Multi-source heterogeneous data-based running state monitoring system of leaf damping machine

Abstract

The invention belongs to the technical field of tobacco production equipment monitoring, and particularly relates to a multi-source heterogeneous data-based running state monitoring system of a leaf dampening machine, which comprises a roller transmission monitoring system, a steam pipeline monitoring system, a humidifying waterway monitoring system, a valve opening detection encoder and a PLC (Programmable Logic Controller), the roller transmission monitoring system, the steam pipeline monitoring system, the humidifying water path monitoring system and the valve opening detection encoder are all in electric signal connection with the PLC. According to the technical scheme, by monitoring the states of the transmission system, the roller, the steam pipeline, the hot air pipeline and the like of the blade dampening machine in real time, the problems that the states of all parts cannot be monitored during operation of an existing blade dampening machine, and equipment suddenly breaks down due to sudden damage of the parts are solved.

Description

Technical Field

[0001] The invention belongs to the technical field of tobacco production equipment monitoring, and in particular relates to an operating status monitoring system of a leaf rehumidifier based on multi-source heterogeneous data. Background Art

[0002] The leaf rehumidification machine is an important process in the processing of silk leaf. Its function is to loosen, rehumidify and humidify the tobacco slices after vacuum rehumidification, so that the temperature and moisture content of the tobacco slices meet the requirements of the process technology, and provide qualified tobacco slices for the next process. Its working principle is: the material is sent into the equipment drum by the upstream conveying equipment, and the drum is driven to rotate by the transmission device. Due to the axial inclination of the drum and the guiding effect of the rake nails and the copying board in the drum, the material automatically flows toward the discharge port. When the material runs into the drum and is about 1.5m away from the feed port, the steam pipeline and the humidification water pipeline are in working state. The humidification water is mixed with steam and sprayed out in a mist and sprinkled on the material to increase the temperature and humidify the material. At the same time, the material temperature is controlled by adjusting the hot air volume or steam flow.

[0003] The current maintenance method of blade rehumidification machines is to carry out daily inspections, regular shutdown inspections, and maintenance of the equipment. Since it is impossible to grasp the health status of each component of the equipment and the status information of some wearing parts in real time during equipment operation, emergency repairs take a long time when the equipment fails suddenly, consuming a lot of manpower, energy, and time, causing production line interruptions, affecting product quality, and seriously restricting production efficiency. In addition, due to the lack of effective tracing of the cause of the failure, repeated failures occur repeatedly. Therefore, an operation status monitoring system for the blade rehumidification machine based on multi-source heterogeneous data is established to monitor and diagnose the status of each component of the blade rehumidification machine online, providing guiding data for the preventive maintenance of the equipment. Summary of the invention

[0004] The object of the present invention is to provide an operation status monitoring system for a blade rehumidifier based on multi-source heterogeneous data to solve the problems existing in the above-mentioned background technology.

[0005] To achieve the above objectives, this application is implemented through the following technical solutions:

[0006] The operating status monitoring system of a blade rehumidifier based on multi-source heterogeneous data includes a drum transmission monitoring system, a steam pipeline monitoring system, a humidification water circuit monitoring system, a valve opening detection encoder and a PLC controller; the drum transmission monitoring system, the steam pipeline monitoring system, the humidification water circuit monitoring system, and the valve opening detection encoder are all connected to the PLC controller by electrical signals.

[0007] Further, the drum transmission monitoring system includes:

[0008] A first vibration monitoring sensor and a second vibration monitoring sensor are arranged at the rotating bearings at both ends of the drum roller;

[0009] A first temperature detection sensor and a second temperature detection sensor are arranged at the drum roller driving motor;

[0010] A distance meter arranged at the roller;

[0011] The first vibration monitoring sensor, the second vibration monitoring sensor, the first temperature detection sensor, the second temperature detection sensor and the distance meter are all connected to the PLC controller by electrical signals.

[0012] Further, the steam pipeline includes:

[0013] A first steam pipeline entering the heating coil of the discharge chamber to heat the inner wall of the discharge chamber;

[0014] Entering into the second steam pipeline located at the feed end, the steam spraying pipe sprays steam into the drum to directly heat the material;

[0015] The third steam pipeline enters the upper radiator to heat the circulating air;

[0016] The fourth steam pipeline enters the steam-water dual-medium nozzle in the feed chamber as humidified water atomized steam;

[0017] The fifth steam pipeline enters the steam-water dual-medium nozzle in the discharge chamber as humidified water atomized steam;

[0018] The sixth steam pipeline enters the lower radiator to heat the fresh air.

[0019] Furthermore, the steam pipeline monitoring system includes a first flow detector and a first pressure detector respectively arranged on the first steam pipeline to the sixth steam pipeline, and the first flow detector and the first pressure detector are both connected to the PLC controller with electrical signals.

[0020] Furthermore, the humidification water pipeline monitoring system includes a second flow detector and a second pressure detector respectively arranged on the front chamber water supply pipeline and the rear chamber water supply pipeline, and the second flow detector and the second pressure detector are both connected to the PLC controller with electrical signals.

[0021] Furthermore, the total amount of water added by the leaf loosening and rehumidifying machine is the sum of the water added in the front chamber and the water added in the rear chamber. The amount of water added is adjusted according to the leaf flow of the electronic belt scale at the inlet, the actual moisture of the inlet tobacco leaves, the actual moisture of the outlet tobacco leaves and the set moisture of the outlet tobacco leaves, and the water added in the front chamber and the rear chamber are distributed according to the water addition coefficient.

[0022] Furthermore, the PLC controller is connected with the central control and the local HMI electrical signals to display the status of each monitoring data of the blade loosening and rehumidifying machine in real time. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 It is a monitoring schematic diagram of the roller transmission system in the present invention;

[0024] Figure 2 It is a schematic diagram for monitoring the steam pipeline, humidifying water pipeline, hot air and moisture exhaust pipeline in the present invention.

[0025] Description of reference numerals:

[0026] 1. First vibration monitoring sensor; 2. Second vibration monitoring sensor; 3. First temperature detection sensor; 4. Second temperature detection sensor; 5. Distance meter; 6. First flow detector; 7. First pressure detector; 8. Second flow detector; 9. Second pressure detector; 10. Encoder; 11. Hot air valve; 12. Dehumidification valve; 19. Block wheel; 20. Drum drive motor; 111. First steam pipeline; 112. Second steam pipeline; 113. Third steam pipeline; 114. Fourth steam pipeline; 115. Fifth steam pipeline; 116. Sixth steam pipeline. DETAILED DESCRIPTION

[0027] The technical solution of the present invention is described in detail below in conjunction with the accompanying drawings. The following embodiments are merely exemplary and can only be used to explain and illustrate the technical solution of the present invention, but cannot be construed as limiting the technical solution of the present invention.

[0028] like Figure 1 and Figure 2 As shown, the present application provides an operation status monitoring system of a blade rehumidifier based on multi-source heterogeneous data, comprising:

[0029] Drum drive system monitoring, including:

[0030] (1) The first vibration monitoring sensor 1 and the second vibration monitoring sensor 2 are arranged at the rotating bearings of the four rollers, and are used to monitor the vibration of the bearings at both ends of the rollers, respectively. When the vibration exceeds the set value, an alarm is issued.

[0031] (2) The first temperature detection sensor 3 and the second temperature detection sensor 4 are arranged at the four roller drive motors, and are used to monitor the temperature of the roller drive reducer and the motor respectively. When the temperature of the roller drive reducer and the motor exceeds the set value, an alarm is issued.

[0032] (3) The distance meter 5 provided at the drum is used to monitor the distance between the drum and the distance meter during the drum rotation process, that is, whether the drum deviates during the operation. When the detection data of the distance meter exceeds the set value, it indicates that the drum deviates and an alarm is issued.

[0033] Steam piping system monitoring, including:

[0034] The steam pipelines of the blade loosening and rehumidifying machine include: (1) a first steam pipeline 111 that enters the heating coil of the discharge chamber to heat the inner wall of the discharge chamber; (2) a second steam pipeline 112 that enters the steam nozzle located at the feed end to spray steam into the drum to directly heat the material; (3) a third steam pipeline 113 that enters the upper radiator to heat the circulating air; (4) a fourth steam pipeline 114 that enters the steam-water dual-medium nozzle of the feed chamber to serve as humidifying water atomization steam; (5) a fifth steam pipeline 115 that enters the steam-water dual-medium nozzle of the discharge chamber to serve as humidifying water atomization steam; and (6) a steam pipeline 116 that enters the lower radiator to heat the fresh air.

[0035] (1) A first flow detector 6 is installed on each steam pipeline. The first flow detector 6 monitors the flow data of each steam pipeline in real time during the production process, and establishes a steam flow database for each brand of tobacco. The steam flow is monitored based on the historical database, and an alarm is issued when it deviates from a certain range of historical data.

[0036] (2) A first pressure detector 7 is provided on each steam pipeline. The first pressure detector 7 is used to monitor the pressure of each steam pipeline during the operation of the blade loosening and rehumidification machine. When the steam pipeline pressure is not within the set value range, an alarm is issued.

[0037] Humidification water pipeline system monitoring, humidification water pipeline monitoring includes front room water supply pipeline and back room water supply pipeline monitoring. It includes:

[0038] (1) A second flow detector 8 is installed on the front chamber water supply pipeline and the rear chamber water supply pipeline. The second flow detector 8 monitors the water supply flow of the front chamber and the rear chamber in real time. The total water supply flow of the leaf loosening and rehumidifying machine is the total amount of water supply of the front chamber and the rear chamber. The water supply is adjusted according to the leaf flow of the electronic belt scale at the entrance, the actual moisture content of the inlet tobacco leaves, the actual moisture content of the outlet tobacco leaves and the set moisture content of the outlet tobacco leaves, and the water supply of the front chamber and the rear chamber is distributed according to the water supply coefficient. According to the water supply principle, a water supply flow database for each brand of tobacco leaves is established, and a water supply flow and the actual moisture content and flow model of each brand of inlet tobacco leaves are established. On this basis, the water supply flow in the production process is monitored, and an alarm is issued when it deviates from the water supply flow and the actual moisture content and flow model of each brand of inlet tobacco leaves within a certain range.

[0039] (2) A second pressure detector 9 is provided on the front chamber water supply pipeline and the rear chamber water supply pipeline. The second pressure detector 9 is used to monitor the pressure of the front chamber and the rear chamber water supply pipeline during the operation of the blade loosening and rehumidification machine. When the pressure of the water supply pipeline is not within the set value range, an alarm is issued.

[0040] 4. The encoder 10 for valve opening detection arranged on the hot air duct and the dehumidification duct is used to monitor the actual value of the valve opening, compare it with the set value, monitor whether there is any abnormality in the valve opening, and issue an alarm when the actual value of the valve opening does not match the set value.

[0041] All the above-mentioned monitoring device signals are collected and uploaded to the PLC controller, and the corresponding operation status monitoring program, alarm program, historical database, etc. are established through the PLC controller. The status of each monitoring data of the blade loosening and rehumidification machine can be displayed in real time on the central control and local HMI. When an alarm is required, a flashing alarm will be given on the HMI to realize the visualization of the status and early warning of the blade loosening and rehumidification machine.

[0042] When the leaf loosening and rehumidifying machine is in operation, four roller drive motors 20 drive the rollers to rotate, and the rollers drive the rollers to rotate, so as to realize the flow of tobacco leaves from the feed port to the discharge port. During operation, the bearings at the roller drive motors are damaged, and replacement is time-consuming and labor-intensive. When the bearings are abnormal, their vibration amount will change. The first vibration monitoring sensor 1 and the second vibration monitoring sensor 2 located at the bearings can monitor their vibration amount in real time. When the bearings change and show a tendency to be damaged, the bearings can be replaced in time to avoid shutdown failures during the production process. When the motor rotates abnormally, its temperature changes significantly. The first temperature detection sensor 3 and the second temperature detection sensor 4 located at the motor can monitor its temperature changes in real time, and timely repairs can be performed when there are abnormalities to avoid shutdown failures during the production process, thereby achieving preventive maintenance effects.

[0043] During the production process, the heating coil in the discharge chamber heats the discharge chamber during preheating to avoid the generation of condensed water that affects the quality of the tobacco leaves.

[0044] The discharge temperature and the moisture content of the outlet material are important evaluation indicators of the leaf loosening and rehumidifying machine. The discharge temperature is adjusted by the amount of hot air entering the drum and the amount of direct steam injection. The hot air entering the drum is formed by two routes: one is steam entering the lower radiator to heat the fresh air to form new hot air, and the other is the hot air in the drum to form circulating air after partial dehumidification. The circulating air is heated by steam entering the upper radiator to ensure the temperature of the circulating air. The new hot air is mixed with the circulating air and enters the drum through the front chamber to heat the tobacco leaves. The opening of the hot air valve 11 and the dehumidification valve 12 can adjust the amount of hot air entering the drum; and the direct steam is injected from the front chamber as compensation steam to heat the tobacco leaves.

[0045] Tobacco leaf humidification is mainly achieved through the dual-medium nozzles in the front chamber and the rear chamber. Steam is used to inject water to humidify the tobacco leaves. The moisture content of the outlet material is adjusted by adjusting the amount of water added.

[0046] In the above process, the steam pressure, flow, water pressure, flow, hot air pipeline valve opening, and dehumidification pipeline valve opening will affect the temperature or moisture regulation control process. Therefore, the steam pipeline, water pipeline pressure, flow, and hot air pipeline and dehumidification pipeline valve opening are monitored to monitor the operating status of the blade loosening and dehumidification machine and achieve the purpose of preventive maintenance.

[0047] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. The operating status monitoring system of the blade rehumidifier based on multi-source heterogeneous data is characterized by: It includes a drum transmission monitoring system, a steam pipeline monitoring system, a humidification water circuit monitoring system, a valve opening detection encoder and a PLC controller; the drum transmission monitoring system, the steam pipeline monitoring system, the humidification water circuit monitoring system, and the valve opening detection encoder are all connected to the PLC controller with electrical signals.

2. The operating status monitoring system of a blade rehumidifier based on multi-source heterogeneous data according to claim 1 is characterized in that: The drum drive monitoring system includes: A first vibration monitoring sensor and a second vibration monitoring sensor are arranged at the rotating bearings at both ends of the drum roller; A first temperature detection sensor and a second temperature detection sensor are arranged at the drum roller driving motor; A distance meter arranged at the roller; The first vibration monitoring sensor, the second vibration monitoring sensor, the first temperature detection sensor, the second temperature detection sensor and the distance meter are all connected to the PLC controller by electrical signals.

3. The operating status monitoring system of a blade rehumidifier based on multi-source heterogeneous data according to claim 1 is characterized in that: The steam pipeline includes: A first steam pipeline entering the heating coil of the discharge chamber to heat the inner wall of the discharge chamber; Entering into the second steam pipeline located at the feed end, the steam spraying pipe sprays steam into the drum to directly heat the material; The third steam pipeline enters the upper radiator to heat the circulating air; The fourth steam pipeline enters the steam-water dual-medium nozzle in the feed chamber as humidified water atomized steam; The fifth steam pipeline enters the steam-water dual-medium nozzle in the discharge chamber as humidified water atomized steam; The sixth steam pipeline enters the lower radiator to heat the fresh air.

4. The operating status monitoring system of a blade rehumidifier based on multi-source heterogeneous data according to claim 3 is characterized in that: The steam pipeline monitoring system includes a first flow detector and a first pressure detector respectively arranged on the first steam pipeline to the sixth steam pipeline, and the first flow detector and the first pressure detector are both connected to the PLC controller with electrical signals.

5. The operating status monitoring system of a blade rehumidifier based on multi-source heterogeneous data according to claim 1 is characterized in that: The humidification water pipeline monitoring system includes a second flow detector and a second pressure detector respectively arranged on the front chamber water supply pipeline and the rear chamber water supply pipeline. The second flow detector and the second pressure detector are both connected to the PLC controller with electrical signals.

6. The operating status monitoring system of a blade rehumidifier based on multi-source heterogeneous data according to claim 5 is characterized in that: The total amount of water added to the leaf loosening and rehumidifying machine is the sum of the water added in the front chamber and the water added in the rear chamber. The amount of water added is adjusted according to the leaf flow of the electronic belt scale at the entrance, the actual moisture content of the inlet tobacco leaves, the actual moisture content of the outlet tobacco leaves and the set moisture content of the outlet tobacco leaves, and the water added in the front chamber and the rear chamber are distributed according to the water addition coefficient.

7. The operating status monitoring system of a blade rehumidifier based on multi-source heterogeneous data according to claim 1 is characterized in that: The PLC controller is connected with the central control and local HMI electrical signals to display the status of each monitoring data of the blade loosening and rehumidification machine in real time.

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