Automatic batch distinguishing method for tobacco continuous batch production process and storage medium thereof

Abstract

The invention discloses an automatic batch distinguishing method in a tobacco continuous batch production process and a storage medium thereof. The automatic batch distinguishing method comprises the following steps: acquiring tobacco material weight, moisture content and related data detected according to a certain frequency in the tobacco continuous batch production process on line; obtaining the weight, moisture content and related data of each batch of tobacco materials before continuous batch production of the tobacco; calculating continuous batch process loss according to a process loss data calculation formula; and carrying out batch automatic distinguishing on the tobacco continuous batch production process by adopting a continuous batch distinguishing criterion. According to the method, batch distinguishing in the continuous batch production process can be effectively achieved, and a reference basis is provided for product quality homogenization control and material consumption control.

Description

Technical Field

[0001] The invention relates to an automatic batch differentiation method, in particular to an automatic batch differentiation method in a tobacco continuous batch production process and a storage medium thereof, and belongs to the technical field of tobacco processing. Background Art

[0002] Generally speaking, in the tobacco production process, the continuous batch production mode is a beneficial exploration of "reducing costs, increasing efficiency, improving quality and reducing consumption" in the silk-making link of cigarette enterprises. That is, changing the batch processing mode of the traditional silk-making link and breaking the time and space intervals between the original batches. It can achieve continuous production in a certain process in the silk-making production process, reduce the quality defects of work-in-progress caused by the non-steady-state production state under the single batch production mode of the proposed continuous batch process, and greatly shorten the batch production change time, thereby achieving the effect of reducing costs and increasing efficiency.

[0003] At present, the current data acquisition process of the silk-making batch production mode adopts a single batch theoretical (fixed) delay to distinguish the batch data acquisition data, which will cause the production data of the previous and subsequent batches to be mixed in the batch production mode, which is not conducive to the control and analysis and improvement of batch processing parameters and quality indicators. At the same time, the mixing of batch data will have a negative impact on the refined management of material consumption in the batch production process; resulting in large differences in the number of single batch data acquisition points and the cumulative amount of materials in the batch process in the actual batch production mode, which is not conducive to quality control and material consumption analysis management in the single batch production process. Therefore, it is necessary to effectively distinguish batch data according to batches in the batch mode to realize the processing quality evaluation and material consumption management of the single batch process of silk making. In short, it is often very inconvenient.

[0004] Therefore, the key to solving the above technical problems is to develop a stable, reliable and accurate method for automatic batch differentiation in the tobacco batch production process. Summary of the invention

[0005] In view of the many defects and shortcomings in the above-mentioned background technology, the present invention has made improvements and innovations thereto, with the aim of providing a stable, reliable and practical method for automatic batch differentiation in the tobacco batch production process, so as to effectively solve the problems of abnormal processing parameters, quality indicators and material consumption data caused by the inadaptability of data sampling rules in the process batch production mode, and the inability to objectively standardize and evaluate the control stability of the batch silk drying process, so as to achieve the improvement of product quality homogenization control.

[0006] In order to solve the above problems and achieve the above invention objectives, the present invention provides a method for automatically distinguishing batches in a tobacco batch production process by adopting the following design structure and the following technical solution:

[0007] A method for automatically distinguishing batches in a tobacco batch production process comprises the following steps:

[0008] S1. Obtain the average moisture content of tobacco at the entrance of a process before the start of the batch mode, denoted as H 前单 ; and obtain the average moisture content of the tobacco at the entrance of the last batch PLC group in the batch production mode process, recorded as H 后连 ;

[0009] S2. Obtain the cumulative weight of the tobacco at the entrance of the process before the start of the batch mode, recorded as W 前单 ; and obtain the real-time material accumulation of the last batch PLC group of tobacco in the batch production mode process, recorded as W 后连 ;

[0010] S3. Obtain the cumulative weight of a single batch of liquid added during the tobacco leaf moistening and feeding process, recorded as W 料 ; Obtain the corresponding material weight during the dilution preparation process, and the weight of the concentrate is recorded as W 浓 The weight of water added during the dilution process is recorded as W 水 , use H 料 Indicates the moisture content of the feed liquid, H 料 =W 水 / (W 浓 +W 水 );

[0011] S4. Obtain the cumulative amount of materials added to the tobacco in the process before the start of the batch mode, recorded as W 掺 ; and obtain the average moisture content of the added material, recorded as H 掺 ;

[0012] S5. Obtain the weight of the tobacco material remaining in the process after the production of the process before the start of the batch mode is completed, recorded as W 残 ; and obtain the average moisture content of the residual material, recorded as H 残 ;

[0013] S6. Obtain the weight of all screened materials from the process before the start of the batch mode to the batch process, recorded as W 筛 ; and obtain the average moisture content of the screened material, recorded as H 筛 ;

[0014] S7. Obtain the dry-based material process change of tobacco from the process before the start of the batch mode to the batch process, recorded as W 损 ; W 损 Obtained by the following formula: 损 =W 料 (1-H 料 )+W 掺 (1-H 掺 )-W 残 (1-H残 )-W 筛 (1-H 筛 );

[0015] S8. Obtain the cumulative weight distinction point of a single batch of materials in the process under the batch production mode, recorded as W 区 , W 区 The calculation formula is as follows:

[0016]

[0017] S9, according to W in step S8 区 The calculation formula can be used to calculate the cumulative weight distinction points of each batch of materials in the batch production process. 区 After comparing the values, they are automatically distinguished.

[0018] Preferably, the real-time material cumulative weight (W) collected by the last group of PLC in the batch production process 后连 ) and W 区 For comparison, when W 后连 =W 区 When the weight value is set, the last group of PLC performs batch switching. The production data before this weight value is the previous batch data, and the production data after this weight value is the next batch data. The moisture content, temperature, and process flow data of other corresponding production data are automatically distinguished according to the original parameter data collection time interval.

[0019] Preferably, in step S1, the average moisture content of the tobacco at the inlet of a process before the start of the batch mode and the average moisture content of the tobacco at the inlet of the last batch PLC group in the batch production mode are measured by a moisture content detection device.

[0020] Preferably, in step S2, the cumulative weight of the tobacco at the inlet of a process before the start of the batch mode and the real-time cumulative weight of the tobacco at the inlet of the last batch PLC group in the batch production mode are both measured by a weight detection device.

[0021] Preferably, in step S3, the cumulative weight of a single batch of liquid added during tobacco leaf moistening and feeding is measured by a flow measuring device; the corresponding material weight during the liquid dilution and preparation process is measured by a weight measuring device. If the barrel water adding mode is adopted, H 料 Recorded as 1.

[0022] Preferably, in step S4, the cumulative amount of the added materials in the process before the batch mode starts is measured by a weight measuring device; the average moisture content of the added materials is measured by a moisture content detection device, wherein, if no material is added, W 掺 =0.

[0023] Preferably, in step S5, the weight of the tobacco material remaining in the process after the process before the batch mode start process is completed is measured by a weight measuring device; the average moisture content of the residual material is measured by a moisture content detection device.

[0024] Preferably, in step S6, the weight of all screened materials from the process before the start of the batch mode to the batch process of the tobacco is measured by a weight measuring device; the average moisture content of the screened materials is measured by a moisture content detection device.

[0025] Preferably, the steps of the tobacco batch production process include one or more key steps in leaf threshing, redrying and silk making;

[0026] In step S9, according to the W obtained in each batch during the batch production process, 区 The data classification system is used to automatically distinguish each batch in the batch production process.

[0027] Preferably, a computer-readable storage medium stores a computer program, which, when executed by one or more processors, implements the steps of the described method.

[0028] Compared with the prior art, the present invention has the following beneficial effects:

[0029] 1. The present invention adopts an automatic batch differentiation method based on tobacco silk continuous batch production, which can relatively accurately determine the data sampling interval points between batches in the tobacco material continuous batch production mode, and then effectively characterize the actual situation of single batch process quality control in the continuous batch production mode of different batches, objectively discover and eliminate the fluctuations of processing parameters and quality indicators in the production process, and provide a scientific basis for improving product quality homogeneity control;

[0030] 2. The present invention introduces an automatic batch differentiation method based on continuous batch production of tobacco silk. On the one hand, it makes up for the deficiency that the fixed delay method is used as the data acquisition judgment point for batch conversion of production section groups in the original continuous batch mode, which leads to abnormal batch data acquisition data; on the other hand, it provides a reference basis for objectively evaluating the stability of single process / batch processing and scientifically evaluating the level of material consumption control in the continuous batch production mode;

[0031] 3. The method of the present invention is simple, effective, and has strong practicality, and has good practical significance and application value. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] The specific embodiments of the present invention are further described in detail below in conjunction with the accompanying drawings, wherein:

[0033] Figure 1It is a process flow diagram of the continuous batch production mode of the silk production line of the present invention;

[0034] Figure 2 It is a schematic diagram of the data acquisition and interception process of the embodiment of the silk-making batch production mode of the present invention;

[0035] Figure 3 It is the moisture content trend chart of shredded silk after the data of the first batch of continuous batches are collected under the original fixed delay silk-making continuous batch production mode;

[0036] Figure 4 It is a trend diagram of moisture content of shredded silk after data of the first batch of the continuous batch are aggregated in the embodiment of the continuous batch production mode of silk making of the present invention. DETAILED DESCRIPTION

[0037] In order to make the technical means, creative features, objectives and effects of the present invention easy to understand, the technical solution of the present invention is further described in detail below in conjunction with the accompanying drawings and specific implementation methods. It should be noted that the embodiments and features in the embodiments of the present application can be combined with each other without conflict. The present invention will be described in detail below with reference to the accompanying drawings and in conjunction with the embodiments.

[0038] Figure 1 It is a process flow diagram of an embodiment of a continuous batch production mode of a silk production line (cutting, drying and drying processes in batches). It can be seen from the figure that the processing technology links involved in the continuous batch production mode are mainly: leaf storage and unloading, leaf cutting, drying and drying processes, and the remaining processes in the process flow diagram are all single batch production modes;

[0039] Figure 2 : is a schematic diagram of data acquisition and interception flow of an embodiment of a silk batch production mode (cutting, drying and drying processes in batches). In the batch production mode, the corresponding data acquisition is calculated according to the following process. When W 后连 =W 区 When batching, the data acquisition data of continuous batch production can be divided into batches;

[0040] Figure 3 It is a trend chart of moisture content of shredded silk after data of the first batch of continuous batches are collected in the original fixed delay mode of the continuous batch embodiment of the shredded silk production mode, wherein the green area is the actual data of the first batch of continuous batches, the red area is the non-steady-state data between the previous and next batches, which should be eliminated, and the yellow area is the actual data of the second batch of continuous batches, which should not be included in the first batch data set);

[0041] Figure 4 The silk batch production mode is the shredding and drying process. The moisture content trend chart of the shredded silk after the first batch of data is collected in the batch mode of the present invention does not exist. Figure 3 There is confusion before and after the batch data.

[0042] In summary, a more specific embodiment of the present invention is:

[0043] A method for automatically distinguishing batches in a tobacco batch production process comprises the following steps:

[0044] S1. Obtain the average moisture content of tobacco at the entrance of a process before the start of the batch mode, denoted as H 前单 ; and obtain the average moisture content of the tobacco at the entrance of the last batch PLC group in the batch production mode process, recorded as H 后连 ;

[0045] S2. Obtain the cumulative weight of the tobacco at the entrance of the process before the start of the batch mode, recorded as W 前单 ; and obtain the real-time material accumulation of the last batch PLC group of tobacco in the batch production mode process, recorded as W 后连 ;

[0046] S3. Obtain the cumulative weight of a single batch of liquid added during the tobacco leaf moistening and feeding process, recorded as W 料 ; Obtain the corresponding material weight during the dilution preparation process, and the weight of the concentrate is recorded as W 浓 The weight of water added during the dilution process is recorded as W 水 , use H 料 Indicates the moisture content of the feed liquid, H 料 =W 水 / (W 浓 +W 水 );

[0047] S4. Obtain the cumulative amount of materials added to the tobacco in the process before the start of the batch mode, recorded as W 掺 ; and obtain the average moisture content of the added material, recorded as H 掺 ;

[0048] S5. Obtain the weight of the tobacco material remaining in the process after the production of the process before the start of the batch mode is completed, recorded as W 残 ; and obtain the average moisture content of the residual material, recorded as H 残 ;

[0049] S6. Obtain the weight of all screened materials from the process before the start of the batch mode to the batch process, recorded as W 筛 ; and obtain the average moisture content of the screened material, recorded as H 筛 ;

[0050] S7. Obtain the dry-based material process change of tobacco from the process before the start of the batch mode to the batch process, recorded as W 损 ; W 损 Obtained by the following formula: 损=W 料 (1-H 料 )+W 掺 (1-H 掺 )-W 残 (1-H 残 )-W 筛 (1-H 筛 );

[0051] S8. Obtain the cumulative weight distinction point of a single batch of materials in the process under the batch production mode, recorded as W 区 , W 区 The calculation formula is as follows:

[0052]

[0053] S9, according to W in step S8 区 The calculation formula can be used to calculate the cumulative weight distinction points of each batch of materials in the batch production process. 区 After comparing the values, they are automatically distinguished.

[0054] Furthermore, the real-time material cumulative weight (W 后连 ) and W 区 For comparison, when W 后连 =W 区 When the weight value is set, the last group of PLC performs batch switching. The production data before this weight value is the previous batch data, and the production data after this weight value is the next batch data. The moisture content, temperature, and process flow data of other corresponding production data are automatically distinguished according to the original parameter data collection time interval.

[0055] In the present invention, specifically, the real-time material cumulative weight (W) collected by the feeding electronic scale in the last group of the PLC corresponding to the batch production process 后连 ) and W 区 For comparison, when W 后连 =W 区 When W 后连 As the accumulated weight of the first batch of materials in batch production, the PLC starts the delay program and the automatic batch change operation at the same time. At this time, the production batch signal changes (the batch number of the "current actual formula" in the PLC automatically switches to the batch number of the "next batch formula"); after receiving the batch change signal, the upper digital acquisition system completes the batch archiving of the production data of the batch process according to the fixed time difference between the original digital acquisition sensors and the feeding electronic scale of the batch process (under the premise of constant process flow, the digital acquisition time difference between each digital acquisition sensor and the feeding electronic scale is constant), thereby realizing the automatic distinction of batch data before and after the batch production. Among them, for multi-batch batch production, the above steps can be repeated to complete the automatic distinction and collection of batch data.

[0056] Furthermore, in step S1, the average moisture content of the tobacco at the inlet of a process before the start of the batch mode and the average moisture content of the tobacco at the inlet of the last batch PLC group in the batch production mode are measured by the moisture content detection device.

[0057] Furthermore, in step S2, the cumulative weight of the tobacco inlet of a process before the start of the batch mode and the real-time cumulative weight of the tobacco inlet of the last batch PLC group in the batch production mode process are both measured and obtained by the weight detection device.

[0058] Furthermore, in step S3, the cumulative weight of a single batch of liquid added during the tobacco leaf moistening process is measured by a flow measuring device; the corresponding material weight during the liquid dilution preparation process is measured by a weight measuring device. If the barrel water adding mode is adopted, H 料 Recorded as 1.

[0059] Furthermore, in step S4, the cumulative amount of the added materials in the process before the batch mode starts is measured by a weight measuring device; the average moisture content of the added materials is measured by a moisture content detection device, wherein, if no material is added, W 掺 =0.

[0060] Furthermore, in step S5, the weight of the tobacco material remaining in the process before the batch mode start process is measured by a weight measuring device; the average moisture content of the residual material is measured by a moisture content detection device.

[0061] Furthermore, in step S6, the weight of all screened materials from the process before the start of the batch mode to the batch process of the tobacco is measured by a weight measuring device; the average moisture content of the screened materials is measured by a moisture content detection device.

[0062] Furthermore, the processes of the tobacco batch production process include one or more key processes in the leaf threshing, re-drying and silk making links;

[0063] In step S9, according to the W obtained in each batch during the batch production process, 区 The data classification system is used to automatically distinguish each batch in the batch production process.

[0064] In the present invention, the steps of the tobacco batch production process include: tobacco sheet rehumidification, tobacco sheet re-roasting, loosening and rehumidification, leaf moistening and adding materials, shred drying, blending and flavoring, etc.

[0065] Furthermore, a computer-readable storage medium stores a computer program, which, when executed by one or more processors, implements the steps of the method described in the present invention.

[0066] In summary, a more specific embodiment of the present invention is:

[0067] The shred cutting and drying process is the production process section that produces the most intense physical deformation and chemical changes in the tobacco shred production line. The use of a continuous batch production mode in this process section can reduce the probability of "head and tail" quality and material consumption defects between batches in the production process. This specific implementation plan takes the shred cutting and drying process section as an example.

[0068] Specific application examples are as follows:

[0069] Example 1

[0070] The continuous production data of 30 batches of silk making, cutting and drying sections of a certain brand and specification can be automatically distinguished.

[0071] The steps include:

[0072] (1) The average moisture content of tobacco at the entrance of the process (feeding process) before the start of the batch mode is measured using a moisture content detection device, denoted as H 前单 The average moisture content of tobacco in the batch production process (the drying process, the PLC group from the mixing cabinet to the drying after cutting) is measured by the moisture content detection device, which is recorded as H 后连 ,as follows:

[0073]

[0074]

[0075] (2) Use a weight measuring device to measure the cumulative weight of the tobacco at the entrance of a process before the start of the process in the batch mode, recorded as W 前单 ; Use a weight detection device to measure the real-time material accumulation at the entrance of the tobacco batch production mode process (the last batch PLC group), recorded as W 后连 ,as follows:

[0076]

[0077]

[0078] (3) Use a flow measurement device to measure the cumulative weight of a single batch of liquid added during the tobacco leaf moistening process, recorded as W 料 Since this specification adopts the barrel water adding mode, H 料 Recorded as 1, that is, the value of this item is 0;

[0079] (4) Use a weight measuring device to measure the cumulative amount of added materials before the tobacco starts the process in batch mode, recorded as W 掺 Since this specification has no material added during the batch process, W 掺 =0, that is, the value of this item is 0;

[0080] (5) Use a weight measuring device to measure the weight of the material remaining in the process before the tobacco starts the process in the batch mode after the production of the process is completed, and record it as W 残 ; Use the moisture content detection device to measure the average moisture content of the residual material, recorded as H 残 ;

[0081]

[0082]

[0083] (6) Use a weight measuring device to measure the weight of all screened materials from one process before the tobacco starts the process in batch mode to the batch process, and record it as W 筛 ; Use the moisture content detection device to measure the average moisture content of the screened material, recorded as H 筛 ;

[0084] <![CDATA[Serial number W 筛 (kg)H 筛 (%)]]> 1 23.28 20.23 2 25.06 19.3 3 25.76 18.93 4 23.46 18.12 5 21.83 18.47 6 18.67 18.48 7 23.61 18.64 8 28.80 18.47 9 27.42 19.73 10 33.13 18.18 11 27.44 20.22 12 27.92 19.96 13 22.58 19.23 14 23.79 19.22 15 24.09 17.06 16 29.35 17.09 17 31.40 19.78 18 19.43 19.26 19 21.17 18.71 20 33.62 18.43 21 32.81 17.91 22 33.04 18.83 23 29.78 17.12 24 26.20 18.17 25 27.77 17.83 26 34.79 19.08 27 28.03 19.79 28 25.01 18.19 29 25.36 17.67 30 26.17 18.54

[0085] (7) Use W 损 It represents the process change of dry material in tobacco from one process before the start of batch mode to the batch process, W 损 Obtained by the following formula: 损 =W 料 (1-H 料 )+W 掺 (1-H 掺 )-W 残 (1-H 残 )-W 筛 (1-H 筛 )

[0086] (8) Obtain the cumulative weight distinction point of a single batch of materials in the process under the batch production mode, denoted as W 区 , W 区 The calculation formula is as follows:

[0087]

[0088] <![CDATA[Serial number W 区 (kg)]]> 1 8883.753337 2 8922.64832 3 8909.727059 4 8883.544435 5 8890.212699 6 8905.022538 7 8901.80793 8 8908.308919 9 8905.103788 10 8903.729952 11 8837.376165 12 8785.863294 13 8890.217801 14 8871.585574 15 8887.062317 16 8895.268184 17 8936.625981 18 8897.333025 19 8871.003968 20 8892.081023 21 8897.839793 22 8940.857849 23 8910.266424 24 8928.767426 25 8917.935837 26 8869.627075 27 8870.49742 28 8896.75185 29 8914.360964 30 8880.594606

[0089] (9) According to W in step S8 区 The calculation formula can be used to calculate the cumulative weight distinction points of each batch of materials in the batch production process. 区After comparing the values, they are automatically distinguished.

[0090] (10) When W 后连 =W 区 When the weight value is set, the last group of PLC performs batch switching. The production data before this weight value is the previous batch data, and the production data after this weight value is the next batch data. Other corresponding production data (water content, temperature, process flow rate, etc.) are automatically distinguished according to the original parameter data collection time interval.

[0091] The results of comparing the original fixed delay switching group method with the present invention are as follows:

[0092]

[0093] In the original fixed delay switching group method, the range of valid sampling points of a single batch in continuous batch production is 820, and the range of the cumulative amount of batch materials is 3156.98, indicating that due to the actual differences in the start and stop states of the PLC equipment in the cutting and drying section, the original method will cause significant differences in the effective points of data collection between batches. The range of the valid data collection points of a single batch corresponding to the method of the present invention is only 37, and the range of the cumulative amount of a single batch of materials is reduced to 377.33kg, which are reduced by 95.49% and 88.05% respectively compared with the original method, effectively avoiding the data anomalies caused by the batch data collection errors caused by the data collection distinction method.

[0094] Example 2

[0095] This embodiment is a practical application of the batch data differentiation method constructed based on the first embodiment.

[0096] (1) During the continuous production of the cutting and drying section of a certain specification, the data acquisition batches were distinguished according to the original fixed delay switching group method. The input-output ratio data of the batch cutting and drying section fluctuated greatly, as shown in the table below. Some batches of data far exceeded the original material consumption control standard requirements for this section (≥98.0%).

[0097]

[0098]

[0099] (2) According to the method of the present invention, the input-output ratio of the process from feeding to drying is monitored, and the specific data are as follows:

[0100]

[0101]

[0102] (3) The overall dry basis input-output ratio data are relatively stable and meet the factory's internal material consumption control requirements (≥98.00).

[0103] (4) According to the method of the present invention, the input-output ratio of the process from drying to blending is monitored, and the specific data are as follows:

[0104] <![CDATA[Serial number W 区 H 后连 W 烘后 H 烘后 Input-output ratio on dry basis]]> 1 8843.52 20.70 7778.01 13.12 96.354％ 2 8758.65 20.74 7830.33 13.11 98.007％ 3 8818.38 20.68 7703.13 13.10 95.699％ 4 8827.36 20.73 7791.81 13.09 96.778％ 5 8810.27 20.61 7845.84 13.10 97.486％ 6 8869.18 20.72 7854.82 13.11 97.067％ 7 8752.92 20.63 7816.21 13.10 97.770％ 8 8851.76 20.66 7745.24 13.10 95.838％ 9 8867.19 20.54 7808.52 13.10 96.308％ 10 8787.15 20.57 7885.39 13.12 98.148％ 11 8820.73 20.68 7843.47 13.09 97.426％ 12 8862.19 20.66 7768.01 13.10 96.011％ 13 8807.17 20.78 7743.01 13.12 96.418％ 14 8901.85 20.68 7812.77 13.10 96.153％ 15 8903.21 20.73 7786.51 13.11 95.869％ 16 8787.49 20.70 7721.62 13.09 96.304％ 17 8800.71 20.75 7828.05 13.10 97.529％ 18 8834.52 20.63 7843.59 13.10 97.208％ 19 8774.91 20.72 7848.48 13.10 98.028％ 20 8830.29 20.75 7806.13 13.10 96.936％ 21 8898.16 20.67 7802.04 13.09 96.057％ 22 8899.47 20.64 7801.68 13.09 95.999％ 23 8801.41 20.62 7868.30 13.09 97.871％ 24 8749.30 20.67 7820.46 13.12 97.891％ 25 8801.33 20.70 7830.16 13.10 97.491％ 26 8891.80 20.57 7825.12 13.09 96.296％ 27 8834.99 20.68 7799.27 13.08 96.739％ 28 8891.15 20.68 7650.19 13.11 94.256％ 29 8899.72 20.70 7690.02 13.10 94.683％ 30 8895.73 20.66 7650.09 13.11 94.173％

[0105] (5) The overall dry basis input-output ratio data was relatively stable, and most batches met the factory's internal material consumption control requirements (≥95.00). However, starting from batch 28, the dry basis input-output ratio was lower than the internal control standard.

[0106] (6) Further analysis of the processing conditions of each batch revealed that since the silk drying process began to be tested from batch 28, in order to further confirm the effect of the bottom air damper opening of the VAS air separation equipment on the elimination of the hidden dangers of "water smoke" and "yellow spot smoke" after drying, the corresponding equipment damper baseline was adjusted to increase the online rejection amount, resulting in fluctuations in the input-output ratio of this section. After adjusting and optimizing the bottom and top air damper openings of the VAS air separation equipment and the ratios of each zone, while taking into account the subsequent product quality defect control needs, the input-output ratio of the above process was restored to the range required by the internal control standard.

[0107] (7) The results of comparing the original fixed delay switching group method with the present invention are as follows:

[0108]

[0109] In the original fixed delay switching group mode, the input-output ratio of the corresponding batch fluctuates greatly, indicating that the original mode cannot meet the needs of continuous batch production material consumption control data collection, while the corresponding batch data range of the present invention is narrower and meets the requirements of the factory material consumption internal control standard. At the same time, stable and appropriate digital data is conducive to monitoring the real material consumption control process of the production section, effectively tracing the abnormal points of material consumption control in the production process, and initiating targeted optimization and adjustment of process equipment control parameters to ensure accurate control of material consumption during batch processing.

[0110] Example 3

[0111] This embodiment is a practical application of the batch data differentiation method constructed based on the first embodiment.

[0112] (1) During the continuous batch production of the cutting and drying section of a certain specification, the data batches are distinguished according to the original fixed delay switching group method. Some quality index data of the cutting and drying section of a batch will be mixed with the data of the batches before and after the continuous batches. That is, the non-steady-state data between batches and the second batch data are mixed during the collection process of the first batch of continuous batches, resulting in the statistical deviation of the quality index of a single batch from the actual situation. For details, see the attached Figure 3 .

[0113] (2) During the batch production of the shredded wire section of a certain specification, the batch data differentiation method constructed in Example 1 is used to differentiate the data in batches, thereby avoiding the mixing of batch data before and after the batch production. The data can restore the actual moisture content control of the shredded wire in the batch. For details, see the attached Figure 4 .

[0114] (3) Due to the current process control mode, the historical data of the moisture content of batch shredded wire is used to predict and derive the control center value of the moisture content of subsequent batches of shredded wire. Since the aforementioned original fixed delay switching group method affects the actual data of the moisture content of batch shredded wire, it will cause the control center value of the moisture content of subsequent batches of shredded wire to deviate from the actual requirements, resulting in the degradation of the assessment indicators of the moisture content of multiple batches of shredded wire. The Cpk rate of excellent moisture content of shredded wire is 81.06%, which is lower than the internal assessment indicator requirements of the factory (the Cpk rate of excellent moisture content of shredded wire ≥ 85.0%).

[0115] (4) The method of the present invention is used to distinguish continuous batch data, and the production process is traced for batches with abnormal moisture content control of shredded wire. After optimizing the moisture content control mode of shredded wire and the batch moisture content prediction model of shredded wire, the inventors compared the actual moisture content control of shredded wire in the annual production process corresponding to the two methods. The Cpk excellent rate of moisture content in the production process corresponding to the distinction method of the present invention is 96.50%, which meets the requirements of the factory's internal assessment indicators (Cpk excellent rate of moisture content in shredded wire ≥ 85.0%). See the table below for details. It can be seen that the method of the present invention is conducive to truly reflecting the control situation and implementing on-site control improvements in a targeted manner, thereby further improving the control stability of key quality indicators of the product process and promoting the realization of product homogeneity control.

[0116]

[0117] In summary, it can be seen that the present invention can effectively adapt to the accurate collection of batch production data under the batch production mode in the current production process. The purpose of the batch data differentiation method of the present invention is to accurately restore the actual control situation of the material consumption and quality data of a single batch under the batch production mode, and it has the characteristics of high efficiency, accuracy and good stability. The batch data differentiation method of the present invention provides a reliable basis for accurately quantifying, monitoring and analyzing the single batch process under the batch production mode, and targetedly carrying out improvements in material consumption control and quality control shortcomings, thereby ensuring the online product homogenization control of tobacco products.

[0118] The basic principle, main features and advantages of the present invention are shown and described above. Those skilled in the art should understand that the present invention is not limited to the above embodiments, and the above embodiments and descriptions are only for explaining the principles of the present invention. Without departing from the spirit and scope of the present invention, the present invention may have various changes and improvements, and these changes and improvements all fall within the scope of the present invention claimed for protection.

Claims

1. A method for automatically distinguishing batches in a tobacco batch production process, characterized in that: The following steps are involved: S1. Obtain the average moisture content of tobacco at the entrance of a process before the start of the batch mode, denoted as H 前单 ; and obtain the average moisture content of the tobacco at the entrance of the last batch PLC group in the batch production mode process, recorded as H 后连 ; S2. Obtain the cumulative weight of the tobacco at the entrance of the process before the start of the batch mode, recorded as W 前单 ; and obtain the real-time material accumulation of the last batch PLC group of tobacco in the batch production mode process, recorded as W 后连 ; S3. Obtain the cumulative weight of a single batch of liquid added during the tobacco leaf moistening and feeding process, recorded as W 料 ; Obtain the corresponding material weight during the dilution preparation process, and the weight of the concentrate is recorded as W 浓 The weight of water added during the dilution process is recorded as W 水 , use H 料 Indicates the moisture content of the feed liquid, H 料 =W 水 / (W 浓 +W 水 ); S4. Obtain the cumulative amount of materials added to the tobacco in the process before the start of the batch mode, recorded as W 掺 ; and obtain the average moisture content of the added material, recorded as H 掺 ; S5. Obtain the weight of the tobacco material remaining in the process after the production of the process before the start of the batch mode is completed, recorded as W 残 ; and obtain the average moisture content of the residual material, recorded as H 残 ; S6. Obtain the weight of all screened materials from the process before the start of the batch mode to the batch process, recorded as W 筛 ; and obtain the average moisture content of the screened material, recorded as H 筛 ; S7. Obtain the dry-based material process change of tobacco from the process before the start of the batch mode to the batch process, recorded as W 损 ; W 损 Obtained by the following formula: 损 =W 料 (1-H 料 )+W 掺 (1-H 掺 )-W 残 (1-H 残 )-W 筛 (1-H 筛 ); S8. Obtain the cumulative weight distinction point of a single batch of materials in the process under the batch production mode, recorded as W 区 , W 区 The calculation formula is as follows: S9, according to W in step S8 区 The calculation formula can be used to calculate the cumulative weight distinction points of each batch of materials in the batch production process. 区 After comparing the values, they are automatically distinguished.

2. The method for automatically distinguishing batches in a tobacco batch production process according to claim 1, characterized in that: The real-time material cumulative weight (W) collected by the last group of PLC in the batch production process 后连 ) and W 区 For comparison, when W 后连 =W 区 When the weight value is set, the last group of PLC performs batch switching. The production data before this weight value is the previous batch data, and the production data after this weight value is the next batch data. The moisture content, temperature, and process flow data of other corresponding production data are automatically distinguished according to the original parameter data collection time interval.

3. The method for automatically distinguishing batches in a tobacco batch production process according to claim 1, characterized in that: In step S1, the average moisture content of the tobacco inlet of the process before the start of the batch mode and the average moisture content of the tobacco inlet of the last batch PLC group in the batch production mode are measured by the moisture content detection device.

4. The method for automatically distinguishing batches in a tobacco batch production process according to claim 1, characterized in that: In step S2, the cumulative weight of the tobacco inlet of a process before the start of the batch mode and the real-time cumulative weight of the tobacco inlet of the last batch PLC group in the batch production mode process are measured and obtained by the weight detection device.

5. The method for automatically distinguishing batches in a tobacco batch production process according to claim 1, characterized in that: In step S3, the cumulative weight of a single batch of liquid added during the tobacco leaf moistening process is measured by a flow measuring device; the corresponding material weight during the liquid dilution preparation process is measured by a weight measuring device. If the barrel water adding mode is adopted, H 料 Recorded as 1.

6. The method for automatically distinguishing batches in a tobacco batch production process according to claim 1, characterized in that: In step S4, the cumulative amount of materials added to the tobacco in the process before the batch mode starts is measured by a weight measuring device; the average moisture content of the added materials is measured by a moisture content detection device, wherein, if no material is added, W 掺 =0.

7. The method for automatically distinguishing batches in a tobacco batch production process according to claim 1, characterized in that: In step S5, the weight of the tobacco material remaining in the process after the process before the batch mode starts is measured by a weight measuring device; the average moisture content of the residual material is measured by a moisture content detection device.

8. The method for automatically distinguishing batches in a tobacco batch production process according to claim 1, characterized in that: In step S6, the weight of all screened materials from the process before the start of the batch mode to the batch process of the tobacco is measured by a weight measuring device; the average moisture content of the screened materials is measured by a moisture content detection device.

9. The method for automatically distinguishing batches in a tobacco batch production process according to claim 1, characterized in that: The process of the tobacco batch production process includes one or more key processes in the leaf threshing, re-drying and silk making links; In step S9, according to the W obtained in each batch during the batch production process, 区 The data classification system is used to automatically distinguish each batch in the batch production process.

10. A computer-readable storage medium having a computer program stored thereon, characterized in that: When the computer program is executed by one or more processors, the steps of the method according to any one of claims 1 to 9 are implemented.

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