Storage cabinet tobacco leaf discharging flow control method

Abstract

A storage cabinet tobacco leaf discharge flow control method comprises the following steps: a first image acquisition device acquires cross sectional areas of materials at a first position and a second position of a storage cabinet, calculates a first volume and a second volume of the materials according to the cross sectional areas, and predicts the time T1 when the materials at the first position reach the tail end of the storage cabinet according to the first volume and the initial speed of the storage cabinet; adjusting the speed of the storage cabinet to V1 according to the first volume; according to the second volume and the storage cabinet speed V1, predicting the time T2 when the material at the second position reaches the tail end of the storage cabinet, and adjusting the storage cabinet speed to V2 according to the second volume; the first image acquisition device acquires the cross sectional areas of materials at the first position, the second position and the third position of the storage cabinet according to a set time interval, predicts the contact areas of the materials at the first position, the second position and the third position of the storage cabinet and the material stirring roller according to the cross sectional areas, and adjusts the rotating speed of the material stirring roller according to the contact areas of the materials and the material stirring roller; the discharging stability of the storage cabinet is improved, and the production cost and the energy consumption are reduced.

Description

Technical Field

[0001] The present invention belongs to the technical field of automatic control, and particularly relates to a method for controlling the discharge flow of tobacco leaves in a storage cabinet. Background Art

[0002] When each storage cabinet in the current tobacco leaf processing production line discharges materials, in the existing production control, some storage cabinets give a fixed speed for discharging materials when the photoelectric tube detects that there is material, but it is not known how much the discharge flow rate is. However, due to the structural characteristics of the storage cabinet, the thickness of the materials stored in the storage cabinet is different (the cross-section is trapezoidal), especially in the starting end and the ending end regions of the storage cabinet. The fixed speed will cause the discharge flow rate of the storage cabinet to be unstable, and it may be higher or lower than the subsequent flow rate requirements, unable to meet the flow rate requirements of the subsequent processing procedures, thus making the processing accuracy unable to meet the process indicators and seriously affecting the product quality.

[0003] In view of the above problems, when each storage cabinet in the current tobacco leaf processing production line discharges materials, due to some factors, the materials in the storage cabinet are prone to appear in lumps when leaving the cabinet, and are distributed in piles on the discharge conveyor belt, which has an impact on the subsequent homogenization production.

[0004] Therefore, the present invention provides a method for controlling the discharge flow of tobacco leaves in a storage cabinet, adding corresponding equipment for real-time flow data acquisition, and combining intelligent control algorithms to perform frequency conversion adjustment on the speeds of the storage cabinet and the conveyor belt, so as to improve the discharge stability. Summary of the Invention

[0005] The purpose of the present invention is to overcome the deficiencies of the prior art and provide a method for controlling the discharge flow of tobacco leaves in a storage cabinet. By performing frequency conversion control on the bottom belt motor and the conveyor belt motor of the storage cabinet, the discharge stability of the storage cabinet is improved, thereby improving the production efficiency and the stability of product quality, and reducing the production cost and energy consumption.

[0006] To solve the above technical problems, the basic concept of the technical solution adopted by the present invention is as follows:

[0007] A method for controlling the discharge flow of tobacco leaves in a storage cabinet, wherein a first image acquisition device acquires the cross-sectional areas of the materials at the first position and the second position in the storage cabinet, and calculates the first volume and the second volume of the materials according to the cross-sectional areas.

[0008] Predict the time T1 for the materials at the first position to reach the end of the storage cabinet according to the first volume and the initial speed of the storage cabinet, and adjust the speed of the storage cabinet to V1 according to the first volume.

[0009] Predict the time T2 for the materials at the second position to reach the end of the storage cabinet according to the second volume and the speed V1 of the storage cabinet, and adjust the speed of the storage cabinet to V2 according to the second volume.

[0010] Further, the first image acquisition device acquires the cross-sectional areas of the materials at the first, second, and third positions of the storage cabinet at set time intervals, predicts the contact areas between the materials at the first, second, and third positions of the storage cabinet and the material pushing rollers based on the cross-sectional areas, and adjusts the rotation speeds of the material pushing rollers according to the contact areas between the materials and the material pushing rollers.

[0011] Further, at time T1, the second image acquisition device acquires the cross-sectional area of the material at the starting end of the conveyor belt, calculates the volume based on the cross-sectional area; predicts the time t when the material at the starting end of the conveyor belt reaches the end of the conveyor belt according to the speed of the conveyor belt; at time T1 + t, adjusts the speeds of the conveyor belt and the storage cabinet;

[0012] At time T1, it is judged whether the volume of the material at the current starting end of the conveyor belt is greater than the set volume;

[0013] If so, before time T2, continuously control the speed V1 of the storage cabinet.

[0014] Further, at time T + t, the first image acquisition device acquires the cross-sectional area of the material at the current first position of the storage cabinet, calculates the volume of the material at the current first position based on the cross-sectional area, and predicts the time T when the material at the current first position reaches the end of the storage cabinet according to the current speed of the storage cabinet and the volume of the material.

[0015] Further, at time T, the second image acquisition device acquires the cross-sectional area of the material at the current starting end of the conveyor belt, calculates the volume of the material at the current starting end of the conveyor belt based on the cross-sectional area, and predicts the time t when the material at the starting end of the conveyor belt reaches the end of the conveyor belt according to the current speed of the conveyor belt and the volume of the material at the starting end of the conveyor belt;

[0016] The first image acquisition device obtains the volume information of the material at the starting end of the conveyor belt, and at time t, adjusts the speed of the storage cabinet according to the volume of the material at the end of the conveyor belt.

[0017] Further, three material pushing rollers are coaxially arranged vertically above the end of the storage cabinet. When the material pushing rollers contact the material, the rotation speeds of the material pushing rollers are adjusted according to the contact areas between the material and the material pushing rollers;

[0018] When the contact area between the material and the material pushing rollers is greater than or equal to the first area and less than the second area, adjust the rotation speed of the first material pushing roller, and keep the rotation speeds of the second and third material pushing rollers unchanged;

[0019] When the contact area between the material and the material pushing rollers is greater than or equal to the first area and less than the second area, the rotation speed of the first material pushing roller is greater than the rotation speeds of the second and third material pushing rollers.

[0020] Further, when the contact area between the material and the material feeding roller is greater than or equal to the second area and less than the third area, adjust the rotational speeds of the first material feeding roller and the second material feeding roller, and keep the rotational speed of the third material feeding roller unchanged;

[0021] When the contact area between the material and the material feeding roller is greater than or equal to the second area and less than the third area, the rotational speed of the first material feeding roller is greater than that of the second material feeding roller, and the rotational speed of the second material feeding roller is greater than that of the third material feeding roller.

[0022] Further, when the contact area between the material and the material feeding roller is greater than or equal to the third area, adjust the rotational speeds of the first, second, and third material feeding rollers simultaneously;

[0023] When the contact area between the material and the material feeding roller is greater than or equal to the third area, the rotational speed of the first material feeding roller is greater than that of the second material feeding roller, and the rotational speed of the second material feeding roller is greater than that of the third material feeding roller;

[0024] Or, when the contact area between the material and the material feeding roller is greater than or equal to the third area, the rotational speeds of the three material feeding rollers are the same.

[0025] Further, it further includes a constant-speed conveyor belt. A third image acquisition device is fixedly arranged at any position above the constant-speed conveyor belt. At time t, the third image acquisition device acquires the cross-sectional area of the material on the constant-speed conveyor belt in real time and calculates the volume of the material on the constant-speed conveyor belt.

[0026] Judge whether the volume of the material on the constant-speed conveyor belt is greater than the set volume. If so, adjust the speed of the conveyor belt according to the volume of the material on the current constant-speed conveyor belt.

[0027] Further, the storage cabinet, the conveyor belt, and the constant-speed conveyor belt are arranged horizontally in sequence. The horizontal plane where the storage cabinet is located is the first horizontal plane, and the horizontal plane where the constant-speed conveyor belt is located is the second horizontal plane.

[0028] The first horizontal plane is higher than the second horizontal plane;

[0029] The conveyor belt is inclined. The bottom surface of the conveyor belt forms an angle greater than 30° and less than 60° with the second horizontal plane. The starting end of the conveyor belt is located on the second horizontal plane, and the end of the conveyor belt is higher than the first horizontal plane;

[0030] A first image acquisition device is arranged above the storage cabinet. The first image acquisition device moves back and forth horizontally to acquire the cross-sectional area of the material from the starting end to the end of the storage cabinet.

[0031] A second image acquisition device is fixedly arranged above the starting end of the conveyor belt. The second image acquisition device acquires the cross-sectional area of the material at the starting end of the conveyor belt.

[0032] After adopting the above technical solution, the present invention has the following beneficial effects compared with the prior art:

[0033] 1. At least calculate the volume of the material at the first and second positions of the storage cabinet, predict the time when the material at the first position reaches the end of the storage cabinet, which can avoid adjusting the discharge flow rate too early or too late, improve the utilization rate of resources, and reduce waste. Through the calculus control algorithm, the blanking speed is adjusted in real time according to the cross-sectional area of the material at the starting end of the conveyor belt and the change in the volume of the material in the storage cabinet.

[0034] 2. Continuously collect the cross-sectional area of the material on the storage cabinet in real time, and the speed to be adjusted can be calculated according to the cross-sectional area of the material; calculate the volume according to the cross-sectional area, and predict the discharge time of the storage cabinet according to the volume and the speed of the storage cabinet, so as to stabilize the discharge flow rate and improve production efficiency.

[0035] 3. The blanking speed of the storage cabinet can be adjusted according to the cross-sectional area of the material at the starting end of the conveyor belt at this moment, and the change in speed is calculated by combining the calculus control algorithm with the material volume. By using the calculus control algorithm, the automatic adjustment of the blanking speed can be realized, which reduces the burden on the operator, improves the automation degree of the production line, reduces the need for manual intervention, and further improves the production efficiency and the reliability of the production line.

[0036] The following further describes in detail the specific embodiments of the present invention with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] The accompanying drawings, as part of the present invention, are used to provide a further understanding of the present invention. The schematic embodiments and descriptions thereof of the present invention are used to explain the present invention, but do not constitute an improper limitation to the present invention. Obviously, the accompanying drawings in the following description are only some embodiments, and those of ordinary skill in the art can obtain other drawings based on these drawings without creative efforts. In the drawings:

[0038] Figure 1 is a schematic diagram of tobacco leaves leaving the storage cabinet;

[0039] Figure 2 is a flow chart of tobacco leaves leaving the cabinet of the present invention;

[0040] Figure 3 is a schematic diagram of material transmission on the conveyor belt of the present invention;

[0041] Figure 4 is a schematic diagram of the material contacting the deflector roller of the present invention.

[0042] It should be noted that these drawings and the text description are not intended to limit the scope of the concept of the present invention in any way, but to illustrate the concept of the present invention to those skilled in the art by referring to specific embodiments. DETAILED DESCRIPTION OF THE INVENTION

[0043] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the following will clearly and completely describe the technical solutions in the embodiments in conjunction with the accompanying drawings in the embodiments of the present invention. The following embodiments are used to illustrate the present invention but are not used to limit the scope of the present invention.

[0044] In the description of the present invention, it should be noted that the orientation or positional relationship indicated by the terms "upper", "lower", "front", "rear", "left", "right", "vertical", "inner", "outer", etc. is based on the orientation or positional relationship shown in the accompanying drawings. It is only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be construed as a limitation to the present invention.

[0045] In the description of the present invention, it should be noted that unless otherwise clearly specified and defined, the terms "installed", "connected", and "coupled" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be directly connected or indirectly connected through an intermediate medium. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0046] Based on high-precision and fast-response flow meters and edge devices, the present invention combines the LSTM flow intelligent control algorithm to optimize the PLC electric control program, realizing variable-frequency control of the bottom belt motor and conveyor belt motor of the storage cabinet, so as to achieve the purpose of accurately controlling the flow rate when the material exits the cabinet. Thereby improving the production efficiency and the stability of product quality, reducing production costs and energy consumption, and creating greater economic benefits for tobacco production enterprises.

[0047] In this embodiment, the storage cabinet, the conveyor belt, and the constant-speed conveyor belt are arranged horizontally and sequentially in a transverse direction. The horizontal plane where the storage cabinet is located is the first horizontal plane, and the horizontal plane where the constant-speed conveyor belt is located is the second horizontal plane.

[0048] The first horizontal plane is higher than the second horizontal plane;

[0049] The conveyor belt is inclined. The surface of the bottom belt of the conveyor belt forms an angle greater than 30° and less than 60° with the second horizontal plane. The starting end of the conveyor belt is located on the second horizontal plane, and the end of the conveyor belt is higher than the first horizontal plane;

[0050] In this embodiment, the inclination angle of the conveyor belt is 45°.

[0051] A first image acquisition device is arranged above the storage cabinet. The first image acquisition device moves back and forth horizontally to acquire the cross-sectional area of the material from the starting end to the ending end of the storage cabinet. The first image acquisition device can move back and forth above the storage cabinet and is capable of acquiring the cross-sectional area of the material at all positions on the storage cabinet.

[0052] A second image acquisition device is fixedly arranged above the starting end of the conveyor belt. The second image acquisition device acquires the cross-sectional area of the material at the starting end of the conveyor belt. When the length of the conveyor belt is H, the starting end of the conveyor belt can be H / 2, that is, the position half of the conveyor belt length is defined as the starting end of the conveyor belt, and the other half position is defined as the ending end of the conveyor belt.

[0053] Both the first image acquisition device and the second image acquisition device are devices that can acquire the image of an object and obtain the cross-sectional area of the object. In the present invention, an infrared lidar detector is adopted. After the image acquisition device obtains the cross-sectional area, the image acquisition device can continue to calculate the volume, or the controller can calculate the volume of the material.

[0054] The controller is communicatively connected to the first image acquisition device and the second image acquisition device.

[0055] A method for controlling the discharge flow rate of tobacco leaves includes the following steps:

[0056] S1: The first image acquisition device acquires the cross-sectional area of the material at the first position of the storage cabinet and calculates the volume of the material according to the cross-sectional area.

[0057] S2: Predict the time T when the material at the first position of the storage cabinet reaches the ending end of the storage cabinet according to the volume, and adjust the speed of the storage cabinet at time T.

[0058] S3: At time T, the second image acquisition device acquires the cross-sectional area of the material at the starting end of the conveyor belt and calculates the volume of the material according to the cross-sectional area.

[0059] S4: Predict the time t when the material at the starting end of the conveyor belt reaches the ending end of the conveyor belt according to the volume of the material at the starting end of the conveyor belt, and adjust the speed of the conveyor belt and the speed of the storage cabinet at time T + t.

[0060] S5: At time T + t, execute S1 to S5.

[0061] S6: Adjust the speed of the deflector roll according to the cross-sectional area of the material at the first position of the storage cabinet and the contact area between the material and the deflector roll.

[0062] S1 - S5 are executed in a loop; S6 can be started at any time. As long as the material is in contact with the deflector roll, the speed of the deflector roll can be adjusted according to the contact area between the material and the deflector roll.

[0063] For example, if T n +t nAt a moment, the volume of the material at the first position of the storage cabinet is greater than T n-1 +t n-1 At the moment, the volume of the material at the first position of the storage cabinet, then T n is greater than T n-1 ;

[0064] If T n At a moment, the volume of the material at the starting end of the conveyor belt is greater than T n-1 At the moment of the volume of the material at the starting end of the conveyor belt, then t n is greater than t n-1 This shows that the speed of the storage cabinet at this time is increased because the volume of the previous section of the material is small, so the time for the current material to reach the end of the storage cabinet is fast at the current speed of the storage cabinet.

[0065] A method for controlling the discharge flow rate of tobacco leaves in a storage cabinet, the first image acquisition device acquires the cross-sectional areas of the materials at the first position and the second position of the storage cabinet, and calculates the first volume and the second volume of the materials according to the cross-sectional areas

[0066] Predict the time T1 for the material at the first position to reach the end of the storage cabinet according to the first volume and the initial speed of the storage cabinet, and adjust the speed V1 of the storage cabinet according to the first volume;

[0067] Predict the time T2 for the material at the second position to reach the end of the storage cabinet according to the second volume and the speed V1 of the storage cabinet, and adjust the speed V2 of the storage cabinet according to the second volume.

[0068] At the moment of T1, the second image acquisition device acquires the cross-sectional area of the material at the starting end of the conveyor belt, and calculates the volume according to the cross-sectional area; predict the time t for the material at the starting end of the conveyor belt to reach the end of the conveyor belt according to the volume of the material at the starting end of the conveyor belt, and adjust the speed of the conveyor belt and the speed of the storage cabinet at the moment of T1+t.

[0069] At the moment of T1, judge whether the volume of the current material at the starting end of the conveyor belt is greater than the set volume;

[0070] If so, continuously control the speed V1 of the storage cabinet before the moment of T2.

[0071] In this embodiment, the speeds of the storage cabinet, the conveyor belt, and the feeding roller are adjusted in real time according to the volume of the material.

[0072] The first image acquisition device and the second image acquisition device acquire the cross-sectional areas of the materials in real time, and calculate the volumes according to the cross-sectional areas.

[0073] A method for controlling the discharge flow rate of tobacco leaves in a storage cabinet, the first image acquisition device acquires the cross-sectional area of the material at the first position of the storage cabinet, and calculates the volume of the material according to the cross-sectional area

[0074] Predict the time T when the material at the first position reaches the end of the storage cabinet, and adjust the rotation speed of the feeding roller and the speed of the storage cabinet according to the volume of the material at time T;

[0075] At time T, the second image acquisition device acquires the cross-sectional area of the material at the starting end of the conveyor belt, and calculates the volume of the material according to the cross-sectional area.

[0076] Predict the time t when the material at the starting end of the conveyor belt reaches the end of the conveyor belt, and adjust the speed of the conveyor belt and the speed of the storage cabinet according to the volume of the material at time T + t.

[0077] The first position of the storage cabinet can be a position with a certain distance from the end of the storage cabinet, which can make the predicted material at the first position reach the end of the storage cabinet with a certain time. The end of the storage cabinet is the position where the storage cabinet discharges materials, not exceeding half of the length of the storage cabinet. Preferably, it can be one-third of the length of the storage cabinet for discharging materials.

[0078] Such as Figure 3 As shown, the material on the conveyor belt is transported in the direction indicated by the arrow. Both the starting end and the ending end of the conveyor belt can be set to half of the length of the conveyor belt. Record the positions of the materials at the starting end and the ending end of the conveyor belt. In one conveyor belt, record three points as distinguishing points. Point a is at the starting end, point b is at the middle position, and point c is at the ending discharging position. ab = bc, the time taken for the material at position a to reach position b is equal to the time taken for the material at position b to reach position c. When the material at position b reaches position c, the second image acquisition device acquires the cross-sectional area of the material between the current position a and position b again.

[0079] At time T + t, the first image acquisition device acquires the cross-sectional area of the material at the current first position of the storage cabinet, calculates the volume of the material at the current first position according to the cross-sectional area, and predicts the time T when the material at the current first position reaches the end of the storage cabinet according to the current speed of the storage cabinet and the volume of the material.

[0080] T represents a definite moment when the material at the first position of the storage cabinet reaches the end of the storage cabinet, and t represents a time period from time T when the material at the starting end of the conveyor belt reaches the end of the conveyor belt. Therefore, T + t represents a new moment obtained after a time period of t starting from time T.

[0081] For example, assume that at time T, the cross-sectional area of the material at the current first position in the storage cabinet collected by the first image acquisition device is 1 square meter. Based on this cross-sectional area, we calculate that the volume of the material at the current first position is 2 cubic meters. Assume that the current speed of the storage cabinet is 0.5 meters per minute. We can predict the time T when the material at the current first position reaches the end of the storage cabinet based on the speed and the volume of the material. According to the physical formula: speed = distance / time, we can obtain time = distance / speed. Assume that the length of the storage cabinet is 3 meters, then the time required for the material to reach the end from the first position is 3 meters / 0.5 meters per minute = 6 minutes. Therefore, based on this information, at time T, the volume of the material at the first position is 2 cubic meters, and it is expected that at time T + 6 minutes, this material will reach the end of the storage cabinet.

[0082] At time T, the second image acquisition device collects the cross-sectional area of the material at the starting end of the current conveyor belt, calculates the volume of the material at the starting end of the current conveyor belt based on the cross-sectional area, and predicts the time t when the material at the starting end of the conveyor belt reaches the end of the conveyor belt based on the current speed of the conveyor belt and the volume of the material at the starting end of the conveyor belt;

[0083] The first image acquisition device obtains the volume information of the material at the starting end of the conveyor belt, and at time t, adjusts the speed of the storage cabinet based on the volume of the material at the end of the conveyor belt.

[0084] Both the first image acquisition device and the second image acquisition device collect the cross-sectional area of the material in real time at regular time intervals.

[0085] It is used to monitor and adjust the flow of the material on the conveyor belt and adjust the speed of the storage cabinet to adapt to the changes in the material. Such a system can help optimize the production process, improve production efficiency and reduce resource waste.

[0086] By collecting material information in real time and predicting the arrival time of the material, the speed of the storage cabinet can be adjusted in a timely manner to avoid the situation of material accumulation or the storage cabinet being idle. Optimizing the flow and storage of the material can improve the overall efficiency of the production line, reduce the stagnation and waste in the production process. It avoids the resource waste caused by excessive material accumulation or premature feeding, making the production process more resource-saving.

[0087] The material in the storage cabinet is in an irregular and piled-up state. Denote the area of the empty storage cabinet as Sr and the area of the full storage cabinet as Sm, then the cross-sectional area of the material Ss = Sr - Sm.

[0088] As Figure 1 shown, different regions of the material include the head (a, b, c), steady state (d), and tail (e, f, g) parts of the material; collect the height of the material in different regions; perform clustering analysis based on the feeding speed obtained after the material in different heights contacts the feeding roller to obtain the central height values of the material in different regions of the storage cabinet.

[0089] The volume of the material is represented by the central height value of the material and the cross-sectional area of the material.

[0090] The unit volume flow rate C of the material is measured by the product of the speed of the storage cabinet or conveyor belt and the cross-sectional area of the material: v t+Δt S t = C

[0091] In order to make the volume flow rate stable, it is only necessary to keep C constant. The length H of the conveyor belt is fixed; the calculus control algorithm controls the speed of the storage cabinet;

[0092]

[0093]

[0094]

[0095]

[0096]

[0097] H, C, S u , t are all known quantities, storing S u The list L of data S :

[0098] If we set the time interval for collecting data in L S as δ, and the actual speed v t ∈[0, v max , then the cross-sectional area data actually collected at time t should satisfy:

[0099]

[0100] In this embodiment, the speed of the conveyor belt can also be obtained according to the above calculation formula.

[0101] In this embodiment, the speed of the storage cabinet is adjusted while adjusting the speed of the conveyor belt at time T2;

[0102] The controller processes the data through the calculus control algorithm and transforms the speed value into the corresponding variable-frequency voltage value and writes it into the PLC electric control program to achieve the stability of the out-of-cabinet flow rate.

[0103] Obtain the speed value: First, obtain the speed value of the bottom belt motor of the storage cabinet or conveyor belt through an encoder, a sensor, an infrared radar detector, or other controllers. For example, the speed value is 1000 RPM.

[0104] Design the mapping relationship between the variable-frequency voltage value and the speed: Assume that the variable-frequency voltage value (V) = 0.1 * speed value (RPM). According to this relationship, when the speed value is 1000 RPM, the corresponding variable-frequency voltage value is 100V.

[0105] Perform the calculation of the variable-frequency voltage value: According to the above mapping relationship, calculate the variable-frequency voltage value: 100V.

[0106] Write the variable-frequency voltage value into the PLC electric control program: In the PLC programming software, through the corresponding logic block or function block, write the calculated variable-frequency voltage value (100V) into the specified output register or data register.

[0107] Control the output signal: Configure the corresponding logic in the PLC program so that the voltage value in the output register or data register can be converted into a control signal and sent to the frequency converter through the digital output port or analog output port of the PLC, to achieve the control of the bottom belt motor of the storage cabinet or the first conveyor belt motor.

[0108] Therefore, the steps of converting the speed value into the corresponding variable-frequency voltage value and writing it into the PLC electric control program are summarized as follows:

[0109] S1. Obtain the speed value: Obtain the speed of the storage cabinet or conveyor belt from devices such as sensors or controllers.

[0110] S2. Design the mapping relationship: Determine the functional relationship between the variable-frequency voltage value and the speed, which can be a linear function, a look-up table, or other mathematical models. In the present invention, it shows a linear negative correlation.

[0111] S3. Calculate the variable-frequency voltage value: According to the mapping relationship, convert the speed value into the corresponding variable-frequency voltage value through programming logic or arithmetic functions.

[0112] S4. Write into the PLC program: Write the calculated variable-frequency voltage value into the output register or data register of the PLC through the PLC programming software.

[0113] S5. Control the output signal: According to the PLC program design, convert the output variable-frequency voltage value into the corresponding control signal and send it to the frequency converter or other control devices to achieve the control of the motor. Three material-deflecting rollers are coaxially arranged vertically above the end of the storage cabinet. When the material-deflecting rollers contact the material, adjust the rotation speed of the material-deflecting rollers according to the contact area between the material and the material-deflecting rollers;

[0114] When the contact area between the material and the material-deflecting rollers is greater than or equal to the first area and less than the second area, adjust the rotation speed of the first material-deflecting roller, and keep the rotation speeds of the second and third material-deflecting rollers unchanged;

[0115] Preferably, when the contact area between the material and the material feeding roller is greater than or equal to the first area and less than the second area, the rotational speed of the first material feeding roller is greater than the rotational speeds of the second and third material feeding rollers.

[0116] As Figure 4 shown, the rotational speed of the material feeding roller is determined according to the contact area between the material and the material feeding roller. The first area is the area when the material is in full contact with the first material feeding roller, the second area is the area when the material is in contact with the first and second material feeding rollers, and the third area is the area when the material is in contact with the first, second, and third material feeding rollers.

[0117] When the contact area between the material and the material feeding roller is greater than or equal to the second area and less than the third area, adjust the rotational speeds of the first and second material feeding rollers, and the rotational speed of the third material feeding roller remains unchanged at its original speed;

[0118] Preferably, when the contact area between the material and the material feeding roller is greater than or equal to the second area and less than the third area, the rotational speed of the first material feeding roller is greater than the rotational speed of the second material feeding roller, and the rotational speed of the second material feeding roller is greater than the rotational speed of the third material feeding roller.

[0119] When the contact area between the material and the material feeding roller is greater than or equal to the third area, adjust the rotational speeds of the first, second, and third material feeding rollers simultaneously;

[0120] Preferably, when the contact area between the material and the material feeding roller is greater than or equal to the third area, the rotational speed of the first material feeding roller is greater than the rotational speed of the second material feeding roller, and the rotational speed of the second material feeding roller is greater than the rotational speed of the third material feeding roller;

[0121] Or, when the contact area between the material and the material feeding roller is greater than or equal to the third area, the rotational speeds of the three material feeding rollers are the same.

[0122] When the contact area between the material and the material feeding roller is within a certain specific range, the rotational speed of the material feeding roller will be adjusted accordingly to better handle the material flow.

[0123] Dynamically adjusting the rotational speed of the material feeding roller according to the contact area between the material and the material feeding roller can better adapt to the material flow under different conditions and improve the efficiency and stability of the material flow.

[0124] By adjusting the rotational speed of the material feeding roller in a timely manner, the blockage and accumulation of materials during transmission can be effectively reduced, and the continuous operation of the production line can be maintained.

[0125] The rotational speed of the material feeding roller can also be adjusted according to the volume of the material at the starting end of the conveyor belt;

[0126] The first image acquisition device obtains the volume of the material at the starting end of the conveyor belt, and determines whether the material at the starting end of the conveyor belt exceeds the first volume. If so, it adjusts the rotational speeds of the first, second, and third material deflecting rollers;

[0127] If not, it adjusts the rotational speeds of the first and second material deflecting rollers, or adjusts the rotational speed of the first material deflecting roller.

[0128] The first volume at this time represents the maximum volume obtained by multiplying the cross-sectional area collected when the material contacts the first, second, and third material deflecting rollers by the height of the material.

[0129] When at the maximum volume, the rotational speeds of the first, second, and third material deflecting rollers are simultaneously adjusted to improve the efficiency of the production line.

[0130] When it is less than the first volume, the rotational speed of the first material deflecting roller or the rotational speeds of the first and second material deflecting rollers are appropriately adjusted according to the contact area between the material and the material deflecting rollers.

[0131] It further includes a constant-speed conveyor belt. A third image acquisition device is fixedly arranged at any position above the constant-speed conveyor belt. At time t, the third image acquisition device real-time collects the cross-sectional area of the material on the constant-speed conveyor belt and calculates the volume of the material on the constant-speed conveyor belt.

[0132] It determines whether the volume of the material on the constant-speed conveyor belt is greater than the set volume. If so, it adjusts the speed of the conveyor belt according to the volume of the material on the current constant-speed conveyor belt.

[0133] The set volume represents that when the material is conveyed to the constant-speed conveyor belt, the collected cross-sectional area should be the minimum cross-sectional area, and the height of the material is relatively less than the height of the material in the storage cabinet and on the conveyor belt. At this time, the material presented on the constant-speed conveyor belt is evenly distributed and stable in different positions. In this way, the purpose of stable final discharge is achieved.

[0134] When the production process does not require manual operation and is fully intelligent, the third image acquisition device can be used to real-time observe whether the volume flow rate of the material on the constant-speed conveyor belt is stable. When it exceeds the set stability standard, a prompt can be issued to indicate that the speed of the conveyor belt and / or the storage cabinet needs to be adjusted.

[0135] By dynamically adjusting the speed of the material deflecting rollers, the entire production line can maintain a stable operating state under different conditions, thereby optimizing the production process and improving the overall efficiency of the production line.

[0136] The calculus algorithm is used to obtain the speed value and correspondingly adjust the speeds of the storage cabinet and the conveyor belt, making the control more intelligent and precise to meet the production requirements under different conditions.

[0137] The optimized storage cabinet control scheme can effectively improve production efficiency, reduce costs, optimize the production process, achieve intelligent production control, and bring significant benefits to enhancing the operating efficiency of the overall production line and product quality.

[0138] As Figure 1 shown, the method of obtaining the height of materials in different areas includes that the first image acquisition device dynamically obtains the material distribution form in different areas of the storage cabinet to establish a material form model, and conducts model training according to the machine learning method of mean clustering;

[0139] After model training, k central heights are obtained, and linear regression training is performed on the k central heights to form a corresponding prediction model;

[0140] The discharging speed of the storage cabinet is intelligently controlled according to the prediction model.

[0141] Through the cloth running of the first image acquisition device, the material distribution form of the storage cabinet is obtained, and the volume information of different areas of the material head (a, b, c), stability (d), and material tail (e, f, g) is calculated. Model training is carried out by the machine learning method of mean clustering (Kmeans) to reduce the difficulty of data acquisition and expand the sample size. There are at least three material distributing rollers in contact with the materials, and its mechanism is affected by factors such as contact area, tobacco strand winding degree, water content, etc. Therefore, model training is carried out by the machine learning method of mean clustering (Kmeans).

[0142] Mean clustering belongs to unsupervised learning in machine learning. After clustering analysis is carried out on the discharging speed obtained after the materials at different heights are in contact with the material distributing rollers, k central heights are obtained.

[0143] For the k different central heights, corresponding prediction models are respectively formed through linear regression training, and the speed of the bottom belt is intelligently controlled through the prediction model, so that the discharging speed on the bottom belt of the storage cabinet and the conveyor belt speed form a linear negative correlation within a unit time.

[0144] The instantaneous speed value output by the prediction model is transformed into the corresponding variable frequency voltage value and written into the PLC electric control program, and the speed of the bottom belt is intelligently controlled through variable frequency, and finally the stability of the discharging flow is improved.

[0145] A real-time flowmeter is installed on the conveyor belt to dynamically obtain the cross-sectional area information of the real-time flow on the conveyor belt, and the real-time flow volume information is obtained by combining the transmission speed of the conveyor belt. By adding edge devices to provide relevant data acquisition fusion and computing power, combined with the LSTM real-time flow control intelligent algorithm, variable frequency control is carried out on the power motors of the storage cabinet and the conveyor belt to achieve a relatively stable material flow output on the subsequent constant-speed conveyor belt.

[0146] Real-time flow information is obtained through a second image acquisition device on the conveyor belt. Combining the real-time speed, the time for the flow to reach the end of the conveyor belt is obtained through an LSTM algorithm, and at this time, the motor of the conveyor belt is instantaneously speed-controlled according to the cross-sectional area information obtained by the second image acquisition device, and the corresponding frequency conversion voltage value is written into the PLC electric control program to achieve relatively stable flow stability on the constant-speed conveyor belt.

[0147] Frequency conversion control refers to using a frequency converter (also known as a variable frequency speed regulator, variable frequency regulator) to control the speed of an AC motor, that is, to control the speed of the conveyor belt. By adjusting the frequency and voltage output by the frequency converter, precise control of the motor speed can be achieved. The variable frequency control system can dynamically adjust the motor speed according to needs, thus achieving advantages such as energy saving, stable operation, and precise control.

[0148] In industrial production, frequency conversion control is commonly used to regulate conveying equipment, such as conveyor belts, and other equipment that requires speed adjustment. By changing the power supply frequency of the motor, the purposes of adjusting the operating speed of the equipment, saving energy, and improving the operating efficiency of the equipment can be achieved.

[0149] The flow rate is calculated in real time based on the cross-sectional area and speed information of the materials on the conveyor belt, including the accumulation of materials on the conveyor belt, the material volume in different areas, etc.; the flow rate of the materials is calculated, and the speed of the conveyor belt is adjusted according to the calculation results. By continuously collecting and calculating, the speed of the conveyor belt can be precisely controlled at different time periods to meet the stable discharge of materials on the constant-speed conveyor belt in this application. This control process can be realized through the PLC electric control program, thus realizing an automatic variable frequency control system.

[0150] Whether the materials on the constant-speed conveyor belt are discharged stably is determined according to the material volume information in different areas of the constant-speed conveyor belt. For example, the volumes of the materials in different areas are within the same set volume range, achieving the effect of constant flow control.

[0151] In the method of this application, multiple conveyor belts can be arranged in combination, and at least one conveyor belt arranged at the end is used as a constant-speed conveyor belt to achieve constant flow stability on the constant-speed conveyor belt.

[0152] During the material transmission process from the storage cabinet to the constant-speed conveyor belt, materials with originally uneven volume sizes or different stacking degrees become evenly arranged on the constant-speed conveyor belt, and a constant flow stability is maintained on the constant-speed conveyor belt. This setting can be adjusted and optimized according to specific production requirements and material flow characteristics to improve production efficiency and product quality.

[0153] The first image acquisition device and the second image acquisition device are connected in series and operate in coordination. The speed of the storage cabinet and the speed of the conveyor belt can be adjusted according to the volume of the material on the storage cabinet, or the speed of the storage cabinet and the speed of the conveyor belt can be adjusted according to the volume of the material on the conveyor belt. Or in a system with multiple conveyor belt combinations, the motor speed of other conveyor belts is adjusted at least according to the volume flow rate of the material on one conveyor belt, so as to achieve precise flow control.

[0154] Under the condition that the total material flow rate remains unchanged per unit time, the feeding speed of the material in the storage cabinet is flexibly controlled to meet different requirements in the production process.

[0155] Collect the different heights of the material in the storage cabinet; perform clustering analysis according to the feeding speed obtained after the material at different heights contacts the feeding roller, and obtain the central height values of the material in different areas of the storage cabinet;

[0156] The volume of the material in different positions corresponds to different control algorithms.

[0157] There are at least two conveyor belts. The image acquisition device and the frequency conversion controller between the conveyor belts are connected in series to control the material flow on the constant-speed conveyor belt to tend to be stable. The control algorithm includes the LSTM algorithm;

[0158] The main code of the LSTM algorithm:

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[0163] The above are only the preferred embodiments of the present invention, and there is no any form of limitation to the present invention. Although the present invention has been disclosed above with the preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art of this patent, without departing from the scope of the technical solution of the present invention, can make some changes or modifications to the above-mentioned technical content disclosed as equivalent embodiments of equivalent changes. The implementation schemes in the above embodiments can be further combined or replaced, but any simple modification, equivalent change and modification made to the above embodiments based on the technical essence of the present invention without departing from the content of the technical solution of the present invention still fall within the scope of the present invention.

Claims

1. A method for controlling the discharge flow of tobacco leaves from a storage cabinet, characterized in that: The first image acquisition device acquires the cross-sectional area of ​​the material at the first position and the second position of the storage cabinet, and calculates the first volume and the second volume of the material according to the cross-sectional area. Predict the time T1 when the material at the first position arrives at the end of the storage tank according to the first volume and the initial speed of the storage tank, and adjust the speed of the storage tank to V1 according to the first volume; The time T2 when the material at the second position arrives at the end of the storage tank is predicted according to the second volume and the storage tank speed V1, and the storage tank speed is adjusted to V2 according to the second volume.

2. A method for controlling the discharge flow of tobacco leaves from a storage cabinet according to claim 1, characterized in that: The first image acquisition device acquires the cross-sectional areas of the material at the first, second and third positions of the storage cabinet at set time intervals, predicts the contact areas between the material and the material transfer roller at the first, second and third positions of the storage cabinet based on the cross-sectional areas, and adjusts the rotation speed of the material transfer roller based on the contact areas between the material and the material transfer roller.

3. A method for controlling the discharge flow of tobacco leaves from a storage cabinet according to claim 2, characterized in that: At time T1, the second image acquisition device acquires the cross-sectional area of ​​the material at the starting end of the conveyor belt, and calculates the volume based on the cross-sectional area; the time t when the material at the starting end of the conveyor belt reaches the end of the conveyor belt is predicted based on the speed of the conveyor belt, and at time T1+t, the speed of the conveyor belt and the speed of the storage cabinet are adjusted; At time T1, determine whether the material volume at the starting end of the current conveyor belt is greater than the set volume; If so, before time T2, the tank speed V1 is continuously controlled.

4. A method for controlling the discharge flow of tobacco leaves from a storage cabinet according to claim 3, characterized in that: At time T+t, the first image acquisition device acquires the cross-sectional area of ​​the material at the current first position of the storage cabinet, calculates the volume of the material at the current first position based on the cross-sectional area, and predicts the time T when the material at the current first position reaches the end of the storage cabinet based on the current speed of the storage cabinet and the volume of the material.

5. A method for controlling the discharge flow of tobacco leaves from a storage cabinet according to claim 4, characterized in that: At time T, the second image acquisition device acquires the cross-sectional area of ​​the material at the starting end of the current conveyor belt, calculates the volume of the material at the starting end of the current conveyor belt based on the cross-sectional area, and predicts the time t when the material at the starting end of the conveyor belt reaches the end of the conveyor belt based on the current conveyor belt speed and the volume of the material at the starting end of the conveyor belt; The first image acquisition device obtains the volume information of the material at the starting end of the conveyor belt, and at time t, adjusts the speed of the storage cabinet according to the volume of the material at the end of the conveyor belt.

6. A method for controlling the discharge flow of tobacco leaves from a storage cabinet according to claim 5, characterized in that: Three feeding rollers are coaxially arranged vertically above the end of the storage cabinet. When the feeding rollers come into contact with the materials, the rotation speed of the feeding rollers is adjusted according to the contact area between the materials and the feeding rollers. When the contact area between the material and the material-dispensing roller is greater than or equal to the first area and smaller than the second area, the rotation speed of the first material-dispensing roller is adjusted, and the rotation speeds of the second and third material-dispensing rollers remain unchanged; When the contact area between the material and the material-digging roller is greater than or equal to the first area and smaller than the second area, the rotation speed of the first material-digging roller is greater than the rotation speeds of the second and third material-digging rollers.

7. A method for controlling the discharge flow of tobacco leaves from a storage cabinet according to claim 6, characterized in that: When the contact area between the material and the feeding roller is greater than or equal to the second area and less than the third area, the rotation speeds of the first feeding roller and the second feeding roller are adjusted, and the rotation speed of the third feeding roller remains unchanged; When the contact area between the material and the feeding roller is greater than or equal to the second area and less than the third area, the rotation speed of the first feeding roller is greater than the rotation speed of the second feeding roller, and the rotation speed of the second feeding roller is greater than the rotation speed of the third feeding roller.

8. A method for controlling the discharge flow of tobacco leaves from a storage cabinet according to claim 7, characterized in that: When the contact area between the material and the material-dispensing roller is greater than or equal to the third area, the rotation speeds of the first, second and third material-dispensing rollers are adjusted simultaneously; When the contact area between the material and the feeding roller is greater than or equal to the third area, the rotation speed of the first feeding roller is greater than the rotation speed of the second feeding roller, and the rotation speed of the second feeding roller is greater than the rotation speed of the third feeding roller; Or, when the contact area between the material and the material-discharging roller is greater than or equal to the third area, the rotation speeds of the three material-discharging rollers are the same.

9. A method for controlling the discharge flow of tobacco leaves from a storage cabinet according to claim 8, characterized in that: It also includes a constant-speed conveyor belt, and a third image acquisition device is fixedly arranged at any position above the constant-speed conveyor belt. At time t, the third image acquisition device collects the cross-sectional area of ​​the material on the constant-speed conveyor belt in real time to calculate the volume of the material on the constant-speed conveyor belt. Determine whether the volume of the material on the constant-speed conveyor belt is greater than the set volume. If so, adjust the speed of the conveyor belt according to the volume of the material on the current constant-speed conveyor belt.

10. A method for controlling the discharge flow of tobacco leaves from a storage cabinet according to claims 1-9, characterized in that: The storage cabinet, the conveyor belt, and the constant-speed conveyor belt are arranged in sequence in the horizontal direction. The horizontal plane where the storage cabinet is located is the first horizontal plane, and the horizontal plane where the constant-speed conveyor belt is located is the second horizontal plane. The first horizontal plane is higher than the second horizontal plane; The conveyor belt is tilted, the bottom surface of the conveyor belt forms an angle greater than 30° and less than 60° with the second horizontal plane, the starting end of the conveyor belt is located on the second horizontal plane, and the end of the conveyor belt is higher than the first horizontal plane; A first image acquisition device is arranged above the storage cabinet, and the first image acquisition device moves back and forth in a horizontal direction to acquire the cross-sectional area of ​​the material from the starting end to the end of the storage cabinet; A second image acquisition device is fixedly arranged above the starting end of the conveyor belt, and the second image acquisition device acquires the cross-sectional area of ​​the material at the starting end of the conveyor belt.

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