An automatic control method for reducing cigarette empty rate

Abstract

The present invention discloses an automatic control method for reducing the empty cigarette rate, comprising the following steps: S1: when a cigarette making machine rejects an empty cigarette, an internal program of an industrial control computer records the MCP pulse value corresponding to the empty cigarette; S2: comparing the MCP pulse value with a pulse setting range to determine whether the empty cigarette is an internal discharge empty cigarette or an external discharge empty cigarette; S3: producing cigarettes according to a set output value, and cumulatively calculating the number of internal discharge empty cigarettes and the number of external discharge empty cigarettes; S4: comparing the absolute value of the difference between the internal discharge number and the external discharge number with a set difference value to pre-determine whether the cigarette making machine's head tightening position is offset; S5: based on whether the offset is established in the pre-determination, the industrial control computer performs the following corresponding actions: automatically adjusting the offset of the head tightening position, issuing an alarm and manually adjusting the offset of the head tightening position, continuing normal production without adjustment, and repeating S1. The present method achieves high product quality and production efficiency.

Description

Technical Field

[0001] The present invention relates to the field of tobacco production, in particular to an automatic control method for reducing the empty cigarette rate. Background Art

[0002] Cigarette making machines produce substandard cigarettes during the production process. One quality defect is hollow ends, which are areas where the tobacco at the end of the cigarette is not fully filled, missing, or hollow. Hollow ends not only affect the appearance of the cigarette but also its ignition performance. During production, most of these defects can be detected and rejected by the cigarette making machine.

[0003] To reduce the end surface of the cigarette, a compensation amount is added to the cutting position of the end surface of the cigarette. That is, three grooves are added to the corresponding chopping disc position to reduce the amount of tobacco cut off at the end surface position, thereby achieving the purpose of reducing the end surface of the cigarette. The position where the compensation is made has more tobacco, so it is also called the tight end position. The tight end position has a great influence on whether the cigarette is hollow. The amount of tobacco in the cigarette is controlled by the chopping disc mechanism. The more tobacco the chopping disc cuts off, the less tobacco is in the cigarette. In other words, the amount of tobacco cut off by the chopping disc determines the amount of tobacco contained in the cigarette. Chinese patents CN202286281 U and CN109918736A introduce the existing technology related to the tight end position.

[0004] During production, the splitter disc's compensation position (i.e., tight end position) can shift. This causes the cutter to miss the tight end position. The proper tight end position should be midway between a pair of inner and outer stacks. After the cutter's cut, the inner and outer stacks each account for half of the tight end increase, resulting in fuller ends for both stacks. Once the splitter disc's groove shifts, the tight end position shifts, resulting in an imbalance in the amount of tobacco added to the inner or outer stacks, increasing the empty tobacco rate.

[0005] Currently, the operator's experience is primarily used to determine whether the inner and outer rows of tightening heads are offset. If offset, the operator uses an Allen wrench to manually rotate the cutter disc groove mechanism, shifting the cutter disc groove position and adjusting the tightening head position. Existing technology relies too heavily on operator experience. In real-world production, many operators fail to assess the relationship between empty end rejection and tightening head position, and fail to adjust the tightening head position due to imbalanced empty end rejection between the inner and outer rows. Even if they do make adjustments, manual adjustments using an Allen wrench are imprecise and unsatisfactory. Summary of the Invention

[0006] The purpose of the present invention is to provide an automatic control method for reducing the empty cigarette rate, actively determine whether the position of the inner and outer rows of tight heads is offset and make corresponding adjustments, improve processing efficiency, and simplify the device structure.

[0007] In order to achieve the above technical objectives, the present invention provides an automatic control method for reducing the empty cigarette rate, which includes: S1: when the cigarette making machine removes an empty cigarette, the internal program of the industrial control computer records the MCP pulse value corresponding to the empty cigarette; S2: comparing the MCP pulse value with the pulse setting range to determine whether the empty cigarette is an inner-discharged empty cigarette or an outer-discharged empty cigarette; S3: producing cigarettes according to the output setting value, and accumulating and calculating the inner-discharge number of the inner-discharged empty cigarettes and the outer-discharged number of the outer-discharged empty cigarettes respectively; S4: comparing the absolute value of the difference between the inner-discharge number and the outer-discharge number with the difference setting value to pre-judge whether there is an offset in the tightening position of the cigarette making machine; S5: according to whether the offset is established in the pre-judgment, the industrial control computer performs the following corresponding actions: automatically adjusting the offset of the tightening position, giving an alarm and manually adjusting the offset of the tightening position, continuing normal production without adjustment and repeating S1.

[0008] This invention provides an automatic control method for reducing the empty cigarette rate. By calculating and comparing MCP pulse values, the method determines whether there is a tight end position deviation and takes appropriate action. This method is highly automated and accurate, ensuring smooth production and achieving high product quality and efficiency.

[0009] As a further improvement, the pulse setting range includes: 0 to 9 corresponding to the inner empty cigarettes and 10 to 19 corresponding to the outer empty cigarettes.

[0010] As a further improvement, the output setting value is 10,000 pieces.

[0011] As a further improvement, during the normal production, the industrial computer records the cigarette output and the amount of empty cigarettes rejected.

[0012] As a further improvement, the difference setting value is 20. When the difference setting value is greater than or equal to 20, the offset in the pre-judgment is established. When the difference setting value is less than 20, the offset in the pre-judgment is not established. No adjustment is required and normal production continues and S1 is repeated.

[0013] As a further improvement, when the offset in the pre-judgment is established, the industrial computer reads the current tightening head position and compares it with the set tightening head position to obtain the deviation percentage. The industrial computer makes corresponding actions according to the deviation percentage: automatically adjusts the offset of the tightening head position, alarms and manually adjusts the offset of the tightening head position, continues normal production without adjustment and repeats S1.

[0014] As a further improvement, when the deviation percentage is greater than or equal to 20%, the industrial computer sends a stop command and waits for manual processing. When the deviation percentage is less than 20% and greater than or equal to 5%, the industrial computer sends an adjustment instruction and adjusts the current tightening head position. When the deviation percentage is less than 5%, normal production continues without adjustment and S1 is repeated.

[0015] As a further improvement, the industrial computer sends a shutdown command and waits for manual processing, which includes: the industrial computer sends an alarm command to the PLC, the PLC controls the shutdown and displays an alarm on the human-computer interaction interface, and waits for manual processing.

[0016] As a further improvement, a chopping disc groove fine-tuning device is further arranged at the chopping disc groove of the cigarette making machine, and the chopping disc groove fine-tuning device rotates to adjust the relative position of the chopping disc groove and the tobacco rod, thereby changing the tightening head position.

[0017] As a further improvement, the industrial computer sends an adjustment instruction and adjusts the current tightening head position, including: the industrial computer sends a control signal to the servo controller, and the servo controller drives the servo motor to rotate the cutter disc groove fine-tuning device to adjust the tightening head position.

[0018] The method of the present invention is easy to use, can quickly and accurately determine whether the tight head position is offset and automatically adjust it, thereby reducing manual operation misjudgment and improving the level of production automation. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 Flow chart of the method of the present invention;

[0020] Figure 2 Schematic diagram of the groove of the riving cutter disc in the present invention.

[0021] Figure numerals: 1 - fine-adjustment device for the groove of the riving blade disc; 2 - groove of the riving blade disc. DETAILED DESCRIPTION

[0022] like Figure 1 and Figure 2As shown, the present invention provides an automatic control method for reducing the empty cigarette rate, which includes: S1: when the cigarette making machine removes an empty cigarette, the internal program of the industrial control computer records the MCP pulse value corresponding to the empty cigarette; S2: comparing the MCP pulse value with the pulse setting range to determine whether the empty cigarette is an inner-discharged empty cigarette or an outer-discharged empty cigarette; S3: producing cigarettes according to the output setting value, and accumulating and calculating the inner-discharge number of the inner-discharged empty cigarettes and the outer-discharged number of the outer-discharged empty cigarettes respectively; S4: comparing the absolute value of the difference between the inner-discharge number and the outer-discharge number with the difference setting value to pre-judge whether there is an offset in the tightening position of the cigarette making machine; S5: according to whether the offset is established in the pre-judgment, the industrial control computer performs the following corresponding actions: automatically adjusting the offset of the tightening position, giving an alarm and manually adjusting the offset of the tightening position, continuing normal production without adjustment and repeating S1.

[0023] This invention provides an automatic control method for reducing the empty cigarette rate. By calculating and comparing MCP pulse values, the method determines whether there is a tight end position deviation and takes appropriate action. This method is highly automated and accurate, ensuring smooth production and achieving high product quality and efficiency.

[0024] As a further improvement, the pulse setting range includes: 0 to 9 corresponding to the inner empty cigarettes and 10 to 19 corresponding to the outer empty cigarettes.

[0025] As a further improvement, the output setting value is 10,000 pieces.

[0026] As a further improvement, during the normal production, the industrial computer records the cigarette output and the amount of empty cigarettes rejected.

[0027] As a further improvement, the difference setting value is 20. When the difference setting value is greater than or equal to 20, the offset in the pre-judgment is established. When the difference setting value is less than 20, the offset in the pre-judgment is not established. No adjustment is required and normal production continues and S1 is repeated.

[0028] As a further improvement, when the offset in the pre-judgment is established, the industrial computer reads the current tightening head position and compares it with the set tightening head position to obtain the deviation percentage. The industrial computer makes corresponding actions according to the deviation percentage: automatically adjusts the offset of the tightening head position, alarms and manually adjusts the offset of the tightening head position, continues normal production without adjustment and repeats S1.

[0029] As a further improvement, when the deviation percentage is greater than or equal to 20%, the industrial computer sends a stop command and waits for manual processing. When the deviation percentage is less than 20% and greater than or equal to 5%, the industrial computer sends an adjustment instruction and adjusts the current tightening head position. When the deviation percentage is less than 5%, normal production continues without adjustment and S1 is repeated.

[0030] As a further improvement, the industrial computer sends a shutdown command and waits for manual processing, which includes: the industrial computer sends an alarm command to the PLC, the PLC controls the shutdown and displays an alarm on the human-computer interaction interface, and waits for manual processing.

[0031] As a further improvement, a chopping disc groove fine-tuning device 1 is further arranged at the chopping disc groove 2 of the cigarette making machine. The chopping disc groove fine-tuning device 1 rotates to adjust the relative position of the chopping disc groove 2 and the tobacco rod, thereby changing the tightening head position.

[0032] As a further improvement, the industrial computer sends an adjustment instruction and adjusts the current tightening head position, including: the industrial computer sends a control signal to the servo controller, and the servo controller drives the servo motor to rotate the cutter disc groove fine-tuning device 1 to adjust the tightening head position.

[0033] The method of the present invention is easy to use, can quickly and accurately determine whether the tight head position is offset and automatically adjust it, thereby reducing manual operation misjudgment and improving the level of production automation.

[0034] In a preferred embodiment, each time a cigarette is rejected by the cigarette making machine, the MCP pulse value of the empty cigarette is recorded within the industrial computer. The internal program of the industrial computer reads this MCP pulse value. If the MCP pulse value at the time of rejection is 0-9, the rejected cigarette is determined to be an inner exhaust cigarette; if the MCP pulse value at the time of rejection is 10-19, the rejected cigarette is determined to be an outer exhaust cigarette. The rejection of the first 10,000 cigarettes in the current production is recorded. When the absolute difference between the inner and outer exhaust cigarettes rejected by the cigarette making machine exceeds a set value of 20, it is determined that the tight end position of the cigarette may have shifted, and the position of the chopping disc groove should be adjusted to balance the amount of tobacco on the end faces of the inner and outer exhaust cigarettes. At this time, the program prompts the industrial computer to send a corresponding signal (servo motor rotation direction and angle) to the servo controller, which controls the servo motor to rotate and adjust the chopping disc groove position fine-tuning device, adjusting the tight end position to balance the increase in tobacco on the end faces of the inner and outer exhaust cigarettes, thereby reducing the number of empty cigarettes.

[0035] Turning the fine-tuning device counterclockwise moves the tightening head toward the direction of the tobacco bundle's movement. Turning the fine-tuning device clockwise moves the tightening head away from the direction of the tobacco bundle's movement. Simultaneously, the industrial computer reads the machine's real-time tightening head position data and compares it with the set value.

[0036] If the real-time position differs from the set value by more than 20%, it means that the tightening head position offset is too large and needs to be stopped for manual adjustment. At this time, the industrial computer will send a stop signal to control the cigarette making machine to stop and display the alarm message "Tightening head position offset is too large" on the human-computer interaction interface.

[0037] If the actual position differs from the set position by 5% to 20%, the industrial computer sends a corresponding signal (servo motor rotation direction and angle) to the servo controller, and the servo controller controls the servo motor to rotate the cutter disc groove position fine-tuning device to adjust the tightening head position until it is the same as the set position.

[0038] If the deviation between the actual position and the set position is less than 5%, it means that the reason for the large difference in the internal and external exhaust smoke is not the chopping disc device. The industrial computer will not issue any instructions for the time being, and the program will return to the first step to continue the cycle.

[0039] The present invention automatically identifies the number of empty cigarettes in internal and external exhaust cigarettes, realizes automatic adjustment and correction of the tight head position, and has a high degree of automation. The present invention uses a servo motor to adjust the position of the chopping disc groove, and accurately adjusts the position of the chopping disc groove. By adopting the method described in the present invention, the number of empty cigarettes generated by the tight head position deviating from the set value can be effectively reduced. The present invention uses the MCP pulse value to identify the internal and external exhaust cigarettes, and automatically rotates the chopping disc groove position through the servo motor to adjust the chopping disc groove position, with high adjustment accuracy and feedback adjustment of the chopping disc groove (tight head position). In addition, the factory database can be used to participate in the entire control process.

[0040] It should be understood that the scope of the present invention is not limited to the non-limiting embodiments, and it should be understood that the non-limiting embodiments are only provided as examples. The substantial scope of protection required by this application is further reflected in the scope provided by the independent claims and their dependent claims.

Claims

1. An automatic control method for reducing the empty cigarette rate, characterized by: S1: When the cigarette making machine removes each empty cigarette, the internal program of the industrial computer records the MCP pulse value corresponding to the empty cigarette; S2: Comparing the MCP pulse value with the pulse setting range to determine whether the empty cigarette is an internal empty cigarette or an external empty cigarette; S3: producing cigarettes according to the set output value, and accumulating and calculating the number of internally discharged empty butt cigarettes and the number of externally discharged empty butt cigarettes; S4: Compare the absolute value of the difference between the inner row quantity and the outer row quantity with a difference setting value to pre-judge whether there is an offset in the tightening head position of the cigarette making machine. The difference setting value is 20. When the difference setting value is greater than or equal to 20, the pre-judgment of the offset is established. When the difference setting value is less than 20, the pre-judgment of the offset is not established. No adjustment is required to continue normal production and repeat S1. S5: Based on whether the offset in the pre-judgment is established, the industrial computer performs the following corresponding actions: automatically adjusts the offset of the tightening head position, issues an alarm and manually adjusts the offset of the tightening head position, continues normal production without adjustment and repeats S1; when the offset in the pre-judgment is established, the industrial computer reads the current tightening head position and compares it with the set tightening head position to obtain the deviation percentage, and the industrial computer performs the following corresponding actions based on the deviation percentage: automatically adjusts the offset of the tightening head position, issues an alarm and manually adjusts the offset of the tightening head position, continues normal production without adjustment and repeats S1; when the deviation percentage is greater than or equal to 20%, the industrial computer sends a stop command and waits for manual processing; when the deviation percentage is less than 20% and greater than or equal to 5%, the industrial computer sends an adjustment instruction and adjusts the current tightening head position; when the deviation percentage is less than 5%, continues normal production without adjustment and repeats S1; The chopping disc groove of the cigarette making machine is also provided with a chopping disc groove fine-tuning device, which rotates to adjust the relative position of the chopping disc groove and the tobacco rod, thereby changing the tight head position.

2. The automatic control method for reducing the empty cigarette rate according to claim 1, characterized in that: The pulse setting range includes: 0 to 9 corresponding to the inner empty cigarettes and 10 to 19 corresponding to the outer empty cigarettes.

3. The automatic control method for reducing the empty cigarette rate according to claim 1, characterized in that: The output setting value is 10,000 pieces.

4. The automatic control method for reducing the empty cigarette rate according to claim 1, characterized in that: During the normal production, the industrial computer records the cigarette output and the amount of empty cigarettes rejected.

5. The automatic control method for reducing the empty cigarette rate according to claim 1, characterized in that: The industrial computer sends a shutdown command and waits for manual processing, which includes: the industrial computer sends an alarm command to the PLC, the PLC controls the shutdown and displays an alarm on the human-computer interaction interface, and waits for manual processing.

6. The automatic control method for reducing the empty cigarette rate according to claim 1, characterized in that: The industrial computer sends an adjustment instruction and adjusts the current tightening head position, which includes: the industrial computer sends a control signal to a servo controller, and the servo controller drives a servo motor to rotate the cutter disc groove fine-tuning device to adjust the tightening head position.

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