Tea rolling pressure monitoring method, automatic rolling process, device and storage medium

Abstract

This invention belongs to the field of tea processing machinery, specifically relating to a method for monitoring tea rolling pressure, an automatic rolling process, equipment, and storage medium. The tea rolling pressure monitoring method of this invention includes the following steps: obtaining capping height data within a specified time period by deploying floating sensors to monitor capping status; and determining the current rolling pressure stage of the rolling machine by using the average variance of the capping height data. This invention can accurately detect and determine the current rolling pressure stage in real time during the rolling process, and can be easily installed in various existing rolling machines, offering advantages such as low replacement costs and high detection efficiency.

Description

[0001] This invention is a divisional application of application number CN202210768210.X entitled "Tea Tea Rolling Pressure Monitoring Method, Automatic Rolling Process, Equipment and Storage Medium". The original application was filed on June 30, 2022, and the priority date was July 2, 2021. Technical Field

[0002] This invention belongs to the field of tea processing machinery, specifically relating to a method for monitoring tea rolling pressure, an automatic rolling process, equipment, and storage medium. Background Technology

[0003] Rolling is the most common tea-making process. In my country, disc rolling machines are commonly used instead of manual labor. During rolling, the rolling drum and rolling disc rotate horizontally in opposite directions, causing the fresh leaves to be repeatedly kneaded and rolled under the combined action of the pressure from the side walls and lid of the rolling drum, the reaction force of the rolling disc, and the friction of the edges, ultimately forming tightly rolled strips and releasing tea juice. A rolling process generally includes multiple pressure stages, namely, air pressure stage, light pressure stage, medium pressure stage, heavy pressure stage, etc.

[0004] In recent years, single-machine automation and continuous processing have become widespread in major tea-making processes such as fixation, shaping, and drying. Only rolling machines are used in a small number of large tea factories' continuous production lines because existing automatic rolling devices are expensive and have mediocre results. To this day, the vast majority of small and medium-sized tea factories still rely on workers to manually adjust the pressure throughout the entire process. The key to automatic kneading lies in how to detect and judge the kneading pressure. Traditional automatic kneading devices conventionally use pressure sensors to achieve this purpose, but the industry generally reports that they are ineffective. The root cause, besides the complex structure and high cost, is that existing kneading machines, in order to facilitate the rolling of the tea leaves into clumps, provide a certain amount of independent floating space for the pressure cap in their pressure mechanism. This allows the pressure cap to roll and rotate with the tea clumps in the kneading drum and float up and down. However, precisely because of this, the originally loose tea leaves in the kneading drum may roll into clumps and rise higher at any time during the kneading process, impacting the pressure cap and causing a sharp increase in kneading pressure. When they are loose again, the pressure will drop sharply. Moreover, during the light pressure and air pressure stages, the height change of the fresh leaves from loose to clumped is the greatest. The measured peak kneading pressure at the moment of light pressure is often greater than that during heavy pressure. This results in the actual data obtained by the pressure sensor being highly volatile and random throughout the process. Even after filtering with algorithms, it is difficult to use it to judge the pressure, leading to unsatisfactory measurement results.

[0005] Because the industry has long been unable to make a breakthrough in kneading pressure testing, major domestic kneading machine manufacturers still mainly produce manual pressure-adjustable single kneading machines. Most automatic continuous kneading equipment has chosen to abandon kneading pressure testing and mechanically rotate the pressure handwheel according to a predetermined program at fixed times and times. However, the difficulty of tea making lies in the fact that fresh leaves are typical non-standard agricultural products. Their maturity, moisture content, and required pressure vary every day. Mechanized timed and fixed-time pressure application is obviously difficult to meet the requirements.

[0006] Furthermore, existing kneading machines are primarily made of cast iron, making them extremely durable with an average lifespan exceeding 15 years. Given the large number of manual pressure-adjustable kneading machines of various manufacturers and types currently in use, simply replacing existing equipment with entirely new kneading machines presents significant challenges. Therefore, the question remains: can a method for monitoring kneading pressure be developed that can be attached to a traditional kneading machine as an external attachment, overcoming the interference caused by the tumbling of the kneading blades leading to cap rotation and vertical floating? This method would ensure both testing efficiency and data accuracy while reducing replacement costs and promoting widespread application. This has become a pressing technical problem for those skilled in the art. Summary of the Invention

[0007] The purpose of this invention is to overcome the shortcomings of the prior art and provide a method for monitoring the kneading pressure of tea leaves. This method can accurately detect and judge the current kneading pressure stage in real time during the kneading process. It can be easily installed in various existing kneading machines and has the advantages of low replacement cost and high detection efficiency.

[0008] To achieve the above objectives, the present invention adopts the following technical solution:

[0009] The method for monitoring the pressure during tea leaf rolling is characterized by the following steps:

[0010] By deploying floating sensors to monitor the cap status, data on the cap's floating height over a specified time period is obtained. The kneading pressure stage of the current kneading machine is then determined by using the average variance of the floating height data.

[0011] The method of average variance of buoyancy height includes the following sub-steps:

[0012] The height of the cap rising during the kneading process is collected within a specified time period and stored as an array. Then, the average value and variance of the array are calculated. Kneading pressure stage data are set, and the average value of the rising height is compared with the kneading pressure stage data to determine air pressure and heavy pressure. The variance value, which represents the magnitude of cap fluctuation, is compared with the kneading pressure stage data to distinguish between light pressure and medium pressure.

[0013] When using the average variance of the upward floating height method, the set kneading pressure stage data are as follows:

[0014] When the object is a single-arm screw-type kneading machine with a buffer spring, the average value range for the air pressure stage is (0, 8], the average value range for the heavy pressure stage is (40, 55], and the average value range for the excessively heavy stage is (55, 60]. There is no need to compare the variance values ​​for these stages. However, when the average value falls within (8, 40], the variance value is calculated. If the variance value falls within the (0, 50] range, it is considered the light pressure stage. If the variance value is greater than 50, it is considered the medium pressure stage.

[0015] When the object is a double-column gantry kneading machine with a buffer spring, the average value range for the air pressure stage is (0,5], the average value range for the heavy pressure stage is (30,40], and the average value range for the over-heavy stage is (40,45]. There is no need to compare the variance values ​​for these stages. However, when the average value falls within (5,30], the variance value is calculated. If the variance value falls within the (0,25] range, it is the light pressure stage. If the variance value is greater than 25, it is the medium pressure stage.

[0016] When the object is a Class C double-column gantry kneading machine with a floating cap and a buffer spring, and the object being tested is the cap, the average value range for the air pressure stage is (0,3], the average value range for the heavy pressure stage is (20,27], and the average value range for the excessively heavy stage is (27,30]. There is no need to compare the variance values ​​for these stages. However, when the average value falls within (3,20], the variance value is calculated. If the variance value falls within the range of (0,15], it is considered the light pressure stage. If the variance value is greater than 15, it is considered the medium pressure stage.

[0017] All values ​​above are in mm.

[0018] Preferably, after installing the floating sensor on the kneading machine, manual pressure kneading is performed on the machine, dividing the entire kneading process into specified time intervals. Data on the cap's floating height is collected during each specified time interval, and this data is then categorized, labeled, and stored according to the current kneading pressure stage. Subsequently, a convolutional neural network model is established, and the categorized and labeled data is fed into the convolutional neural network model for deep learning to obtain corresponding model parameters, resulting in a convolutional neural network model with the corresponding model parameters. Finally, the cap's floating height data is tested normally and compared with the convolutional neural network model with the model parameters to obtain the result.

[0019] Preferably, the automatic kneading process based on the tea kneading pressure monitoring method is characterized by including the following steps:

[0020] S1. Select the kneading curve and begin kneading;

[0021] S2. The lid descends and closes the kneading drum inlet; standby mode.

[0022] S3, Begin kneading the Nth segment of the kneading curve;

[0023] S4. The floating sensor begins to continuously collect data;

[0024] S5. The current acquisition cycle ends. The data obtained by the floating sensor is used to obtain the current kneading pressure stage of the kneading machine. The current pressure of the current kneading pressure stage is compared with the set pressure of the set kneading pressure stage. If the current pressure is greater than the set pressure, the pressure cap is controlled to rise to reduce the kneading pressure. If the current pressure is less than the set pressure, the pressure cap is controlled to fall to increase the kneading pressure. If the current pressure is equal to the set pressure, the process proceeds to the next step.

[0025] S6. Determine if the current kneading stage has ended. If not, return to step S4; if yes, proceed to the next step.

[0026] S8. Determine whether all kneading stages are complete. If not, begin kneading for the next stage of the kneading curve. If yes, end all kneading stages.

[0027] Preferably, the device is characterized by comprising a processor, an input device, an output device, and a memory, wherein the processor, input device, output device, and memory are connected in sequence, the memory is used to store a computer program, the computer program includes program instructions, and the processor is configured to call the program instructions to execute the method.

[0028] Preferably, the storage medium is characterized in that: the storage medium stores a computer program, the computer program including program instructions, which, when executed by a processor, cause the processor to perform the method described thereon.

[0029] The beneficial effects of this invention are as follows:

[0030] 1) In actual operation, the kneading pressure during the kneading process needs to overcome the weight of the pressing mechanism, which is then converted into random fluctuation of the pressure cap. Therefore, this invention takes a different approach by collecting and calculating the fluctuation pattern of the pressure cap to determine the kneading pressure stage, rather than directly collecting pressure values. This significantly overcomes the interference of directly collecting kneading pressure values, ultimately providing an effective and reliable determination of the current kneading stage of the kneading machine. The solution of this invention is particularly effective in accurately determining the medium and light pressure stages where kneading pressure fluctuates drastically, demonstrating significant results.

[0031] 2) Based on the above solution, since the present invention only uses a floating sensor for actual measurement, and only needs to be used with existing software for calculation during operation, it can be directly applied to all models of kneading machines. In particular, it only requires the installation of an inductive proximity switch as a floating sensor to realize the detection of kneading pressure. The cost of upgrading is extremely low, which is conducive to popularization and is especially suitable for the vast majority of small and medium-sized tea factories in China.

[0032] Considering the above technical effects, because rolling machines are generally too durable, the vast majority of tea production in China is still carried out by a large number of old rolling machines in small and medium-sized tea factories. These small and medium-sized tea factories are rarely willing to spend high costs to replace their rolling machines with new ones for automation. If a truly feasible automation retrofit solution for old rolling machines is provided, it will greatly improve the appearance and quality of tea products in my country's tea industry while saving a lot of manpower. Attached Figure Description

[0033] Figure 1 This is a diagram illustrating one installation embodiment of the present invention when applied to a single-arm screw-type kneading machine with a buffer spring;

[0034] Figure 2 This is a diagram illustrating one installation embodiment of the present invention when applied to a Class A double-column gantry kneading machine with a buffer spring;

[0035] Figure 3 This is a diagram illustrating one installation embodiment of the present invention when applied to a Class B double-column gantry kneading machine with a buffer spring;

[0036] Figure 4 This is a diagram illustrating one installation embodiment of the present invention when applied to a Class C double-column gantry kneading machine with a floating pressure cap and a buffer spring;

[0037] Figure 5 This is a schematic block diagram of the electronic control system of the present invention;

[0038] Figure 6 This is a schematic block diagram of the device of the present invention;

[0039] Figure 7 This is a flowchart of the automatic kneading process of the present invention.

[0040] The actual correspondence between the reference numerals and component names in this invention is as follows:

[0041] 10-Equipment

[0042] 11-Processor 12-Memory 13-Input Device 14-Output Device

[0043] 20-Floating sensor; 30-Bracket; 40-Clip cap; 50-Optical axis

[0044] 60-Buffer spring; 70-Kneading drum; 80-Secondary bending beam Detailed Implementation

[0045] For ease of understanding, this section combines... Figure 1-7 The specific structure and operation of the present invention are further described below:

[0046] The purpose of this invention is to provide a kneading pressure monitoring method that can overcome the interference of the rotating and floating cap during the kneading process, detect and judge the kneading pressure during the kneading process, is applicable to various types of kneading machines, and is low-cost and easy to install. Simultaneously, it also provides an automatic kneading control device that uses the above method to detect and control the kneading pressure, for retrofitting various new and old kneading machines, and is low-cost and easy to install.

[0047] The basic principle and working process of the kneading pressure monitoring method of the present invention are briefly described as follows:

[0048] In the kneading process, the names of pressure stages such as air pressure, light pressure, medium pressure, and heavy pressure have misled many people into trying various methods to detect the magnitude of kneading pressure in order to distinguish between different pressure stages. This invention takes a different approach, reversing the thinking, and provides a method that can naturally determine the current kneading pressure stage without directly obtaining the accurate value of the kneading pressure.

[0049] The pressure mechanism of various kneading machines in China provides a certain vertical floating space for the pressure cap 40 through the built-in buffer spring 60. However, since the floating range is mostly only 2 to 5 centimeters, and the kneading drum 70 and the pressure cap 40 are constantly rotating horizontally during the kneading process, it is difficult to see the floating of the pressure cap 40 in actual production.

[0050] As one of the world's three major production areas of Qimen black tea, a highly aromatic black tea, Huangshan City has been using a double floating kneading machine with an 80-degree auxiliary curved beam for decades. Figure 4The C-type double-column gantry kneading machine shown has a floating pressure cap 40 and a buffer spring 60; its pressure cap 40 and the secondary curved beam 80 are nested together by an optical shaft 50, and the pressure cap 40 has an additional second floating space in addition to the built-in buffer spring 60 due to the floating pressure cap 40 and the reserved gap. Because the second floating mechanism lacks spring cushioning, each time the pressure cap 40 is squeezed by the leaf clusters and floats up along the optical axis 50 during the kneading process, it directly impacts the secondary curved beam 80, producing a loud thud. Throughout the kneading process, the pressure cap 40 will randomly float up and down, producing impact sounds. Only when the pressure cap 40 is kept at its upper limit for an extended period will the sound cease (this indicates that the kneading pressure exceeds the limit, making it difficult for the leaf clusters inside the kneading drum 70 to tumble). Therefore, during operation, the kneading master cannot visually perceive the floating of the pressure cap using only the naked eye. They mostly rely on observing the state of the scattered kneading leaves on the kneading disc and their experience to make judgments. This obviously places extremely high demands on the kneading master, has very poor universality, and a very high error rate. In particular, the kneading master needs to distinguish between different pressure stages such as air pressure, light pressure, medium pressure, and heavy pressure in a timely manner, which obviously increases the operational threshold significantly. Thus, by continuously counting the number of times the cap 40 floats and the time it takes within a specified time period using the floating sensor 20, this invention finds that the higher the proportion of the cap 40's floating time to the total time, the greater the actual kneading pressure. This is because existing kneading and pressing mechanisms provide kneading pressure through their own weight, while the buffer spring 60 mainly provides floating space. During the kneading process, the alternating floating of the cap 40 with and without its own weight simulates the change in kneading pressure. The principle is similar to simulating PWM pulse width modulation of different voltages by changing the duty cycle of high and low levels. The preferred cap 40 floating time ratio rule of this invention is approximately the same as judging the voltage by reading the duty cycle of the PWM.

[0051] Thus, one aspect of the present invention has been clarified, namely, by installing at least one floating sensor 20 on the pressing mechanism of the kneading machine, continuously collecting floating data of the pressure cap 40 within a specified time period through the floating sensor 20 during the kneading process, and determining the current kneading pressure stage through the kneading pressure calculation method, the automatic determination of the kneading pressure stage can be achieved.

[0052] The aforementioned floating of the pressure cap 40 refers to the situation where, without actively controlling the raising and lowering of the pressure cap 40 by rotating the pressure adjusting handwheel, the pressure cap 40 floats up and down within a certain range during the kneading process, following the rolling of the leaf balls inside the kneading drum 70.

[0053] The aforementioned kneading pressure stages refer to the pressure stages described in the kneading process, such as air pressure, light pressure, medium pressure, and heavy pressure. In actual kneading, although kneading workers may find it difficult to know the precise magnitude of the kneading pressure, they can naturally judge the current kneading pressure stage by observing the kneading blades and relying on experience. This invention also simulates this behavior, and naturally judges the stage by calculating the floating data of the pressure cap 40 collected by the floating sensor 20.

[0054] Since the aforementioned cap 40 floating data only needs to distinguish between different kneading pressure stages, it is preferable to only collect the switching signal indicating whether the cap 40 is floating to meet the basic requirements. Of course, collecting the accurate distance of the cap 40's floating motion would be more precise. That is, the floating sensor 20 is preferably a proximity switch, more preferably an inductive proximity switch, and other proximity or limit switches can also be used to detect the cap 40's floating motion. Preferably, installing one proximity switch is sufficient to determine whether the cap 40 is floating, while installing multiple proximity switches to collect data on the cap 40's floating height can improve accuracy.

[0055] Of course, the floating sensor 20 can also be a distance sensor, including but not limited to infrared, laser, ultrasonic ranging sensors or displacement sensors. Detecting the accurate distance of each floating of the pressure cap 40 can more accurately determine the current kneading pressure stage. However, the cost is high and there are a lot of tea hairs floating in the air in the tea factory. After long-term operation, the emission port is easily blocked, causing malfunction.

[0056] The preferred method for calculating kneading pressure is the proportion of the time it takes for the pressure cap 40 to float. In this case, the floating sensor 20 can preferably be a proximity switch or a limit switch. The method collects and calculates the ratio of the total time the pressure cap 40 floats to that specified time period. A larger ratio indicates a relatively higher kneading pressure, and a longer specified time period results in a more accurate result. Since it is only necessary to distinguish between pressure stages such as air pressure, light pressure, heavy pressure, and critical pressure, this invention can preliminarily determine the pressure in 5 seconds, and 45 seconds is sufficient for a more accurate determination. Specific numerical ranges are shown in Table 1 (the exact range may vary depending on the pressurization structure and materials of the same model):

[0057] Table 1 Pressure Classification of Various Types of Kneading Machines

[0058]

[0059] For example: the object being detected is Figure 1 The single-arm screw-type kneading machine with buffer spring 60 shown has a specified time period of 60 seconds. The floating sensor 20 detects that the pressure cap 40 floats up 5 times within 60 seconds, and the total floating time is 15 seconds. The ratio is η = (15 / 60) * 100% = 25%. Referring to Table 1, this indicates that the current stage is light pressure.

[0060] It should be noted that no testing is needed for the first few minutes of each kneading cycle. This is because workers typically wait until the kneading drum (70) is full of kneading blades before starting kneading. At this time, the fully loaded kneading blades in drum 70 begin to tumble as the kneading machine rotates, causing the blade clumps to expand and frequently press against the pressure cap (40). However, after 3-5 minutes, the initially fluffy kneading blades begin to clump together, and their volume will shrink by at least one-third. Only after this point is it meaningful to test the movement of the pressure cap (40). This means that in the initial few minutes of kneading, although technically termed "air pressure," the blade clumps are actually subjected to pressure equivalent to light to medium pressure. Therefore, no testing is needed during this stage to avoid misjudgment.

[0061] Furthermore, based on the floating time data of the pressure cap 40 measured by the floating sensor 20, the present invention can also achieve the purpose of self-judgment of the current kneading stage of the kneading machine by detecting the floating height data. At the same time, based on the above-mentioned floating height data and floating time data, the judgment process can also be optimized by relying on neural network calculation method.

[0062] The method of average variance of floating height obtained by detecting floating height data involves using a distance sensor to continuously collect the floating height of the cap 40 during the kneading process within a specified time period and storing it in an array. Then, the average value and variance value of the array are calculated. When the average floating height is close to 0 (indicating that the cap 40 has not floated), it is considered light pressure. When it is close to the floating limit of the cap 40 of the current model, it is considered heavy pressure. The remaining values, i.e., the average value is in the middle range, are distinguished as light pressure and medium pressure by comparing the variance value (indicating the magnitude of the fluctuation of the cap 40).

[0063] Assuming the kneading stage is divided into five phases: air pressure, light pressure, medium pressure, heavy pressure, and excessive pressure, the criteria for determining each kneading stage are as follows:

[0064] Air pressure: The average displacement is less than or equal to the set lower threshold.

[0065] Light pressure: The average displacement is less than the upper threshold and greater than the lower threshold, and the displacement variance is less than or equal to the set variance threshold; the upper threshold is greater than the lower threshold.

[0066] Medium pressure: The average displacement is less than the upper limit threshold and greater than the lower limit threshold, and the displacement variance is greater than the variance threshold;

[0067] Heavy pressure; the average displacement is greater than or equal to the set upper limit threshold.

[0068] Specifically:

[0069] When the object is a single-arm screw-type kneading machine with a buffer spring, the average value range for the air pressure stage is (0, 8], the average value range for the heavy pressure stage is (40, 55], and the average value range for the excessively heavy stage is (55, 60]. There is no need to compare the variance values ​​for these stages. However, when the average value falls within (8, 40], the variance value is calculated. If the variance value falls within the (0, 50] range, it is considered the light pressure stage. If the variance value is greater than 50, it is considered the medium pressure stage.

[0070] When the object is a double-column gantry kneading machine with a buffer spring, the average value range for the air pressure stage is (0,5], the average value range for the heavy pressure stage is (30,40], and the average value range for the over-heavy stage is (40,45]. There is no need to compare the variance values ​​for these stages. However, when the average value falls within (5,30], the variance value is calculated. If the variance value falls within the (0,25] range, it is the light pressure stage. If the variance value is greater than 25, it is the medium pressure stage.

[0071] When the object is a Class C double-column gantry kneading machine with a floating cap and a buffer spring, and the object being tested is the cap, the average value range for the air pressure stage is (0,3], the average value range for the heavy pressure stage is (20,27], and the average value range for the excessively heavy stage is (27,30]. There is no need to compare the variance values ​​for these stages. However, when the average value falls within (3,20], the variance value is calculated. If the variance value falls within the range of (0,15], it is considered the light pressure stage. If the variance value is greater than 15, it is considered the medium pressure stage.

[0072] All values ​​above are in mm. Please refer to Table 2 for specific value ranges (the values ​​may vary slightly for the same model due to differences in pressurization structure and materials):

[0073] Table 2 Pressure Classification of Various Types of Kneading Machines

[0074]

[0075] The basic preset conditions in Table 2 are as follows: for single-arm screw press models, the buffer spring capping range is 0–60 mm; for double-column press models, the buffer spring capping range is 0–45 mm; and for Class C double-column floating capping models, the range is 0–30 mm. Of course, the range of floating capping for commercially available models may vary depending on the manufacturer. Due to mechanical vibration and sensor errors during the kneading process, a certain margin should be considered for the air pressure and heavy pressure ranges.

[0076] Taking a Class C dual-column floating capping machine as an example: after continuous sampling, the average value is first calculated to distinguish between air pressure and heavy pressure. For example, if the average value is 3mm, and the range is 0-5mm, it is considered air pressure. If the average value is 10mm, the variance of the array is calculated to distinguish between light pressure and medium pressure. A variance value greater than 15 indicates medium pressure, and less than 15 indicates light pressure. For Class C dual-column floating capping machines, the preferred floating sensor for detecting independent floating caps is the Sharp GP2Y0A51SK0F infrared ranging sensor, with a ranging range of 2-15cm. Alternatively, the VL53L0X laser ranging sensor is preferred.

[0077] The neural network calculation method, based on the aforementioned approach, involves installing a floating sensor 20 and having a skilled kneading master manually control the kneading pressure. The kneading process is divided into specified time intervals, such as 60 seconds. During each specified time interval, the height of the pressure cap 40 rising during kneading is continuously collected and stored in an array. These arrays are then categorized and labeled according to the kneading pressure stage determined by the master. After collecting a large amount of manual kneading data, the categorized arrays are fed into a convolutional neural network, such as a random forest or decision tree, to train the model. Considering cost, performance, and requirements, the Espressif ESP32-S3 microcontroller and the ESP-DL deep learning framework are preferred. Once the model is trained, it can be used to determine the current kneading pressure stage. This type of machine learning algorithm is not only accurate but can even replicate the operating style of a specific kneading master. However, it requires significant manpower to collect data and train the model separately for different machine models and different types of tea, and the main control unit and sensor costs are relatively high. Nevertheless, actual tests show that it is indeed quite accurate.

[0078] Regarding the installation location of the floating sensor 20, it should be noted that the preferred installation location of the floating sensor 20 varies depending on the type of kneading machine. Domestic mainstream kneading machines can be divided into different types based on their pressure structure. Figure 1 The single-arm lead screw type shown and Figure 2-4 The two main categories shown are the double-column gantry type; the latter is further subdivided into, for example, the double-column gantry type. Figure 2 The three types shown are: Type A, where the pressure cap 40 cannot rotate independently; Type B, where an auxiliary bending beam 80 is added to enable the pressure cap 40 to rotate independently; and Type C, where an auxiliary bending beam 80 is added and a gap is reserved so that the pressure cap 40 can both rotate independently and float in a double manner.

[0079] Figure 1 The single-arm screw-type kneading machine shown can provide a certain floating space for the pressure cap 40 through the buffer spring 60. The floating sensor 20 can be fixed to the cantilever beam through the bracket 30. During the kneading process, when the pressure cap 40 is subjected to force, the buffer spring 60 contracts, which can drive the pressure cap 40 and the support column to move upward. When the top of the support column protrudes from the surface of the cantilever beam, the floating sensor 20 is triggered. In actual testing, it is preferable to install a proximity switch 20 to detect whether the pressure cap 40 floats. Of course, it is also possible to consider adding an additional sensor to detect the case where the pressure cap 40 floats significantly, thereby improving the judgment accuracy.

[0080] like Figure 2-3 The A and B type double-column gantry kneading machines shown both use a buffer spring 60 to provide a certain floating space for the pressure cap 40, such as... Figure 2 As shown, the floating sensor is fixed to the gantry beam by a bracket with its sensing surface pointing towards the pressure cap 40. During the kneading process, when the pressure cap is lifted by force, the distance between the sensor 20 and the pressure cap 40 shortens. The height of the pressure cap's rise can be calculated from this distance. Similarly, Figure 1 The distance sensor can be mounted on the horizontal arm (single arm) with the sensing surface pointing towards the pressure cover 40.

[0081] like Figure 3 As shown, the floating sensor 20 is fixed to the gantry beam via the bracket 30. During the kneading process, when the pressure cap 40 is subjected to force, the buffer spring 60 contracts, causing the pressing mechanism, including the pressure cap 40, main screw, auxiliary beam 80, guide rod, and screw bushing, to move upward as a whole. When the screw bushing moves upward and approaches the floating sensor 20, the sensor is triggered to detect the pressure cap 40 floating. It is preferable to install only one floating sensor 20. Adding an additional sensor to detect a significant upward movement of the pressure cap 40 can improve the judgment accuracy. Since the main screw and screw bushing are both metal and can trigger an inductive proximity switch, which may result in false triggering, another option is to fix a detection plate on the top of the screw bushing and change the sensing surface of the floating sensor 20 to face upward and close to the detection plate. That is, when the pressure cap 40 is not subjected to force, it is in the triggered state. When the pressure cap 40 is subjected to force during kneading, it causes the screw bushing and detection plate to move upward and away from the floating sensor 20, thus deactivating the trigger. At this time, the floating sensor 20 can detect the upward movement of the pressure cap 40.

[0082] like Figure 4 The solution for the C-type double-column gantry kneading machine shown is completely different. While the A and B-type kneading machines generally determine whether the pressure cap 40 has floated by detecting the extension and retraction of the built-in buffer spring (i.e., the movement of the screw bushing), this method is complex to install and prone to accidental triggering. The C-type double-floating gantry kneading machine, however, allows the pressure cap to float independently, thus allowing the determination of whether the pressure cap 40 has floated to be based on its independent floating motion. Figure 4 As shown, while monitoring the displacement of the screw bushing or main screw using the first floating sensor, Figure 4An additional floating sensor is also provided, which is fixed to the secondary curved beam 80 by a bracket 30. During the kneading process, when the pressure cap 40 is subjected to force and floats up along the optical axis 50, it is triggered. At this time, the additional floating sensor 20 will detect the pressure cap 40 floating alone. It should be noted that it is preferable to install only the floating sensor 20 on the secondary curved beam 80 to detect the kneading pressure. The floating sensor 20 on the secondary curved beam 80 can be a proximity switch or a distance sensor. If at least two floating sensors 20 are installed to detect the dual floating of the pressure cap 40, that is, to detect the built-in buffer spring 60 and the pressure cap 40 alone, the judgment accuracy can be greatly improved. In this case, one sensor can detect the floating of the pressure cap 40 alone to mainly determine the air pressure and light pressure stages, because the buffer spring 60 is almost unloaded at this time; while the other floating sensor 20 detects the floating of the built-in buffer spring 60 to determine the subsequent stages.

[0083] about Figure 4 The reason why the Class C double-column gantry kneading machine shown significantly improves the detection accuracy of collecting the second floating energy of the individual cap is as follows:

[0084] All types of kneading machines apply kneading pressure through the weight of the pressurizing structure. During kneading, the pressure cap 40 must float up and down to make the tea leaves inside the kneading drum 70 roll into a ball. The single-arm screw type pressure cap 40 only needs to overcome the weight of the pressure cap 40 and the support column to rise. However, the pressure cap 40 of the A and B type double-column gantry kneading machines needs to overcome the weight of the main screw, guide rod, secondary curved beam 80 and the overall weight of the pressure cap 40, which is about 40 pounds. That is, the tea leaves must be subjected to a minimum kneading pressure of 40 pounds to push the pressure cap 40 and the pressurizing mechanism to rise. This is significantly higher than the optimal pressure for light pressing. In actual kneading, the empty kneading time is forced to be greatly extended to replace light pressing. Otherwise, the breakage rate will be extremely high. However, the double-column gantry kneading machine is the absolute mainstream in tea factories.

[0085] and Figure 4The Type C double-column gantry-style rolling machine shown features a special structure that allows the pressure cap 40 to float independently under pressure. The pressure cap 40 itself weighs only about 10 catties, meaning that during rolling, the leaf cluster only needs a minimum rolling pressure of 10 catties to push the pressure cap 40 upwards. Once the rolling pressure exceeds 40 catties, it can push the entire pressure mechanism upwards again. Therefore, this double-floating structure significantly reduces the minimum rolling pressure. Under light pressure, the rolling master can control the pressure application to be solely applied by the floating pressure cap 40 without significantly compressing the built-in buffer spring 60. This is ideal for rolling high-value, delicate raw materials, significantly improving the quality of tea rolling and reducing the breakage rate. Although the Type C double-column gantry-style rolling machine is clearly superior, the need to control the double pressure places higher demands on the rolling master's skill and experience. The master needs to spend more time monitoring and frequently operating the pressure adjustment handwheel throughout the rolling process; otherwise, the rolling effect may be inferior to that of a regular rolling machine. This is why this type of rolling machine is still not widely used. By using the technical solution of this invention, the independent floating of the kneading machine cap 40 can be detected separately or the double floating of the cap can be detected separately and the whole process can be automatically controlled. This allows ordinary workers to maximize the advantages of the C-type double-column gantry type, so as to minimize the triggering of the built-in buffer spring 60 in the light and medium pressure stages, and achieve floating light pressure only by the weight of the cap 40 alone. This can effectively ensure the kneading effect and automated production of this type of kneading machine, especially in the light and medium pressure stages.

[0086] Based on the above technical solution, the kneading pressure monitoring method of the present invention has the following positive technical effects:

[0087] According to the kneading pressure monitoring method of the present invention, the kneading pressure during the kneading process overcomes the self-weight of the pressing mechanism and is converted into the random fluctuation of the pressure cap 40. The present invention judges the kneading pressure stage by collecting and calculating the fluctuation law of the pressure cap 40, which can significantly overcome the interference of directly collecting the kneading pressure value. In particular, it can achieve accurate judgment in the medium and low pressure stages where the kneading pressure fluctuates violently.

[0088] According to the kneading pressure monitoring method of the present invention, the kneading pressure can be determined by utilizing the floating feature of the pressure cap 40, which is present in various types of kneading machines. During operation, even simply fixing the floating sensor 20 is sufficient to accurately determine the kneading pressure stage. This allows for low-cost and quick modification of various kneading machines, especially the large number of existing old kneading machines in the industry. The floating sensor 20 can be an inductive proximity switch. Because inductive proximity switches are non-contact detection and are only triggered by metal, common tea factory contaminants such as dust and tea buds will not cause errors. Furthermore, since there is no physical contact during the detection process, there is no wear or mechanical lifespan limitation. Acquiring the high and low level signals output by the proximity switch only requires a single digital input port common to microcontrollers or PLCs, and industrial isolation only requires a low-speed optocoupler. Compared to pressure sensors, which are expensive and require additional chips and circuits due to their weak millivolt-level output signals, this method is significantly cheaper in terms of both component costs and modification / installation costs compared to existing solutions using pressure sensors.

[0089] For the automatic kneading control device, the technical solution of the present invention is to continuously collect the floating data of the cap 40 by installing a floating sensor 20, and adopting, for example... Figure 5 The electronic control system shown relies on the main control module to determine the current kneading pressure stage, and then uses the motor drive module to operate the lifting motor to rotate forward and backward to adjust the pressure.

[0090] In actual operation, the main control module executes pre-set pressure curves sequentially according to different process requirements, such as 3 minutes of air pressure, 15 minutes of light pressure, 5 minutes of medium pressure, 2 minutes of heavy pressure, and 5 minutes of medium pressure. During operation, the main control module reads data from the floating sensor 20 and determines the pressure. The lifting motor uses a 24V DC reduction gear, retains the pressure adjustment handwheel, and physically disconnects it with a relay when the lifting motor has no output. It also has a built-in remote control and communication module. Simultaneously, the power supply line can be simplified by using a built-in battery and a kneading operation sensor. This is because the pressure cap 40 only floats frequently during kneading; when the machine stops, the pressure cap 40 does not move, and the controller will only output "air pressure" or "excessive pressure." When the power supply is suspended, the automatic kneading controller also controls the power supply of the kneading machine. This problem doesn't exist when the kneading machine is automatically powered at the start of kneading, but once the controller and power supply are suspended on the kneading machine, the controller cannot know when the kneading machine is manually powered on. Therefore, the controller has a built-in vibration sensor, such as a vibration switch, to determine whether the kneading machine is rotating. The kneading pressure is detected only when the kneading machine is rotating, and automatically stops when the kneading machine is not powered on or is manually stopped midway. Thirdly, a DC geared motor is used. Fourthly, the upper and lower limits of the pressure cap 40 can be detected by detecting motor stall.

[0091] Figure 7 This is an automated kneading process based on the aforementioned tea kneading pressure monitoring method, specifically including the following steps:

[0092] 1. Select the kneading curve and begin kneading;

[0093] 2. Lower the lid and seal the inlet of the kneading drum; standby mode.

[0094] 3. A vibration sensor is also installed at the kneading machine to detect the working status of the kneading machine, so that the timing module only starts timing when the vibration sensor detects a vibration signal; the vibration sensor detects whether the equipment vibrates. If there is no vibration signal, it continues to standby. If there is a vibration signal, it proceeds to the next step; it should be noted that the vibration sensor is optional and is preferably used in an environment with built-in battery power. Therefore, if the controller does not have a vibration sensor installed, this step can be skipped directly.

[0095] 4. Begin kneading the Nth segment of the kneading curve;

[0096] 5. The floating sensor begins to continuously collect data;

[0097] 6. The current data acquisition cycle ends. The data obtained by the floating sensor is used to obtain the current kneading pressure stage of the kneading machine. The current pressure of the current kneading pressure stage is compared with the set pressure of the set kneading pressure stage. If the current pressure is greater than the set pressure, the pressure cap is controlled to rise to reduce the kneading pressure. If the current pressure is less than the set pressure, the pressure cap is controlled to fall to increase the kneading pressure. If the current pressure is equal to the set pressure, the next step is performed. The comparison of the pressure magnitude is as follows: excessive pressure > heavy pressure > medium pressure > light pressure > air pressure.

[0098] S7. Determine if the current kneading stage has ended. If not, return to step 5; if yes, proceed to the next step.

[0099] S8. Determine whether all kneading stages are complete. If not, begin kneading for the next stage of the kneading curve. If yes, end all kneading stages.

[0100] Below, for reference Figure 6 The device used in the embodiments of this application is described here; the device may be the mobile device itself, or a stand-alone device independent of it, which can receive the collected input signals and send the selected target decision behavior to it.

[0101] All of the above solutions have been tested in practice. Practice has shown that each solution of the present invention can accurately detect and judge the current kneading pressure stage in real time during the kneading process, and can be put into actual production with significant results.

[0102] Furthermore, such as Figure 6 As shown, device 10 includes one or more processors 11 and corresponding memory 12.

[0103] The processor 11 may be a central processing unit or other processing unit with data processing capabilities and / or instruction execution capabilities, and may control other components in the device 10 to perform desired functions. The memory 12 may include one or more computer program products, which may include various forms of computer storage media, such as volatile memory and / or non-volatile memory. The volatile memory may, for example, include random access memory (RAM) and / or cache memory. The non-volatile memory may, for example, include read-only memory (ROM), hard disk, flash memory, etc. One or more computer program instructions may be stored on the computer storage medium, and the processor 11 may execute the program instructions to implement the decision-making behavior and decision-making methods of the various embodiments of this application described above, and / or other desired functions.

[0104] In the example, device 10 may further include an input device 13 and an output device 14, which are interconnected via a bus system and / or other forms of connection mechanism (not shown). For example, the input device 13 may also include, for example, a keyboard, a mouse, etc. The output device 14 may include, for example, a monitor, a speaker, a printer, and a communication network and its connected remote output devices, etc.

[0105] Of course, for the sake of simplicity, Figure 6 Only some of the components of device 10 relevant to this application are shown in this illustration; components such as buses, input / output interfaces, etc., are omitted. In addition, device 10 may include any other suitable components depending on the specific application.

[0106] In addition to the methods and apparatus described above, embodiments of this application may also extend to computer program products, which include computer program instructions that, when executed by a processor, cause the processor to perform the steps in the decision-making methods according to various embodiments of this application as described in the "Exemplary Methods" section above.

[0107] The computer program product can be written in any combination of one or more programming languages ​​to perform the operations of the embodiments of this application. The programming languages ​​include object-oriented programming languages ​​such as Java and C++, as well as conventional procedural programming languages ​​such as C or similar languages. The program code can be executed entirely on the user's computing device, partially on the user's device, as a standalone software package, partially on the user's computing device and partially on a remote computing device, or entirely on a remote computing device or server.

[0108] Furthermore, embodiments of this application may also be readable computer storage media storing computer program instructions that, when executed by a processor, cause the processor to perform the steps in the decision-making behavior and decision-making method according to various embodiments of this application as described in the detailed implementation process section above.

[0109] The computer storage medium may be any combination of one or more readable media. A readable medium may be a readable signal medium or a storage medium. Storage media may include, but are not limited to, electrical, magnetic, optical, electromagnetic, infrared, or semiconductor systems, apparatuses, or devices, or any combination thereof. More specific examples of storage media (a non-exhaustive list) include: electrical connections having one or more wires, portable disks, hard disks, random access memory (RAM), read-only memory (ROM), erasable programmable read-only memory (EPROM or flash memory), optical fibers, portable compact disk read-only memory (CD-ROM), optical storage devices, magnetic storage devices, or any suitable combination thereof.

[0110] Of course, those skilled in the art will recognize that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0111] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

[0112] All technologies not described in detail in this invention are publicly known technologies.

Claims

1. A method of monitoring the rolling pressure of tea leaves, characterised by Includes the following steps: By deploying floating sensors to monitor the cap status, data on the cap's floating height over a specified time period is obtained. The kneading pressure stage of the current kneading machine is then determined by using the average variance of the floating height data. The method of average variance of buoyancy height includes the following sub-steps: The height of the cap rising during the kneading process is collected within a specified time period and stored as an array. Then, the average value and variance of the array are calculated. Kneading pressure stage data are set, and the average value of the rising height is compared with the kneading pressure stage data to determine air pressure and heavy pressure. The variance value, which represents the magnitude of cap fluctuation, is compared with the kneading pressure stage data to distinguish between light pressure and medium pressure. When using the average variance of the upward floating height method, the set kneading pressure stage data are as follows: When the object is a single-arm screw-type kneading machine with a buffer spring, the average value range for the air pressure stage is (0, 8], the average value range for the heavy pressure stage is (40, 55], and the average value range for the excessively heavy stage is (55, 60]. There is no need to compare the variance values ​​for these stages. However, when the average value falls within (8, 40], the variance value is calculated. If the variance value falls within the (0, 50] range, it is considered the light pressure stage. If the variance value is greater than 50, it is considered the medium pressure stage. When the object is a double-column gantry kneading machine with a buffer spring, the average value range for the air pressure stage is (0,5], the average value range for the heavy pressure stage is (30,40], and the average value range for the over-heavy stage is (40,45]. There is no need to compare the variance values ​​for these stages. However, when the average value falls within (5,30], the variance value is calculated. If the variance value falls within the range of (0,25], it is the light pressure stage. If the variance value is greater than 25, it is the medium pressure stage. When the object is a Class C double-column gantry kneading machine with a floating cap and a buffer spring, and the object being tested is the cap, the average value range for the air pressure stage is (0,3], the average value range for the heavy pressure stage is (20,27], and the average value range for the excessively heavy stage is (27,30]. There is no need to compare the variance values ​​for these stages. However, when the average value falls within (3,20], the variance value is calculated. If the variance value falls within the range of (0,15], it is considered the light pressure stage. If the variance value is greater than 15, it is considered the medium pressure stage. All values ​​above are in mm.

2. The tea rolling pressure monitoring method according to claim 1, characterized by: After installing the floating sensor on the kneading machine, manual pressure kneading is performed on the machine, dividing the entire kneading process into specified time intervals. Data on the cap's floating height is collected within each specified time interval, and this data is then categorized and stored according to the current manual pressure stage. Subsequently, a convolutional neural network model is established, and the categorized and stored data is fed into the convolutional neural network model for deep learning to obtain the corresponding model parameters, resulting in a convolutional neural network model with these parameters. Finally, the cap's floating height data is tested normally and compared with the convolutional neural network model with the model parameters to obtain the results.

3. An automatic rolling process based on the tea rolling pressure monitoring method according to claim 1, characterized in that Includes the following steps: S1. Select the kneading curve and begin kneading; S2. The lid descends and closes the kneading drum inlet; standby mode. S3, Begin kneading the Nth segment of the kneading curve; S4. The floating sensor begins to continuously collect data; S5. The current acquisition cycle ends. The data obtained by the floating sensor is used to obtain the current kneading pressure stage of the kneading machine. The current pressure of the current kneading pressure stage is compared with the set pressure of the set kneading pressure stage. If the current pressure is greater than the set pressure, the pressure cap is controlled to rise to reduce the kneading pressure. If the current pressure is less than the set pressure, the pressure cap is controlled to fall to increase the kneading pressure. If the current pressure is equal to the set pressure, the process proceeds to the next step. S6. Determine if the current kneading stage has ended. If not, return to step S4. If so, proceed to the next step; S7. Determine whether all kneading stages have been completed. If not, begin kneading the next stage of the kneading curve. If so, then the entire kneading stage ends.

4. Apparatus characterized by: The system includes a processor, an input device, an output device, and a memory, which are connected in sequence. The memory is used to store a computer program, which includes program instructions. The processor is configured to call the program instructions to execute the method as described in claim 1.

5. Storage medium, characterized in that: The storage medium stores a computer program, the computer program including program instructions, which, when executed by a processor, cause the processor to perform the method as described in claim 1.

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