An industrial control platform design device and method for an intelligent microwave density detector

Abstract

The application discloses a kind of industrial control platform design device and method for intelligent microwave density detector, belong to cigarette machine cigarette density (weight) detection field.The device of the present application includes main control and processing module and auxiliary arithmetic module.Main control and processing module are mainly used to collect the cigarette density signal detected by microwave density detector in real time, output weight calculation value.Auxiliary arithmetic module is through real-time acquisition of short-term standard deviation of cigarette making machine group, flat disc operating position and other production data, and through the weight value sent by main control and processing module by timing reading, the short-term standard deviation of cigarette weight is calculated, so as to evaluate the weight control performance of microwave density detector.The present application can intelligently diagnose the working state of microwave density detector, automatically optimize and adjust the internal calibration parameters of microwave density detector, so that the microwave density detector always works in the best state.

Description

Technical Field

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

[0002] Cigarette rolling and splicing equipment is a key technical tool in the cigarette industry, specifically designed for producing cigarettes without filters and those with stems that meet specific process requirements. A microwave density detector is used in the rolling and splicing machine to detect the density (weight) of the cigarettes. It acts as a sensor in the weight control device, forming a closed-loop system with the weight control system to jointly control the weight of the cigarettes.

[0003] In recent years, with the development of intelligent manufacturing, intelligent sensor technology, and intelligent upgrading of online detection technology in the tobacco industry, microwave density detectors not only involve high-precision and highly complex calculations and real-time detection and control of large-scale data processing, but also require digital interfaces to enable device networking and data uploading. However, the traditional approach of using a computer industrial control platform with GPU cards cannot achieve the intelligent upgrade of microwave density detectors. Therefore, researching an industrial control platform for intelligent microwave density detectors is of great significance. Summary of the Invention

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

[0005] To achieve the above objectives, 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 calculation module; the main control and processing module and the auxiliary calculation module are connected via lines and interfaces; wherein,

[0007] The main control and processing module is configured to acquire the cigarette density signal detected by the microwave density detector in real time.

[0008] An 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 microcontroller, 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 microcontroller via a line.

[0010] The main microcontroller 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; and it is connected to a weight control system via a CAN communication interface.

[0011] The field-programmable gate array (FPGA) is configured to generate fixed-frequency AD acquisition and conversion signals, or to receive external encoder signals, process them, and use them as conversion signals for the AD acquisition circuit, while simultaneously generating sampling interrupt signals and sending them to the main microcontroller.

[0012] The main microcontroller and the field-programmable gate array (FPGA) work together to acquire the cigarette density signal from the microwave density detector in real time. After internal processing and calculation, the final weight measurement value is sent to the weight control system in the form of a pulse or digital quantity through the weight pulse output circuit.

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

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

[0015] The auxiliary microcontroller is configured to collect production data from the winding and splicing unit in real time, interact with the main control and processing module through a high-speed inter-board interface, and periodically 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 can be evaluated.

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

[0017] Furthermore, this invention also mentions a design method for an industrial control platform for an intelligent microwave density detector. This method employs an industrial control platform design device for an intelligent microwave density detector as described above, which can intelligently diagnose the weight control performance of the microwave density detector and automatically optimize and adjust the internal calibration parameters of the microwave density detector. Specifically, it includes the following steps:

[0018] Step 1: The main control and processing module acquires 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 calculation module collects the short-term standard deviation σ1 data of the machine production speed and cigarette weight sent by the weight control system in real time via CANBUS, EtherCAT or ProfiBUS bus.

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

[0021] Step 4: The auxiliary calculation 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: Based on the analysis results of Step 4, the main control and processing module determines whether it is necessary to adjust the internal calibration parameters of the microwave density detector.

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

[0024] If the result indicates that adjustment is needed, proceed to step 6.

[0025] Step 6: Send a command via 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 send the weight deviation value to the unit weight adjustment value through the microwave density detector;

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

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

[0030] If the result is within 10mg, then proceed to step 10;

[0031] Step 10: Send a command via microwave density detector to activate unit weight control.

[0032] The beneficial technical effects of this invention are as follows:

[0033] 1. The industrial control platform architecture, which adopts a main control module + field-programmable gate array (FPGA) + auxiliary computing module, can meet the requirements of high-speed real-time data acquisition and calculation, as well as real-time data analysis and uploading.

[0034] 2. Without relying on other modules or devices, it can intelligently diagnose the weight control performance of the microwave density detector through interactive data analysis with the cigarette rolling 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 unit's weight control function can be temporarily turned off by automatically sending a command through the microwave. After the optimization is completed, the weight control function will be turned on automatically, without manual intervention, thus achieving fully automated operation. Attached Figure Description

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

[0037] Figure 2 This is a flowchart illustrating the automatic optimization of the working state of the method of the present invention. Detailed Implementation

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

[0039] Example 1:

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

[0041] The main control and processing module is configured to acquire 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 AD acquisition circuits, weight pulse output circuits, bus interface circuits, fault detection circuits, temperature detection circuits, and debugging interfaces connected to the main microcontroller.

[0042] The field-programmable gate array (FPGA) is used to generate fixed-frequency AD acquisition and conversion signals, or to receive external encoder signals, which are then processed and used as conversion signals for the AD acquisition circuit. Simultaneously, a sampling interrupt signal is generated and sent to the main microcontroller. The main microcontroller and FPGA work together to acquire cigarette density signals from the microwave density detector in real time. After internal processing and calculation, the final weight measurement value is sent to the weight control system in the form of pulses or digital signals. The main microcontroller also monitors fault information and temperature data of the microwave density detector in real time. Users can connect to the wireless debugging interface of the microwave density detector using wireless terminals with Bluetooth, Wi-Fi, or 5G capabilities, such as mobile phones, tablets, and laptops, to obtain relevant data and adjust equipment parameters.

[0043] An auxiliary computing module is configured to analyze and evaluate the weight control performance of a microwave density detector. The auxiliary computing module includes an auxiliary microcontroller, and CAN communication circuitry and Ethernet interface circuitry connected to the auxiliary microcontroller.

[0044] The auxiliary microcontroller connects to the weight control system via ANBUS, EtherCAT, or ProfiBUS bus to collect real-time production data from the winding and splicing unit. It interacts with the main control and processing module through a high-speed inter-board interface and periodically reads the calibration parameters and weight calculation results from the microwave density detector. The auxiliary microcontroller then comprehensively analyzes and evaluates the weight control performance of the microwave density detector based on this data. The Ethernet interface allows connection to the factory's digital terminal, facilitating centralized collection of real-time data from the microwave density detector, as well as subsequent analysis and management.

[0045] Example 2:

[0046] Based on the above embodiment 1, this invention also mentions an industrial control platform design method for an intelligent microwave density detector. This method can intelligently diagnose the weight control performance of the microwave density detector through cigarette weight data acquisition and calculation, weight control performance evaluation, and calibration parameter adjustment. It automatically optimizes and adjusts the internal calibration parameters of the microwave density detector, specifically including the following steps (e.g.) Figure 2 As shown):

[0047] Step 1: The main control and processing module acquires 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 calculation module collects the short-term standard deviation σ1 data of the machine production speed and cigarette weight sent by the weight control system in real time via CANBUS, EtherCAT or ProfiBUS bus.

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

[0050] Step 4: The auxiliary calculation 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: Based on the analysis results of Step 4, the main control and processing module determines whether it is necessary to adjust the internal calibration parameters of the microwave density detector.

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

[0053] If the result indicates that adjustment is needed, proceed to step 6.

[0054] Step 6: Send a command via 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 send the weight deviation value to the unit weight adjustment value through the microwave density detector;

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

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

[0059] If the result is within 10mg, then proceed to step 10;

[0060] Step 10: Send a command via microwave density detector to activate unit weight control.

[0061] Of course, the above description is not intended to limit the present invention, and the present invention is not limited to the examples given above. Any changes, modifications, additions or substitutions made by those skilled in the art within the 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 calculation module; the main control and processing module and the auxiliary calculation module are connected via lines and interfaces; among them, The main control and processing module is configured to acquire the cigarette density signal detected by the microwave density detector in real time. An auxiliary computing module is configured to analyze and evaluate the weight control performance of the microwave density detector; The main control and processing module includes a main microcontroller, 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 microcontroller via a line. The main microcontroller 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; and it is connected to a weight control system via a CAN communication interface. The field-programmable gate array (FPGA) is configured to generate fixed-frequency AD acquisition and conversion signals, or to receive external encoder signals, process them, and use them as conversion signals for the AD acquisition circuit, while simultaneously generating sampling interrupt signals and sending them to the main microcontroller. The main microcontroller and the field programmable gate array (FPGA) work together to acquire 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 in the form of a pulse or digital quantity through the weight pulse output circuit. The auxiliary computing module includes an auxiliary microcontroller, as well as a CAN communication interface and an Ethernet interface connected to the auxiliary microcontroller via a circuit; The auxiliary microcontroller is configured to collect production data from the winding and splicing unit in real time, interact with the main control and processing module through a high-speed inter-board interface, and periodically 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 can be evaluated. The auxiliary microcontroller is connected to the weight control system via a CAN communication interface; it is also connected to a digital terminal via an Ethernet interface to centrally collect real-time data from the microwave density detector for subsequent analysis and management.

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 also includes a fault detection circuit and a temperature detection circuit that are connected to the main microcontroller via a circuit.

3. 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 described in claim 1 can intelligently diagnose the weight control performance of the microwave density detector and automatically optimize and adjust the internal calibration parameters of the microwave density detector, specifically including the following steps: Step 1: The main control and processing module acquires the cigarette density signal obtained by the microwave density detector in real time and calculates the cigarette weight measurement value. Step 2: The auxiliary calculation module collects the short-term standard deviation σ1 data of the machine production speed and cigarette weight sent by the weight control system in real time via CANBUS, EtherCAT or ProfiBUS bus. Step 3: The auxiliary calculation module periodically collects the cigarette weight measurement values ​​sent by the microwave density detector from the main control module through the inter-board interface, and calculates the short-term standard deviation σ2 of the cigarette weight. Step 4: The auxiliary calculation 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. Step 5: Based on the analysis results of Step 4, the main control and processing module determines whether it is necessary to adjust the internal calibration parameters of the microwave density detector. If the judgment result is that no adjustment is needed, return to step 1; If the result indicates that adjustment is needed, proceed to step 6. Step 6: Send a command via 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 send the weight deviation value to the unit weight adjustment value through the microwave density detector; Step 9: Reacquire the real-time weight deviation of the unit, calculate the average value of the real-time weight deviation of 5 consecutive times, and determine whether it is within 10mg; If the result is not within 10mg, then return to step 8; If the result is within 10mg, then proceed to step 10; Step 10: Send a command via microwave density detector to activate unit weight control.

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