Industrial control platform design device and method for intelligent microwave density detector

Abstract

The invention discloses an industrial control platform design device and method for an intelligent microwave density detector, and belongs to the field of cigarette density (weight) detection of cigarette making machines. The device comprises a main control and processing module and an auxiliary operation module. And the main control and processing module is mainly used for collecting cigarette density signals detected by the microwave density detector in real time and outputting a weight calculation value. The auxiliary operation module calculates the short-term standard deviation of the cigarette weight by collecting the short-term standard deviation of the cigarette making and tipping unit, the running position of a leveling disc and other production data in real time and reading the weight value sent by the main control and processing module at regular time, and therefore the weight control performance of the microwave density detector is evaluated. According to the invention, the working state of the microwave density detector can be intelligently diagnosed, and the internal calibration parameters of the microwave density detector can be automatically optimized and adjusted, so that the microwave density detector always works in the optimal state.

Description

Technical Field

[0001] The invention belongs to the field of cigarette density (weight) detection of cigarette making machines, and in particular relates to an industrial control platform design device and method for an intelligent microwave density detector. Background Art

[0002] Cigarette rolling and joining equipment is the main technical equipment in the cigarette industry production. It is a special equipment used to produce mouthless cigarettes and filter cigarettes that meet the process requirements. The microwave density detector is used to detect the density (weight) of cigarettes in the rolling and joining machine. It is the sensor of the weight control device and forms a closed-loop system with the weight control system to complete the control of cigarette weight.

[0003] In recent years, with the development of intelligent manufacturing in the tobacco industry, intelligent sensor technology, and the intelligent upgrade of online detection technology, microwave density detectors not only involve high-precision and high-complexity calculations, as well as real-time detection and control of large-scale data processing, but also need to provide digital interfaces to achieve equipment networking and data upload. However, the use of traditional computer industrial control platforms in conjunction with GPU boards cannot achieve the intelligent upgrade of microwave density detectors. Therefore, it is of great significance to study an industrial control platform for intelligent microwave density detectors. Summary of the invention

[0004] In view of the above-mentioned technical problems existing in the prior art, the present invention proposes an industrial control platform design device and method for an intelligent microwave density detector, which has a reasonable design, overcomes the shortcomings of the prior art, and has good effects.

[0005] In order to achieve the above object, the present invention adopts the following technical solution:

[0006] An industrial control platform design device for an intelligent microwave density detector includes a main control and processing module and an auxiliary operation module; the main control and processing module and the auxiliary operation module are connected through lines and interfaces; wherein,

[0007] The main control and processing module is configured to collect cigarette density signals detected by the microwave density detector in real time;

[0008] The auxiliary computing module is configured to analyze and evaluate the weight control performance of the microwave density detector.

[0009] Preferably, the main control and processing module includes a main single-chip microcomputer, a field programmable gate array FPGA, and an AD acquisition circuit, a weight pulse output circuit, a CAN communication interface and a wireless debugging interface connected to the main single-chip microcomputer through a line;

[0010] The main single chip microcomputer is configured to detect the fault information and temperature data of the microwave density detector in real time; it is connected to the wireless terminal through the wireless debugging interface; it is connected to the weight control system through the CAN communication interface;

[0011] The field programmable gate array FPGA is configured to generate a fixed frequency AD acquisition conversion signal, or receive an external encoder signal, and after processing, use it as a conversion signal of the AD acquisition circuit, and synchronously generate a sampling interrupt signal to send to the main microcontroller;

[0012] The main single-chip computer and field programmable gate array FPGA cooperate to collect the cigarette density signal of the microwave density detector in real time. After internal processing and calculation, the final weight measurement value is sent to the weight control system through the weight pulse output circuit in the form of pulse quantity or digital quantity.

[0013] Preferably, the main control and processing module further includes a fault detection circuit and a temperature detection circuit connected to the main single chip computer via lines.

[0014] Preferably, the auxiliary computing module includes an auxiliary single-chip microcomputer, and a CAN communication interface and an Ethernet interface connected to the auxiliary single-chip microcomputer via a line;

[0015] The auxiliary single-chip computer is configured to collect the production data of the roll-to-roll machine group in real time, exchange data with the main control and processing module through the high-speed inter-board interface, and regularly read the calibration parameters and weight calculation results of the microwave density detector. By comprehensively analyzing the above data, the weight control performance of the microwave density detector is evaluated;

[0016] The auxiliary single chip microcomputer is connected to the weight control system via the CAN communication interface; it is connected to the digital terminal via the Ethernet interface to centrally collect the real-time data of the microwave density detector for subsequent analysis and management.

[0017] In addition, the present invention also mentions a method for designing an industrial control platform for an intelligent microwave density detector. The method adopts the industrial control platform design device for an intelligent microwave density detector as described above, and can intelligently diagnose the weight control performance of the microwave density detector, automatically optimize and adjust the internal calibration parameters of the microwave density detector, and specifically includes the following steps:

[0018] Step 1: The main control and processing module collects the cigarette density signal obtained by the microwave density detector in real time and calculates the cigarette weight measurement value;

[0019] Step 2: The auxiliary operation module collects the machine production speed and the short-term standard deviation σ1 data of cigarette weight sent by the weight control system in real time through CANBUS, EtherCAT or ProfiBUS bus;

[0020] Step 3: The auxiliary operation module collects the cigarette weight measurement values ​​of the microwave density detector sent by the main control module at regular intervals through the inter-board interface, and calculates the short-term standard deviation σ2 of the cigarette weight;

[0021] Step 4: The auxiliary operation module comprehensively analyzes the calibration parameters of the microwave density detector based on the short-term standard deviation σ1 and short-term standard deviation σ2 of the cigarette weight obtained in steps 2 and 3, and evaluates the weight control performance of the microwave density detector;

[0022] Step 5: The main control and processing module determines whether it is necessary to adjust the internal calibration parameters of the microwave density detector according to the analysis results of step 4;

[0023] If: the judgment result is that no adjustment is required, return to step 1;

[0024] Or if the judgment result is that adjustment is needed, go to step 6;

[0025] Step 6: Send a command through the microwave density detector to temporarily set the weight control system to manual mode;

[0026] Step 7: The main control and processing module will calculate the parameter adjustment amount and automatically optimize the calibration parameters of the microwave density detector;

[0027] Step 8: Obtain the real-time weight deviation of the unit, and set the weight deviation value in the unit weight adjustment value by sending instructions through the microwave density detector;

[0028] Step 9: Re-obtain the real-time weight deviation of the unit, calculate the average of 5 consecutive real-time weight deviations, and determine whether it is within 10 mg;

[0029] If: the judgment result is not within 10mg, return to step 8;

[0030] Or if the result is within 10 mg, go to step 10;

[0031] Step 10: Send a command through the microwave density detector to turn on the unit weight control.

[0032] Beneficial technical effects brought by the present invention:

[0033] 1. The industrial control platform architecture designed with main control module + field programmable gate array FPGA + auxiliary computing module can meet the needs of high-speed real-time data collection and calculation on the one hand, and real-time data analysis and upload on the other hand.

[0034] 2. Without the help of other modules or devices, it can intelligently diagnose the weight control performance of the microwave density detector through interactive data analysis between itself and the cigarette making unit, automatically optimize and adjust the internal calibration parameters of the microwave density detector, so that the microwave density detector always works in the best condition.

[0035] 3. When automatically optimizing the internal parameters of the microwave, considering that the weight reference may change, the weight control function of the unit can be temporarily turned off by automatically sending instructions through the microwave. After the optimization is completed, the weight control function can be turned on automatically without human intervention, realizing fully automatic operation. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Figure 1 It is a principle block diagram of the method of the present invention.

[0037] Figure 2 It is a flow chart of the method of the present invention for automatically optimizing the working state. DETAILED DESCRIPTION

[0038] The present invention is further described in detail below with reference to the accompanying drawings and specific embodiments:

[0039] Embodiment 1:

[0040] like Figure 1 As shown, a method and device for designing an industrial control platform for an intelligent microwave density detector include: a main control and processing module and an auxiliary operation module.

[0041] The main control and processing module is configured to collect the cigarette density signal detected by the microwave density detector in real time and output the weight measurement value to the weight control system. The main control and processing module includes a high-performance main microcontroller, a field programmable gate array FPGA, and an AD acquisition circuit, a weight pulse output circuit, a bus interface circuit, a fault detection circuit, a temperature detection circuit and a debugging interface connected to the main microcontroller.

[0042] The field programmable gate array FPGA is used to generate a fixed-frequency AD acquisition conversion signal, or receive an external encoder signal, which is used as a conversion signal of the AD acquisition circuit after processing, and synchronously generates a sampling interrupt signal and sends it to the main single-chip microcomputer. The main single-chip microcomputer and the field programmable gate array FPGA cooperate to collect the cigarette density signal of the microwave density detector in real time, and after internal processing and calculation, the final weight measurement value is sent to the weight control system in the form of a pulse quantity or a digital quantity. The main single-chip microcomputer will also detect the fault information and temperature data of the microwave density detector in real time, and the user can connect to the wireless debugging interface of the microwave density detector through a wireless terminal with Bluetooth, WIFI or 5G functions such as a mobile phone, tablet computer and laptop computer to obtain relevant data of the detector and debug the equipment parameters.

[0043] The auxiliary operation module is configured to analyze and evaluate the weight control performance of the microwave density detector. The auxiliary operation module includes an auxiliary single chip microcomputer, and a CAN communication circuit and an Ethernet interface circuit connected to the auxiliary single chip microcomputer.

[0044] The auxiliary microcontroller is connected to the weight control system via ANBUS, EtherCAT or ProfiBUS bus to collect the production data of the roll-to-roller group in real time, and exchanges data with the main control and processing module through the high-speed inter-board interface, and regularly reads the calibration parameters and weight calculation results of the microwave density detector. The auxiliary microcontroller analyzes and evaluates the weight control performance of the microwave density detector based on the above data. The Ethernet interface can be connected to the factory digital terminal, which is convenient for centralized collection of real-time data of the microwave density detector, as well as subsequent analysis and management.

[0045] Embodiment 2:

[0046] On the basis of the above-mentioned embodiment 1, the present invention further mentions a design method of an industrial control platform for an intelligent microwave density detector, which can intelligently diagnose the weight control performance of the microwave density detector, automatically optimize and adjust the internal calibration parameters of the microwave density detector through cigarette weight data collection and calculation, weight control performance evaluation and calibration parameter adjustment, etc., and specifically includes the following steps (such as Figure 2 shown):

[0047] Step 1: The main control and processing module collects the cigarette density signal obtained by the microwave density detector in real time and calculates the cigarette weight measurement value;

[0048] Step 2: The auxiliary operation module collects the machine production speed and the short-term standard deviation σ1 data of cigarette weight sent by the weight control system in real time through CANBUS, EtherCAT or ProfiBUS bus;

[0049] Step 3: The auxiliary operation module collects the cigarette weight measurement values ​​of the microwave density detector sent by the main control module at regular intervals through the inter-board interface, and calculates the short-term standard deviation σ2 of the cigarette weight;

[0050] Step 4: The auxiliary operation module comprehensively analyzes the calibration parameters of the microwave density detector based on the short-term standard deviation σ1 and short-term standard deviation σ2 of the cigarette weight obtained in steps 2 and 3, and evaluates the weight control performance of the microwave density detector;

[0051] Step 5: The main control and processing module determines whether it is necessary to adjust the internal calibration parameters of the microwave density detector according to the analysis results of step 4;

[0052] If: the judgment result is that no adjustment is required, return to step 1;

[0053] Or if the judgment result is that adjustment is needed, go to step 6;

[0054] Step 6: Send a command through the microwave density detector to temporarily set the weight control system to manual mode;

[0055] Step 7: The main control and processing module will calculate the parameter adjustment amount and automatically optimize the calibration parameters of the microwave density detector;

[0056] Step 8: Obtain the real-time weight deviation of the unit, and set the weight deviation value in the unit weight adjustment value by sending instructions through the microwave density detector;

[0057] Step 9: Re-obtain the real-time weight deviation of the unit, calculate the average of 5 consecutive real-time weight deviations, and determine whether it is within 10 mg;

[0058] If: the judgment result is not within 10mg, return to step 8;

[0059] Or if the result is within 10 mg, go to step 10;

[0060] Step 10: Send a command through the microwave density detector to turn on the unit weight control.

[0061] Of course, the above description is not a limitation of the present invention, and the present invention is not limited to the above examples. Changes, modifications, additions or substitutions made by technicians in this technical field within the essential scope of the present invention should also fall within the protection scope of the present invention.

Claims

1. An industrial control platform design device for an intelligent microwave density detector, characterized in that: It includes a main control and processing module and an auxiliary operation module; the main control and processing module and the auxiliary operation module are connected through lines and interfaces; wherein, The main control and processing module is configured to collect cigarette density signals detected by the microwave density detector in real time; The auxiliary computing module is configured to analyze and evaluate the weight control performance of the microwave density detector.

2. The industrial control platform design device for an intelligent microwave density detector according to claim 1, characterized in that: The main control and processing module includes a main single-chip microcomputer, a field programmable gate array FPGA, and an AD acquisition circuit, a weight pulse output circuit, a CAN communication interface, and a wireless debugging interface connected to the main single-chip microcomputer through lines; A main single chip microcomputer is configured to detect fault information and temperature data of the microwave density detector in real time; It is connected to a wireless terminal via a wireless debugging interface; it is connected to a weight control system via a CAN communication interface; The field programmable gate array FPGA is configured to generate a fixed frequency AD acquisition conversion signal, or receive an external encoder signal, and after processing, use it as a conversion signal of the AD acquisition circuit, and synchronously generate a sampling interrupt signal to send to the main microcontroller; The main single-chip computer and field programmable gate array FPGA cooperate to collect the cigarette density signal of the microwave density detector in real time. After internal processing and calculation, the final weight measurement value is sent to the weight control system through the weight pulse output circuit in the form of pulse quantity or digital quantity.

3. The industrial control platform design device for an intelligent microwave density detector according to claim 1, characterized in that: The main control and processing module also includes a fault detection circuit and a temperature detection circuit connected to the main single-chip computer through lines.

4. The industrial control platform design device for an intelligent microwave density detector according to claim 1, characterized in that: The auxiliary operation module includes an auxiliary single chip microcomputer, and a CAN communication interface and an Ethernet interface connected to the auxiliary single chip microcomputer through a line; The auxiliary single-chip computer is configured to collect the production data of the roll-to-roll machine group in real time, exchange data with the main control and processing module through the high-speed inter-board interface, and regularly read the calibration parameters and weight calculation results of the microwave density detector. By comprehensively analyzing the above data, the weight control performance of the microwave density detector is evaluated; The auxiliary single chip microcomputer is connected to the weight control system via the CAN communication interface; it is connected to the digital terminal via the Ethernet interface to centrally collect the real-time data of the microwave density detector for subsequent analysis and management.

5. A design method for an industrial control platform for an intelligent microwave density detector, characterized in that: The industrial control platform design device for an intelligent microwave density detector as claimed in claim 1 can intelligently diagnose the weight control performance of the microwave density detector, automatically optimize and adjust the internal calibration parameters of the microwave density detector, and specifically includes the following steps: Step 1: The main control and processing module collects the cigarette density signal obtained by the microwave density detector in real time and calculates the cigarette weight measurement value; Step 2: The auxiliary operation module collects the machine production speed and the short-term standard deviation σ1 data of cigarette weight sent by the weight control system in real time through CANBUS, EtherCAT or ProfiBUS bus; Step 3: The auxiliary operation module collects the cigarette weight measurement values ​​of the microwave density detector sent by the main control module at regular intervals through the inter-board interface, and calculates the short-term standard deviation σ2 of the cigarette weight; Step 4: The auxiliary operation module comprehensively analyzes the calibration parameters of the microwave density detector based on the short-term standard deviation σ1 and the short-term standard deviation σ2 of the cigarette weight obtained in steps 2 and 3, and evaluates the weight control performance of the microwave density detector; Step 5: The main control and processing module determines whether it is necessary to adjust the internal calibration parameters of the microwave density detector according to the analysis results of step 4; If: the judgment result is that no adjustment is required, return to step 1; Or if the judgment result is that adjustment is needed, go to step 6; Step 6: Send a command through the microwave density detector to temporarily set the weight control system to manual mode; Step 7: The main control and processing module will calculate the parameter adjustment amount and automatically optimize the calibration parameters of the microwave density detector; Step 8: Obtain the real-time weight deviation of the unit, and set the weight deviation value in the unit weight adjustment value by sending instructions through the microwave density detector; Step 9: Re-obtain the real-time weight deviation of the unit, calculate the average of 5 consecutive real-time weight deviations, and determine whether it is within 10 mg; If: the judgment result is not within 10mg, return to step 8; Or if the result is within 10 mg, go to step 10; Step 10: Send a command through the microwave density detector to turn on the unit weight control.

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