Intelligent control system and method for corrugated paper product production

Abstract

The invention discloses an intelligent control system and method for corrugated paper product production. The intelligent control system for corrugated paper product production comprises an acquisition module, a PLC control module, a heating module and an early warning module. The acquisition module is used for acquiring temperature data and moisture content data of corrugated base paper in a production process in real time and transmitting the data to the PLC control module; the PLC control module is used for analyzing the temperature data and the water content data, judging whether the data are abnormal or not, sending alarm information to the early warning module if the data are abnormal, and meanwhile, calculating a control instruction according to the temperature data and the water content data and sending the control instruction to the heating module; the heating module is used for heating corrugated base paper, and the output power of the heating module is automatically adjusted according to a control instruction sent by the PLC control module; and the early warning module is used for carrying out early warning after receiving the alarm information.

Description

Technical Field

[0001] The present invention relates to the technical field of corrugated paper product production, and in particular to an intelligent control system and method for producing corrugated paper products. Background Art

[0002] Temperature control is crucial in the production process of corrugated cardboard. Currently, the temperature control systems used in many production lines rely on traditional temperature control devices, such as mechanical thermostats and single temperature sensors, which are often unable to monitor and adjust the temperature in real time and accurately.

[0003] In addition, it is also very important to control the moisture content of corrugated paperboard during the production process, otherwise it will also affect the quality of the paperboard. At present, in the production process, only the environmental humidity is controlled to control the moisture content of the final corrugated paperboard. However, in the process of gluing different layers of corrugated paper, the difference in moisture content of different layers can easily lead to longitudinal size differences, causing the corrugated paperboard to warp. In the preheating process of corrugated paper, the heating process will reduce its moisture content. The existing technology lacks a solution that combines temperature control with moisture content control. Summary of the invention

[0004] In order to solve the problems raised in the above background technology, the technical solution adopted by the present invention is:

[0005] An intelligent control system for corrugated paper product production, comprising a collection module, a PLC control module, a heating module and an early warning module;

[0006] The acquisition module is used to collect the temperature data and moisture content data of the corrugated paper during the production process in real time, and transmit the data to the PLC control module;

[0007] The PLC control module is used to analyze the temperature data and the moisture content data, determine whether the data is abnormal, and send an alarm message to the early warning module if the data is abnormal. At the same time, the control command is calculated based on the temperature data and the moisture content data and sent to the heating module;

[0008] The heating module is used to heat the corrugated paper, and the output power of the heating module is automatically adjusted according to the control instruction sent by the PLC control module;

[0009] The early warning module is used to issue an early warning after receiving the alarm information.

[0010] Preferably, the acquisition module includes an air temperature sensor, a temperature transmitter, an air humidity sensor and an infrared moisture meter;

[0011] The air temperature sensor is used to collect the air temperature around the corrugated paper;

[0012] The temperature transmitter is used to collect the temperature of the corrugated paper before and after heating;

[0013] The air humidity sensor is used to collect the air humidity around the corrugated paper;

[0014] The infrared moisture meter is used to collect the moisture content of corrugated paper before and after heating.

[0015] Preferably, the heating module comprises a preheating cylinder arranged on a corrugated paper guide roller, and a controller for controlling the power output of the preheating cylinder.

[0016] Preferably, the abnormal warning module is configured in the production control center and / or the staff's intelligent terminal.

[0017] Another aspect of the present invention provides an intelligent temperature control method for corrugated paper product production, which uses the aforementioned intelligent control system for corrugated paper product production and includes the following steps:

[0018] S1. The temperature data and moisture content data of the corrugated paper product production process are collected in real time through the collection module, and the data are transmitted to the PLC control module;

[0019] S2, analyzing the data in the PLC control module to determine whether the data is abnormal. If the data is abnormal, proceed to step S3, otherwise directly proceed to step S4;

[0020] S3, sending abnormal alarm information to the early warning module for abnormal warning;

[0021] S4, calculating the control instruction according to the temperature data and the moisture content data and sending it to the heating module;

[0022] S5, automatically adjusting the output power of the heating module according to the control instructions sent by the PLC control module;

[0023] S6. Return to step S1 to implement real-time feedback adjustment.

[0024] Preferably, in step S1, the acquisition module includes an air temperature sensor, a temperature transmitter, an air humidity sensor and an infrared moisture meter.

[0025] Preferably, in step S3, the abnormal warning module is configured in the production control center and / or the staff's intelligent terminal.

[0026] Preferably, in step S4, the heating module is used to heat the corrugated paper, and the heating module includes a preheating cylinder arranged on the corrugated paper guide roller, and a controller for controlling the power output of the preheating cylinder.

[0027] Preferably, before actual production, the temperature threshold and moisture content threshold of the corrugated base paper after being preheated by the preheating cylinder are determined through experiments;

[0028] In step S2, the collected temperature data and moisture content data are compared with the preset temperature threshold and moisture content threshold to determine whether the data is abnormal.

[0029] Preferably, in step S4, the following method is specifically adopted, when the PLC control module calculates the control instruction according to the temperature data and the moisture content data:

[0030] The following relationship between moisture content and temperature is established:

[0031]

[0032] Among them, ΔX represents the change of moisture content, which is the moisture content of the corrugated paper after heating minus the moisture content before heating, K represents the mass transfer coefficient between the corrugated paper and the air, M represents the molar mass of water, G represents the absolute dry weight of the corrugated paper, R is the Clapeyron constant, P1 and P2 represent the water vapor partial pressure on the surface of the corrugated paper and the water vapor saturation pressure around the corrugated paper, T1 and T2 represent the Kelvin temperature of the corrugated paper and the air around the corrugated paper, respectively. represents the relative humidity of the air around the corrugated paper, and t represents the heating time, which is calculated according to the following formula:

[0033]

[0034] Among them, r and α represent the diameter and wrap angle of the preheating cylinder respectively, and v represents the conveying speed of the corrugated base paper in the production line;

[0035] In addition, in formula (1), M and R are constants, K and G can be calculated through experiments, P1 and P2 can be calculated from the data collected in step S1, and T1, T2 and Obtained through collection in step S1;

[0036] When other parameters remain unchanged, the temperatures T1 and T2 are only related to the output power P of the preheating cylinder. Therefore, the functional relationship between T1, T2 and P is established through experiments, which is expressed as:

[0037] T1=f1(P) (3)

[0038] T2=f2(P) (4)

[0039] The PLC control module uses the PID algorithm to automatically adjust the output power P of the preheating cylinder based on the data collected in step S1 in combination with equations (1) to (4) so ​​that the temperature and moisture content of the corrugated base paper after heating are maintained within a preset threshold range.

[0040] Compared with the prior art, the intelligent control system and method for the production of corrugated paper products provided by the present invention can dynamically adjust the operation of the heating module by collecting relevant data in real time for feedback, and organically combine temperature control with moisture content control, so that the temperature and moisture content are maintained within the appropriate range as much as possible, and an early warning mechanism is also set under abnormal conditions; it is conducive to improving production efficiency, reducing energy consumption and improving product quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0041] Figure 1 A schematic diagram of an intelligent control system for corrugated paper product production provided by the present invention;

[0042] Figure 2 A schematic flow chart of an intelligent temperature control method for producing corrugated paper products provided by the present invention. DETAILED DESCRIPTION

[0043] In order to make the technical means, creative features, objectives and effects achieved by the present invention easy to understand, the following further describes how the present invention is implemented in conjunction with the accompanying drawings and specific implementation methods.

[0044] Reference Figure 1 As shown, in the first embodiment, the present invention provides an intelligent temperature control system for the production of corrugated paper products, including an acquisition module 1, a PLC control module 2, a heating module 3 and an early warning module 4; the acquisition module 1 is used to collect temperature data and moisture content data of corrugated paper corrugated base paper in the production process in real time, and transmit the data to the PLC control module 2; the PLC control module 2 is used to analyze the temperature data and moisture content data, determine whether the data is abnormal, and if the data is abnormal, send an alarm message to the early warning module 4, and at the same time, calculate a control instruction based on the temperature data and moisture content data and send it to the heating module 3; the heating module 3 is used to heat the corrugated base paper, and the output power of the heating module 3 is automatically adjusted according to the control instruction sent by the PLC control module 2; the early warning module 4 is used to issue an early warning after receiving the alarm information.

[0045] In this embodiment, the acquisition module 1 includes an air temperature sensor, a temperature transmitter, an air humidity sensor and an infrared moisture meter; the air temperature sensor is used to collect the air temperature around the corrugated paper; the temperature transmitter is used to collect the temperature of the corrugated paper before and after heating; the air humidity sensor is used to collect the air humidity around the corrugated paper; the infrared moisture meter is used to collect the moisture content of the corrugated paper before and after heating.

[0046] In this embodiment, the heating module 3 includes a preheating cylinder arranged on the corrugated paper guide roller, and a controller for controlling the power output of the preheating cylinder.

[0047] In this embodiment, the abnormal warning module 4 is configured in the production control center and / or the intelligent terminal of the staff.

[0048] In a second embodiment, the present invention provides an intelligent temperature control method for corrugated paper product production, which adopts the above-mentioned intelligent control system for corrugated paper product production and includes the following steps:

[0049] S1, collect temperature data and moisture content data in the production process of corrugated paper products in real time through the acquisition module 1, and transmit the data to the PLC control module 2;

[0050] S2, analyzing the data in the PLC control module 2 to determine whether the data is abnormal, if the data is abnormal, proceed to step S3, otherwise directly proceed to step S4;

[0051] S3, sending the abnormal alarm information to the early warning module 4 for abnormal early warning;

[0052] S4, calculating a control instruction based on the temperature data and the moisture content data and sending it to the heating module 3;

[0053] S5, automatically adjusting the output power of the heating module 3 according to the control instruction sent by the PLC control module 2;

[0054] S6. Return to step S1 to implement real-time feedback adjustment.

[0055] Furthermore, in step S1, the acquisition module 1 includes an air temperature sensor, a temperature transmitter, an air humidity sensor and an infrared moisture meter.

[0056] Furthermore, in step S3, the abnormal warning module 4 is configured in the production control center and / or the intelligent terminal of the staff.

[0057] Further, in step S4, the heating module 3 is used to heat the corrugated paper, and the heating module 3 includes a preheating cylinder arranged on the corrugated paper guide roller, and a controller for controlling the power output of the preheating cylinder.

[0058] Furthermore, before actual production, the temperature threshold and moisture content threshold of the corrugated base paper after preheating in the preheating cylinder are determined through experiments; in step S2, the collected temperature data and moisture content data are compared with the preset temperature threshold and moisture content threshold to determine whether the data is abnormal.

[0059] Further, in step S4, the following method is specifically adopted, when the PLC control module 2 calculates the control instruction according to the temperature data and the moisture content data:

[0060] The following relationship between moisture content and temperature is established:

[0061]

[0062] Among them, ΔX represents the change of moisture content, which is the moisture content of the corrugated paper after heating minus the moisture content before heating, K represents the mass transfer coefficient between the corrugated paper and the air, M represents the molar mass of water, G represents the absolute dry weight of the corrugated paper, R is the Clapeyron constant, P1 and P2 represent the water vapor partial pressure on the surface of the corrugated paper and the water vapor saturation pressure around the corrugated paper, T1 and T2 represent the Kelvin temperature of the corrugated paper and the air around the corrugated paper, respectively. represents the relative humidity of the air around the corrugated paper, and t represents the heating time, which is calculated according to the following formula:

[0063]

[0064] Among them, r and α represent the diameter and wrap angle of the preheating cylinder respectively, and v represents the conveying speed of the corrugated base paper in the production line;

[0065] In addition, in formula (1), M and R are constants, K and G can be calculated through experiments, P1 and P2 can be calculated from the data collected in step S1, and T1, T2 and Obtained through collection in step S1;

[0066] It can be understood that the temperatures T1 and T2 are mainly related to the ambient temperature and the heating temperature of the preheating cylinder, and production can usually ensure that the ambient temperature changes little. Therefore, when other parameters remain unchanged, it can be considered that the temperatures T1 and T2 are only related to the output power P of the preheating cylinder. The functional relationship between T1, T2 and P can be established in advance through experiments and stored in the database, which is expressed as:

[0067] T1=f1(P) (3)

[0068] T2=f2(P) (4)

[0069] The PLC control module 2 uses the PID algorithm to automatically adjust the output power P of the preheating cylinder according to the data collected in step S1 in combination with equations (1) to (4), so that the temperature and moisture content of the corrugated base paper after heating are maintained within the preset threshold range.

[0070] It is understandable that in the corrugated paper production line, the corrugated base paper enters from one paper guide roller and is sent out from another paper guide roller. The two paper guide rollers are close to the preheating cylinder so that the corrugated base paper wraps the preheating cylinder to achieve the purpose of heating. The angle formed by the two paper guide rollers and the center of the preheating cylinder is the wrap angle of the corrugated base paper. Referring to formula (2), it can be seen that the wrap angle directly affects the preheating time, and then affects the heating effect and moisture content. Therefore, before actual production, the appropriate wrap angle data can be pre-calculated according to needs to ensure the overall preheating effect.

[0071] Before preheating, the temperature of the corrugated paper is generally maintained at 70-90°C, preferably around 80°C, while the temperature of the corrugated paper that has just been preheated will be higher. In this embodiment, the temperature threshold and moisture content threshold of the corrugated paper after preheating can be set according to industrial needs. For example, in this embodiment, the temperature threshold can be set to 90-110°C, and the moisture content threshold can be set to 8%-12%.

[0072] In addition, in this embodiment, in step S4, the PLC control module can use the moisture content as a reference. For example, if the optimal moisture content is set to 10%, the corresponding output power P is calculated based on the data collected in step S1 in combination with equations (1) to (4), and then real-time feedback data is continuously obtained. The output power P of the preheating cylinder is automatically adjusted using the PID algorithm so that the moisture content of the corrugated base paper after heating approaches the set 10%, while maintaining the temperature and moisture content within the preset threshold range. Once it cannot be maintained, that is, in step S2, it is detected that the temperature or moisture content of the corrugated base paper after preheating is not within the above threshold range, then step S3 is entered to trigger an early warning, indicating that there may be a fault in the production line, for example, the wrap angle data needs to be adjusted, prompting the staff to handle it.

[0073] In summary, compared with the prior art, the intelligent control system and method for corrugated paper product production provided by the present invention can dynamically adjust the operation of the heating module by collecting relevant data in real time for feedback, and organically combine temperature control with moisture content control, so that the temperature and moisture content are maintained within an appropriate range as much as possible, and an early warning mechanism is also set under abnormal conditions; it is conducive to improving production efficiency, reducing energy consumption and improving product quality.

[0074] Finally, it should be noted that the above embodiments are only used to illustrate the technical solution of the present invention rather than to limit it. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solution of the present invention can be modified or replaced by equivalents without departing from the purpose and scope of the technical solution of the present invention, which should be included in the scope of the claims of the present invention.

Claims

1. An intelligent control system for corrugated paper product production, characterized in that: It comprises a collection module (1), a PLC control module (2), a heating module (3) and an early warning module (4); The acquisition module (1) is used to collect temperature data and moisture content data of corrugated paper during the production process in real time, and transmit the data to the PLC control module (2); The PLC control module (2) is used to analyze the temperature data and the moisture content data, determine whether the data is abnormal, and if the data is abnormal, send an alarm message to the early warning module (4); at the same time, calculate a control instruction based on the temperature data and the moisture content data and send it to the heating module (3); The heating module (3) is used to heat the corrugated paper, and the output power of the heating module (3) is automatically adjusted according to the control instruction sent by the PLC control module (2); The early warning module (4) is used to issue an early warning after receiving the alarm information.

2. The intelligent control system for corrugated paper product production according to claim 1, characterized in that: The acquisition module (1) comprises an air temperature sensor, a temperature transmitter, an air humidity sensor and an infrared moisture meter; The air temperature sensor is used to collect the air temperature around the corrugated paper; The temperature transmitter is used to collect the temperature of the corrugated paper before and after heating; The air humidity sensor is used to collect the air humidity around the corrugated paper; The infrared moisture meter is used to collect the moisture content of corrugated paper before and after heating.

3. The intelligent control system for corrugated paper product production according to claim 1, characterized in that: The heating module (3) comprises a preheating cylinder arranged on a corrugated paper guide roller, and a controller for controlling the power output of the preheating cylinder.

4. The intelligent control system for corrugated paper product production according to claim 1, characterized in that: The abnormal warning module (4) is configured in the production control center and / or the intelligent terminal of the staff.

5. An intelligent temperature control method for corrugated paper product production, characterized in that: The intelligent control system for corrugated paper product production according to any one of claims 1 to 4 is adopted, and comprises the following steps: S1, collecting temperature data and moisture content data in the production process of corrugated paper products in real time through the collection module (1), and transmitting the data to the PLC control module (2); S2, analyzing the data in the PLC control module (2) to determine whether the data is abnormal. If the data is abnormal, proceed to step S3; otherwise, proceed directly to step S4; S3, sending the abnormal alarm information to the early warning module (4) to issue an abnormal warning; S4, calculating a control instruction based on the temperature data and the moisture content data and sending the control instruction to the heating module (3); S5, automatically adjusting the output power of the heating module (3) according to the control instruction sent by the PLC control module (2); S6. Return to step S1 to implement real-time feedback adjustment.

6. The intelligent temperature control method for corrugated paper product production according to claim 5, characterized in that: In step S1, the acquisition module (1) comprises an air temperature sensor, a temperature transmitter, an air humidity sensor and an infrared moisture meter.

7. The intelligent temperature control method for corrugated paper product production according to claim 6, characterized in that: In step S3, the abnormal warning module (4) is configured in the production control center and / or the intelligent terminal of the staff.

8. The intelligent temperature control method for corrugated paper product production according to claim 7, characterized in that: In step S4, the heating module (3) is used to heat the corrugated paper, and the heating module (3) comprises a preheating cylinder arranged on the corrugated paper guide roller, and a controller for controlling the power output of the preheating cylinder.

9. The intelligent temperature control method for corrugated paper product production according to claim 8, characterized in that: Before actual production, the temperature threshold and moisture content threshold of the corrugated base paper after being preheated in the preheating cylinder are determined through experiments; In step S2, the collected temperature data and moisture content data are compared with the preset temperature threshold and moisture content threshold to determine whether the data is abnormal.

10. The intelligent temperature control method for corrugated paper product production according to claim 9, characterized in that: In step S4, the following method is specifically adopted, when the PLC control module (2) calculates the control instruction according to the temperature data and the moisture content data: The following relationship between moisture content and temperature is established: Among them, ΔX represents the change of moisture content, which is the moisture content of the corrugated paper after heating minus the moisture content before heating, K represents the mass transfer coefficient between the corrugated paper and the air, M represents the molar mass of water, G represents the absolute dry weight of the corrugated paper, R is the Clapeyron constant, P1 and P2 represent the water vapor partial pressure on the surface of the corrugated paper and the water vapor saturation pressure around the corrugated paper, T1 and T2 represent the Kelvin temperature of the corrugated paper and the air around the corrugated paper, respectively. represents the relative humidity of the air around the corrugated paper, and t represents the heating time, which is calculated according to the following formula: Among them, r and α represent the diameter and wrap angle of the preheating cylinder respectively, and v represents the conveying speed of the corrugated base paper in the production line; In addition, in formula (1), M and R are constants, K and G can be calculated through experiments, P1 and P2 can be calculated from the data collected in step S1, and T1, T2 and Obtained through collection in step S1; When other parameters remain unchanged, the temperatures T1 and T2 are only related to the output power P of the preheating cylinder. Therefore, the functional relationship between T1, T2 and P is established through experiments, which is expressed as: T1=f1(P) (3) T2=f2(P) (4) The PLC control module (2) uses a PID algorithm to automatically adjust the output power P of the preheating cylinder based on the data collected in step S1 in combination with equations (1) to (4), so that the temperature and moisture content of the corrugated base paper after heating are maintained within a preset threshold range.

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