed based on the pre-calibrated water addition deviation of each bale of tobacco, and the problem caused by the difference in tobacco water absorption is solved by the differential correction strategy. The feedback hierarchical correction mechanism as the bias compensation further solves the problem of inaccurate feedback control caused by the high delay characteristic of the conditioning feeding system. Therefore, the present application provides a better water addition setting scheme for the tobacco industry to replace the existing mode. BRIEF DESCRIPTION OF DRAWINGS

[0027] In order to make the purpose, technical scheme and advantages of the present application clearer, the present application will be further described below in combination with the drawings, in which:

[0028] Figure 1 The flowchart of the loose conditioning water addition ratio setting method provided by the embodiment of the present application is shown. DETAILED DESCRIPTION

[0029] The embodiments of the present application will be described in detail below, and the examples of the embodiments are shown in the drawings, in which the same or similar reference numerals represent the same or similar elements or elements having the same or similar functions throughout. The embodiments described below by referring to the drawings are exemplary and are only used to explain the present application, and cannot be interpreted as a limitation on the present application.

[0030] The present application proposes an embodiment of a loose conditioning water addition ratio setting method, specifically as shown in Figure 1 , which includes:

[0031] Step S1, real-time acquisition of the outlet moisture of the loose conditioning, the incoming material moisture, the steam flow, the tobacco flow and the preset target moisture;

[0032] Step S2, calculation of the theoretical water addition ratio by using the outlet moisture and the incoming material moisture;

[0033] Step S3, obtaining of the water addition contribution rate coefficient by using the steam flow, the tobacco flow and the theoretical water addition ratio, the water addition contribution rate coefficient being used to characterize the influence of steam in the water addition process;

[0034] Step S4, combination of the water addition contribution rate coefficient and the theoretical water addition ratio to obtain the first water addition ratio prediction value after optimization;

[0035] Step S5, obtaining a pre-stored incoming material characteristic coefficient corresponding to the current production material, the incoming material characteristic coefficient being used to characterize the water absorption characteristic of the tobacco leaf;

[0036] Step S6, combining the incoming material characteristic coefficient with the first water adding proportion prediction value to obtain a second water adding proportion prediction value;

[0037] Step S7, obtaining a feedback correction value corresponding to the current deviation between the outlet moisture and the target moisture based on the current deviation and in combination with a pre-set different deviation level;

[0038] Step S8, correcting the second water adding proportion prediction value by using the feedback correction value to obtain a final prediction value for setting the water adding proportion.

[0039] Based on the above embodiment, the general design idea of the present application is to use the comprehensive means of "feedforward water adding prediction, feedback hierarchical correction, and group differential processing" to completely characterize each element affecting the outlet moisture of the low-temperature moisture conditioning of the tobacco bale.

[0040] The comprehensive control model can be shown as formula (1):

[0041]

[0042] In the formula, W is the final water adding proportion prediction result, M2 is the outlet moisture, M1 is the incoming moisture, λ is the water adding contribution rate coefficient, X1 is the incoming material characteristic coefficient, and X2 is the feedback correction value.

[0043] (1) The water adding contribution rate coefficient λ can be obtained in the following manner:

[0044] It can be understood that the theoretical water adding proportion is W 理论 The water adding contribution rate coefficient λ can be obtained based on formula (2):

[0045]

[0046] In actual operation, the incoming tobacco bale is generally changed into bulk material with moisture between 17-21% after loose moisture conditioning processing, and the increase of the moisture of the conditioned tobacco leaf is mainly composed of water adding and steam, therefore, the present application introduces the water adding contribution rate coefficient λ, and the purpose is to obtain a precise water adding proportion setting value to solve the problem of inaccurate water adding proportion setting prediction. It should be noted that, for convenience of calculation, the aforementioned moisture can be normalized, for example, if the relative value of the outlet moisture is 30%, 30 can be taken as the outlet moisture.

[0047] Based on formula (2), the present application proposes an optimized water adding proportion prediction formula, which can be shown as formula (3):

[0048]

[0049] The water addition contribution rate coefficient λ here can refer to formula (4) shown by the formula:

[0050]

[0051] Wherein, L1 is the steam flow (kg / h), L2 is the tobacco flow (kg / h), and β is the loss coefficient. Because part of the two media of water and steam is discharged as impurity gas by the impurity removal system of the loose conditioning machine, so as to maintain the constant pressure in the drum, under the given working condition, the opening and the impurity removal air volume of the impurity removal system are fixed, and therefore the loss coefficient β can be a preset empirical constant.

[0052] The acquisition method of the incoming material characteristic coefficient X1 is as follows:

[0053] The predicted water addition amount (the first water addition proportion prediction value) calculated according to the optimized water addition amount formula (3) can meet the requirement for most tobacco bales in a batch of 40 tobacco bales, but it cannot be excluded that the value deviation of a certain proportion of tobacco bales is large. Based on this, the outlet moisture and the corresponding set moisture (i.e., the preset outlet moisture control target according to the production process) in the production history data are analyzed when the application is conceived, and the difference between the two is obtained, and then the incoming material characteristic coefficient (the characteristic of tobacco water absorption) X1 of the tobacco bale can be represented, which can refer to the following formula (5). The incoming material characteristic coefficient can be recorded in the data corresponding to each tobacco bale according to the cumulative weight of the material, and provide the basis for fine tuning in the characteristic dimension for the next production.

[0054]

[0055] The acquisition method of the feedback correction value X2 is as follows:

[0056] According to the high delay characteristic of the conditioning system, the size of the actual moisture deviation from the set target at the outlet can be obtained, and the water addition proportion is corrected again by using a preset different correction bias value, and the deviation can be set as α, and the calculation formula is shown in formula (6):

[0057] α=M 出口 -M 设定 (6)

[0058] The conditioning system can be segmented according to the size of the deviation α, and the assignment of the feedback correction value X2 is shown in Table 1.

[0059]

[0060] The introduction of the feedback correction value X2 makes the influence of environmental temperature and humidity, steam saturation and other factors all converted to the feedback correction value X2, and then the moisture regain system can automatically adapt to different working conditions.

[0061] Finally, in combination with the foregoing, it can be supplemented that the material needs 186 seconds from the inlet to the outlet. In order to accurately explore the relationship between the characteristics of each cigarette in the leaf group formula, the moisture content of the incoming material and the water addition ratio and the moisture at the outlet, the application aligns the data obtained in actual application by using the queue technology, realizes the space-time relationship conversion of the key production data, and builds a loose moisture regaining machine moisture auxiliary control system. The system mainly includes three modules: a water addition ratio prediction module, a feedback grading correction module and an incoming material characteristic correction module.

[0062] I. Water addition ratio prediction module:

[0063] The water addition prediction module is used to predict the current water addition ratio according to the tobacco flow, steam flow, outlet moisture, incoming material moisture, output of the feedback grading correction module and output of the incoming material characteristic correction module. Finally, the loose moisture regaining machine control system takes the predicted value as the water addition set value.

[0064] II. Feedback grading correction module:

[0065] The feedback grading correction module is used to output correction components corresponding to different preset levels through the deviation of the target moisture and the actual moisture (from the moisture meter), and further output to the aforementioned water addition ratio prediction module.

[0066] III. Incoming material characteristic correction module:

[0067] The incoming material characteristic correction module is used to calculate the deviation of the actual moisture (from the moisture meter) and the target moisture (here, the deviation also represents the tobacco water absorption characteristics, and its value can be used as the aforementioned incoming material characteristic coefficient). Specifically, the incoming material characteristic coefficient of each cigarette in the formula can be calculated according to the production cumulative amount, that is, the cumulative data is used to obtain the water absorption characteristics of each cigarette material in the formula, and at the same time, the water absorption characteristics of each cigarette material in the formula are recorded in the historical database (the database stores the water absorption characteristics values of the cigarette materials of different batches and formulas recorded during the production of historical batches). The incoming material characteristic correction module is also used to output the water absorption characteristics coefficient of the current production material. Specifically, the water absorption characteristics coefficient of each cigarette is output from the historical database to the aforementioned water addition ratio prediction module according to the production cumulative amount, so as to accurately correct the predicted value.

[0068] In addition, the system framework can be transplanted to a computer in actual application, and the operation difficulty can be reduced and the work efficiency can be improved by machine-assisted manual control, thereby improving the automation level of the moisture control of the moisture regaining machine.

[0069] To sum up, the main design concept of the present application is that, based on feedforward prediction, feedback correction and grouping processing, the three links are overall designed, and each element affecting the moisture at the outlet of the low-temperature conditioning is fully characterized, and the accurate setting of the water addition ratio of the loose conditioning machine is realized, specifically, the water addition contribution rate coefficient is introduced on the theoretical water addition ratio, and the relationship between the moisture at the outlet of the loose conditioning machine and the water addition ratio is fully characterized; then, the results of the historical batches of production are fully utilized to guide the current production, the correction coefficient is formed based on the pre-calibrated water addition deviation of each bale of tobacco leaves, and the problem caused by the difference in tobacco absorption is solved by the differential correction strategy, and the feedback hierarchical correction mechanism as the bias compensation further solves the problem of inaccurate feedback control caused by the high delay characteristic of the conditioning feeding system, so it can be seen that the present application provides a better water setting scheme for the tobacco industry to replace the existing mode.

[0070] In the embodiments of the present application, "at least one" refers to one or more, and "multiple" refers to two or more. The "and / or" describes the association relationship of the associated objects, which means that there can be three kinds of relationships, for example, A and / or B can represent the existence of A alone, the existence of A and B at the same time, and the existence of B alone. Wherein A and B can be singular or plural. The character " / " generally represents that the associated objects before and after it are in an "or" relationship. "At least one of the following" and the like means any combination of these items, including any combination of single or multiple items. For example, at least one of a, b and c can represent: a, b, c, a and b, a and c, b and c, or a and b and c, wherein a, b, c can be single or multiple.

[0071] The above embodiments according to the drawings illustrate the structure, features and effects of the present application, but the above are only preferred embodiments of the present application, and it should be noted that the technical features involved in the above embodiments and preferred modes can be reasonably combined and matched into various equivalent schemes by those skilled in the art without departing from, changing the design idea and technical effects of the present application. Therefore, the present application is not limited by the drawings shown in the drawings, and any change or modification made according to the concept of the present application, or any equivalent embodiment within the scope of the present application, shall be within the scope of the present application.

Claims

1. A method for setting the water ratio for loose, rehydrated products, characterized in that, include: Real-time acquisition of loose and rehydrated outlet moisture, incoming material moisture, steam flow, tobacco leaf flow, and preset target moisture; Using the outlet moisture content and the incoming material moisture content, the theoretical water addition ratio is calculated as follows: Theoretical water addition ratio = (outlet moisture content - incoming material moisture content) / (100 - outlet moisture content). Using steam flow rate, tobacco flow rate, and the theoretical water addition ratio, a water addition contribution rate coefficient is obtained. The water addition contribution rate coefficient is used to characterize the influence of steam during the water addition process, and the water addition contribution rate coefficient = (1 - steam flow rate / (theoretical water addition ratio × tobacco flow rate)) × loss coefficient, wherein the loss coefficient is a preset fixed value. By combining the water addition contribution rate coefficient with the theoretical water addition ratio, the optimized first water addition ratio prediction value is obtained. Obtain the pre-stored incoming material characteristic coefficient corresponding to the current production material. The incoming material characteristic coefficient is used to characterize the water absorption characteristics of tobacco leaves, and the incoming material characteristic coefficient = (outlet moisture - target moisture) / target moisture. The incoming material characteristic coefficient is combined with the first water addition ratio prediction value to obtain the second water addition ratio prediction value; Based on the current deviation between the outlet moisture content and the target moisture content, and in combination with different preset deviation levels, a feedback correction value corresponding to the current deviation is obtained; The second predicted water addition ratio is corrected using the feedback correction value to obtain the final predicted value used to set the water addition ratio.

2. The method for setting the water ratio for loosening and rehydrating as described in claim 1, characterized in that, The method for setting the water addition ratio also includes: The material characteristic coefficient of each package of material in the formula is calculated based on the historical cumulative production volume and recorded in the historical database. Based on the current cumulative production volume, the incoming material characteristic coefficient of each package of material is retrieved from the historical database.

3. The method for setting the water ratio for loosening and rehydrating as described in claim 1, characterized in that, The method for setting the water addition ratio also includes: Several deviation ranges between the outlet moisture content and the target moisture content are preset; Different levels of feedback correction values ​​are set for each of the aforementioned deviation ranges.

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