Raw paper replacement early warning method and system based on outer diameter of raw paper in soft tissue production

Abstract

The invention discloses a body paper replacement early warning method and system based on the outer diameter of body paper in soft tissue production, and is applied to the technical field of soft tissue production. The method comprises the following steps: collecting data of different point positions of a soft extraction tissue production line according to a preset time frequency; preprocessing the data of different point locations of the production line at fixed time intervals; the operation state of the folding machine is judged based on the preprocessed data, and under the conditions of normal operation and a steady speed state, the remaining length of the body paper is calculated based on the outer diameter of the body paper, and the available duration is predicted; and performing early warning on the available duration of the body paper, and when the predicted available duration of the body paper is smaller than an early warning value, sending out an alarm signal. According to the method, the uncertainty caused by manually setting parameter values by using the residual length point position values of the body paper can be avoided, and the actual consumption speed change condition of the body paper can be reflected more accurately.

Description

Technical Field

[0001] The present invention relates to the technical field of soft tissue production, and more particularly to a base paper replacement early warning method and system based on the outer diameter of the base paper in the production of soft tissue. Background Art

[0002] With the increasing awareness of environmental protection and the demand for sustainable development, the papermaking industry pays more and more attention to green production and cost reduction and efficiency improvement, and puts forward higher and higher requirements for the precise control of soft tissue production lines. At the same time, with the deep integration and implementation of new generation information technology and manufacturing technology such as the Internet of Things, big data, artificial intelligence, and digital twins, the manufacturing industry is developing in the direction of digitalization, networking, and intelligence to achieve the deep integration of people, production systems, and information systems.

[0003] The existing soft-draw production base paper replacement warning method mainly relies on the use of real-time collected production status data and industry experience formulas to calculate and predict relevant production indicators, and obtains the current value of the remaining length by subtracting the number of meters of base paper running collected by the sensor from the total length of the base paper manually input; the production status data is mainly the current remaining length of each roll of base paper, and the industry experience formula generally takes the quotient of the current remaining number of meters and the empirical value of the base paper consumption speed as the available time of the base paper. This method has the following main disadvantages: 1. Due to the untimely or incorrect setting of the workers, the predicted available time of the base paper sometimes deviates seriously from the actual situation and cannot provide effective warning; 2. The empirical formula uses a fixed empirical value of the base paper consumption speed, while the base paper consumption speed in actual production is constantly changing, mainly affected by the speed adjustment of the folding machine, so the accuracy of the predicted value is affected to a certain extent, especially when the remaining length of the base paper is small, there is a high requirement for the accuracy of the predicted value. Therefore, how to provide a base paper replacement warning method and system for soft-drawn tissue production based on the outer diameter of the base paper is a problem that technicians in this field need to solve urgently. Summary of the invention

[0004] In view of this, the present invention provides a base paper replacement warning method and system based on the outer diameter of the base paper in the production of soft tissue paper, which uses the remaining length of the base paper calculated by the outer diameter of the base paper collected by the sensor to predict the usable time, thereby solving the problems in the prior art.

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

[0006] A base paper replacement early warning method based on the outer diameter of base paper in the production of soft tissue paper comprises the following steps:

[0007] S1. Collect data from different points of the soft tissue production line according to the preset time frequency;

[0008] S2. Preprocess the data of different points of the production line at fixed intervals according to the preset prediction frequency;

[0009] S3, judging the running state of the folding machine based on the preprocessed data, if it is running normally and in a steady speed state, entering S4;

[0010] S4, calculating the remaining length of the base paper based on the outer diameter of the base paper and predicting the usable time;

[0011] S5. Early warning is given for the available time of the base paper, and an alarm signal is issued when the predicted available time of the base paper is less than the early warning value.

[0012] Optionally, the data collected in S1 include the actual speed of the folding machine, the linear speed of each tailstock tension roller and the outer diameter of the base paper.

[0013] Optionally, the preprocessing in S2 is specifically: calculating the average value, minimum value, maximum value and median of the data at different points of the production line within a preset time period.

[0014] Optional, S3 is:

[0015] The operating state is judged based on the actual speed of the folding machine. If the minimum value of the actual speed of the folding machine is greater than the set minimum threshold, and the difference between the maximum value and the minimum value is less than the fluctuation threshold, it is determined that the folding machine is operating normally and is in a steady speed state.

[0016] Optionally, the remaining length of the base paper is calculated in S4 as follows:

[0017] When the median of the outer diameter of the base paper is less than the dividing point, the statistical extrapolation method is used to calculate the remaining length of the base paper; when the median of the outer diameter of the base paper is not less than the dividing point, the mechanism extrapolation method is used to calculate the remaining length of the base paper.

[0018] Optionally, the calculation process of the statistical inference method is as follows:

[0019] The remaining length time series data and the corresponding base paper outer diameter time series data of the remaining length not exceeding the preset length value are obtained, and the time series data pair of the median of the remaining length and the base paper outer diameter is obtained, and then a mapping table of the remaining length and the base paper outer diameter is obtained. The mapping table is the average value of the base paper outer diameter value less than the dividing point and the corresponding remaining length. For the predicted time t, if the median r of the base paper outer diameter within the preset time period is less than the dividing point, the corresponding remaining length is searched through the mapping table.

[0020] Optionally, the calculation process of the mechanism inference method is as follows:

[0021] For the prediction time t, obtain the median r of the base paper outer diameter within the preset time period. If the median r is not less than the demarcation point β, obtain the two base paper outer diameters r1 and r2 adjacent to the median r and the corresponding calculation coefficients α1 and α2:

[0022]

[0023] In the formula, ρ is the density of the base paper, w is the width of the base paper, and m is the mass of the base paper per unit length;

[0024] The change of outer diameter and coefficient is linear. The linear coefficient is calculated based on the outer diameters r1 and r2 of the base paper and the corresponding calculation coefficients α1 and α2, and the calculation coefficient α3 corresponding to the median r is calculated based on the linear coefficient and the median r. Then the remaining length l of the base paper at time t is predicted. t for:

[0025] l t =α3*((r+d) 2 -d 2 )

[0026] Where d is the roller radius.

[0027] Optionally, the predicted available time in S4 is specifically:

[0028] The average value of the tension roller line speed within the preset time period is used as the base paper consumption speed v, and the available time h is calculated:

[0029]

[0030] Where l is the remaining length of the base paper calculated based on the outer diameter of the base paper.

[0031] A base paper replacement warning system based on the base paper outer diameter in the production of soft tissue paper, which implements the base paper replacement warning method based on the base paper outer diameter in the production of soft tissue paper, comprising:

[0032] The data collection and integration subsystem collects data from different points of the soft tissue production line through sensors at a preset time frequency and stores it in the database;

[0033] The data processing subsystem pre-processes the data at different points of the production line at fixed intervals according to the preset prediction frequency;

[0034] The simulation calculation subsystem determines the operating status of the folding machine and calculates the remaining length of the base paper based on the outer diameter of the base paper and predicts the usable time;

[0035] The early warning subsystem visualizes the predicted value and issues early warning on the usable time of the original paper.

[0036] It can be seen from the above technical solution that, compared with the prior art, the present invention provides a base paper replacement warning method and system based on the outer diameter of base paper in the production of soft tissue paper, which has the following beneficial effects:

[0037] 1. The present invention uses the remaining length of the base paper calculated by the outer diameter of the base paper collected by the sensor to predict the available time, which can avoid using the point value of the remaining length of the base paper and the uncertainty caused by manually setting the parameter value;

[0038] 2. The present invention uses the average value of the tension roller linear speed from the present time to the previous time as the base paper consumption speed, which can more accurately reflect the actual consumption speed change of the base paper compared to the fixed empirical value. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on the provided drawings without paying creative work.

[0040] Figure 1 This is a flow chart of the early warning method for replacing base paper in the production of soft tissue paper of the present invention;

[0041] Figure 2 The present invention is a schematic diagram of the early warning system for replacing base paper in the production of soft tissue paper. DETAILED DESCRIPTION

[0042] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0043] The embodiment of the present invention discloses a base paper replacement early warning method based on the outer diameter of the base paper in the production of soft tissue paper, comprising the following steps:

[0044] S1. Collect data from different points of the soft tissue production line according to the preset time frequency;

[0045] S2. Preprocess the data of different points of the production line at fixed intervals according to the preset prediction frequency;

[0046] S3, judging the running state of the folding machine based on the preprocessed data, if it is running normally and in a steady speed state, entering S4;

[0047] S4, calculating the remaining length of the base paper based on the outer diameter of the base paper and predicting the usable time;

[0048] S5. Early warning is given for the available time of the base paper, and an alarm signal is issued when the predicted available time of the base paper is less than the early warning value.

[0049] Furthermore, the data collected in S1 include the actual speed of the folding machine, the linear speed of each tailstock tension roller and the outer diameter of the base paper.

[0050] Furthermore, the preprocessing in S2 is specifically: calculating the average value, minimum value, maximum value and median of the data at different points of the production line within a preset time period.

[0051] Furthermore, S3 is specifically:

[0052] The operating state is judged based on the actual speed of the folding machine. If the minimum value of the actual speed of the folding machine is greater than the set minimum threshold, and the difference between the maximum value and the minimum value is less than the fluctuation threshold, it is determined that the folding machine is operating normally and is in a steady speed state.

[0053] Furthermore, the remaining length of the base paper is calculated in S4 as follows:

[0054] When the median of the outer diameter of the base paper is less than the dividing point, the statistical extrapolation method is used to calculate the remaining length of the base paper; when the median of the outer diameter of the base paper is not less than the dividing point, the mechanism extrapolation method is used to calculate the remaining length of the base paper.

[0055] The remaining length of the base paper is estimated based on the outer diameter of the base paper collected by the sensor to avoid the deviation caused by manual operation. Due to the non-ideal cylindrical outer side of the base paper roll and the movement of the base paper roll, the measured value of the base paper outer diameter has the characteristics of irregular fluctuations. Especially when the remaining amount of base paper is small, some abnormal values ​​will appear, which can easily lead to a large relative deviation between the estimated value of the remaining length and the actual value. Therefore, the estimation and classification of the remaining length of the base paper are carried out.

[0056] Furthermore, the calculation process of the statistical inference method is as follows:

[0057] The remaining length time series data and the corresponding base paper outer diameter time series data of the remaining length not exceeding the preset length value are obtained, and the time series data pair of the median of the remaining length and the base paper outer diameter is obtained, and then a mapping table of the remaining length and the base paper outer diameter is obtained. The mapping table is the average value of the base paper outer diameter value less than the dividing point and the corresponding remaining length. For the predicted time t, if the median r of the base paper outer diameter within the preset time period is less than the dividing point, the corresponding remaining length is searched through the mapping table.

[0058] The preset length value is determined based on the base paper outer diameter dividing point β plus θ. In an embodiment of the present invention, the dividing points β and θ are pre-set empirical values. When the base paper outer diameter is β+θ, the corresponding base paper remaining length l is obtained by searching the mapping table, and l is the preset length value.

[0059] Furthermore, the calculation process of the mechanism inference method is as follows:

[0060] For the prediction time t, obtain the median r of the base paper outer diameter within the preset time period. If the median r is not less than the demarcation point β, obtain the two base paper outer diameters r1 and r2 adjacent to the median r and the corresponding calculation coefficients α1 and α2:

[0061]

[0062] In the formula, ρ is the density of the base paper, w is the width of the base paper, and m is the mass of the base paper per unit length;

[0063] The change of outer diameter and coefficient is linear. The linear coefficient is calculated based on the outer diameters r1 and r2 of the base paper and the corresponding calculation coefficients α1 and α2, and the calculation coefficient α3 corresponding to the median r is calculated based on the linear coefficient and the median r. Then the remaining length l of the base paper at time t is predicted. t for:

[0064] l t =α3*((r+d) 2 -d 2 )

[0065] Where d is the roller radius.

[0066] In an ideal situation, the following holds true:

[0067] V*ρ=l*m

[0068] In the formula, V is the volume of the base paper, l is the remaining length of the base paper, where:

[0069] V=w*(π*(r+d) 2 -π*d 2 )

[0070] You can get:

[0071]

[0072] The coefficient α is π*base paper width*base paper density / base paper mass per unit length. If α is known, the remaining length l of the base paper can be calculated when the base paper outer diameter is obtained. Considering that the base paper roll is affected by gravity, the smaller the remaining length, the greater the density. Therefore, when the median of the base paper outer diameter is not less than the demarcation point, the mechanism estimation method is used to estimate the remaining length using the base paper outer diameter.

[0073] Furthermore, the predicted available time in S4 is specifically:

[0074] The average value of the tension roller line speed within the preset time period is used as the base paper consumption speed v, and the available time h is calculated:

[0075]

[0076] Where l is the remaining length of the base paper calculated based on the outer diameter of the base paper.

[0077] like Figure 2 As shown, Figure 1 Corresponding to the method, an embodiment of the present invention further discloses a base paper replacement warning system based on the base paper outer diameter in the production of soft tissue paper, and the base paper replacement warning method based on the base paper outer diameter in the production of soft tissue paper is executed, including:

[0078] The data collection and integration subsystem collects data from different points of the soft tissue production line through sensors at a preset time frequency and stores it in the database;

[0079] The data processing subsystem pre-processes the data at different points of the production line at fixed intervals according to the preset prediction frequency;

[0080] The simulation calculation subsystem determines the operating status of the folding machine and calculates the remaining length of the base paper based on the outer diameter of the base paper and predicts the usable time;

[0081] The early warning subsystem visualizes the predicted value and issues early warning on the usable time of the original paper.

[0082] In this specification, each embodiment is described in a progressive manner, and each embodiment focuses on the differences from other embodiments. The same or similar parts between the embodiments can be referred to each other. For the system disclosed in the embodiment, since it corresponds to the method disclosed in the embodiment, the description is relatively simple, and the relevant parts can be referred to the method part.

[0083] The above description of the disclosed embodiments enables one skilled in the art to implement or use the present invention. Various modifications to these embodiments will be apparent to one skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention will not be limited to the embodiments shown herein, but rather to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A method for early warning of base paper replacement based on the outer diameter of base paper in the production of soft tissue paper, characterized in that: The following steps are involved: S1. Collect data from different points of the soft tissue production line according to a preset time frequency; S2. Preprocess the data of different points of the production line at fixed intervals according to the preset prediction frequency; S3, judging the running state of the folding machine based on the preprocessed data, if it is running normally and in a steady speed state, entering S4; S4, calculating the remaining length of the base paper based on the outer diameter of the base paper and predicting the usable time; S5. Early warning is given for the available time of the base paper, and an alarm signal is issued when the predicted available time of the base paper is less than the early warning value.

2. The method for early warning of base paper replacement based on the outer diameter of base paper in the production of soft tissue paper according to claim 1, characterized in that: The data collected in S1 include the actual speed of the folding machine, the linear speed of each tailstock tension roller and the outer diameter of the base paper.

3. The method for early warning of base paper replacement based on the outer diameter of base paper in the production of soft tissue paper according to claim 2, characterized in that: The preprocessing in S2 is specifically: calculating the average value, minimum value, maximum value and median of the data at different points of the production line within a preset time period.

4. The method for early warning of base paper replacement based on the outer diameter of base paper in the production of soft tissue paper according to claim 3, characterized in that: S3 is specifically: The operating state is judged based on the actual speed of the folding machine. If the minimum value of the actual speed of the folding machine is greater than the set minimum threshold, and the difference between the maximum value and the minimum value is less than the fluctuation threshold, it is determined that the folding machine is operating normally and is in a steady speed state.

5. The method for early warning of base paper replacement based on the outer diameter of base paper in the production of soft tissue paper according to claim 3, characterized in that: The remaining length of the base paper is calculated in S4 as follows: When the median of the outer diameter of the base paper is less than the dividing point, the statistical extrapolation method is used to calculate the remaining length of the base paper; when the median of the outer diameter of the base paper is not less than the dividing point, the mechanism extrapolation method is used to calculate the remaining length of the base paper.

6. The method for early warning of base paper replacement based on the outer diameter of base paper in the production of soft tissue paper according to claim 5, characterized in that: The calculation process of statistical inference method is as follows: The remaining length time series data and the corresponding base paper outer diameter time series data of the remaining length not exceeding the preset length value are obtained, and the time series data pair of the median of the remaining length and the base paper outer diameter is obtained, and then a mapping table of the remaining length and the base paper outer diameter is obtained. The mapping table is the average value of the base paper outer diameter value less than the dividing point and the corresponding remaining length. For the predicted time t, if the median r of the base paper outer diameter within the preset time period is less than the dividing point, the corresponding remaining length is searched through the mapping table.

7. The method for early warning of base paper replacement based on the outer diameter of base paper in the production of soft tissue paper according to claim 5, characterized in that: The calculation process of the mechanism inference method is as follows: For the prediction time t, obtain the median r of the base paper outer diameter within the preset time period. If the median r is not less than the demarcation point β, obtain the two base paper outer diameters r1 and r2 adjacent to the median r and the corresponding calculation coefficients α1 and α2: In the formula, ρ is the density of the base paper, w is the width of the base paper, and m is the mass of the base paper per unit length; The change of outer diameter and coefficient is linear. The linear coefficient is calculated based on the outer diameters r1 and r2 of the base paper and the corresponding calculation coefficients α1 and α2, and the calculation coefficient α3 corresponding to the median r is calculated based on the linear coefficient and the median r. Then the remaining length l of the base paper at time t is predicted. t for: l t =α3*((r+d) 2 -d 2 ) Where d is the roller radius.

8. The method for early warning of base paper replacement based on the outer diameter of base paper in the production of soft tissue paper according to claim 1, characterized in that: The specific predicted available time in S4 is: The average value of the tension roller line speed within the preset time period is used as the base paper consumption speed v, and the available time h is calculated: Where l is the remaining length of the base paper calculated based on the outer diameter of the base paper.

9. A base paper replacement early warning system based on the outer diameter of the base paper in the production of soft tissue paper, characterized in that: The method for early warning of base paper replacement based on the outer diameter of base paper in the production of soft tissue paper according to any one of claims 1 to 8 comprises: The data collection and integration subsystem collects data from different points of the soft tissue production line through sensors at a preset time frequency and stores it in the database; The data processing subsystem pre-processes the data at different points of the production line at fixed intervals according to the preset prediction frequency; The simulation calculation subsystem determines the operating status of the folding machine and calculates the remaining length of the base paper based on the outer diameter of the base paper and predicts the usable time; The early warning subsystem visualizes the predicted value and issues early warning on the usable time of the original paper.

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