Method for controlling moisture content of tobacco shreds in cigarette production process

Abstract

The invention belongs to the technical field of cigarette processing, and particularly relates to a tobacco shred moisture content control method in a cigarette production process, and the control method comprises the following steps: (1) synchronously arranging on-line moisture detection points at a tobacco shred mixing and perfuming process outlet, a flexible tobacco shred distribution inlet and a finished product strip running process, and realizing data association with an MES (Manufacturing Execution System); (2) sampling according to a preset period, and performing off-line reinspection on each batch of samples by adopting a drying oven method; (3) dynamically calibrating on-line monitoring data and compensating system deviation by taking a drying oven detection value as a reference; and (4) evaluating the moisture content distribution of the tobacco shreds in real time based on the calibrated data, and reversely deducing and accurately adjusting the tobacco shred making process and the environment temperature and humidity setting. Through on-line / off-line synchronous detection, dynamic calibration, whole-process data association analysis and batch tracing, the method eliminates system errors among different measurement modes, significantly improves the accuracy, coverage and traceability of moisture content detection, and ensures that the product quality is stable and controllable.

Description

Technical Field

[0001] The invention belongs to the technical field of cigarette processing, and in particular relates to a method for controlling the moisture content of shredded tobacco in a cigarette production process. Background Art

[0002] The process from blending and flavoring to tobacco rod running is a key link in cigarette production: first, standard tobacco, recycled tobacco, stem cuts and other raw materials are accurately mixed according to the formula, and the flavors are evenly attached and penetrated into the tobacco by spraying or closed fumigation; then, the flavored tobacco is transferred to the tobacco storage cabinet for humidification and storage, so that the moisture and aroma can be fully diffused in the fiber tissue; then, the prepared tobacco is continuously fed into the rolling machine according to quantitative feeding through the automated conveying system, where it is coordinated with cigarette paper and filter tips for rolling, flattening, and spray-coating; finally, the machine cuts the long tobacco rods at the designated position, completes the tobacco rod running operation and outputs standard cigarettes that meet the length and density requirements.

[0003] Among them, the moisture content of cut tobacco is the core control indicator to ensure production efficiency and cigarette quality. It not only directly affects the empty rate and broken rate of the tobacco strips, but is also a key factor in determining the aroma and combustion characteristics of the finished product. Therefore, online monitoring of the moisture content of cut tobacco and dynamically adjusting the baking temperature and humidification parameters based on the monitoring results can effectively reduce the defective rate and significantly improve the smoking quality of the finished cigarettes.

[0004] In the prior art, the moisture content of cut tobacco is mainly monitored by combining online infrared moisture meter monitoring with manual sampling offline detection. Specifically, an infrared moisture meter is installed at the exit of the blending and flavoring process to monitor the whole batch of cut tobacco in real time online. Then, after the process end or finished product packaging, the operator regularly samples and sends it to the laboratory to measure the moisture content by an offline infrared moisture meter or an oven method. Finally, the online and offline data are combined for environmental temperature and humidity adjustment and cut tobacco moisture content control. However, the existing cut tobacco moisture content control method has at least the following problems:

[0005] 1. The online moisture meter and the offline drying oven method use different detection principles and processes, and the moisture content results measured by them cannot be directly compared. Therefore, if the measurement value of the online instrument is taken as the starting point and the measurement value of the drying oven method is taken as the end point, and the difference between the two is used as the basis for adjusting the ambient temperature and humidity and controlling the moisture content of silk, the method itself is unreasonable.

[0006] 2. Manual sampling at the process endpoint or finished product packaging stage only covers a very small proportion of the entire batch of tobacco and cannot reflect the distribution of moisture content of the entire batch of tobacco;

[0007] 3. There are differences in the length, number of elbows, and layout positions of the conveying pipelines from the outlet of the cut tobacco blending and flavoring process to the inlet of the cigarette making and packing machine, resulting in uneven air flow resistance and cut tobacco residence time in the pipelines, causing deviations in the moisture content of the cut tobacco received by each machine under the same working conditions. These deviations accumulate and amplify in the subsequent finished product inspection process, frequently resulting in abnormal moisture content test results, increasing the noise and interference in quality analysis, and making it difficult to accurately evaluate and control the product moisture content.

[0008] 4. During the conveying process of cut tobacco from the outlet of the cut tobacco blending and flavoring process to the cigarette making and packing machine, most of the time it is exposed to the belt conveyor line and is easily affected by the external temperature and humidity, resulting in moisture absorption or moisture release, causing significant fluctuations in its moisture content. The existing technology only conducts moisture detection at the cigarette making and packing finished product stage, and cannot detect in a timely manner the cut tobacco with excessive moisture in the distribution section and the cut tobacco manufacturing process. A large number of unqualified products will appear at the front end, resulting in serious material waste.

[0009] To solve at least one of the above problems, the present application is proposed. Summary of the Invention

[0010] In view of the deficiencies of the prior art, the present invention provides a method for controlling the moisture content of cut tobacco during the cigarette production process. This method synchronously arranges on-line and off-line detection points at key nodes such as the outlet of the cut tobacco blending and flavoring process, the inlet of the flexible cut tobacco distribution process, and the finished cigarette running strip process. Through real-time dynamic calibration, the systematic deviation between different measurement methods is eliminated; and by means of full-process data correlation analysis and batch traceability, accurate correction and monitoring of the cut tobacco moisture content data are realized, thereby greatly improving the accuracy, coverage, and traceability of the cut tobacco moisture content detection, and ensuring the stable and controllable product quality.

[0011] The first aspect of the present invention provides a method for controlling the moisture content of cut tobacco during the cigarette production process, and the control method includes the following steps:

[0012] Step (1): Set on-line moisture detection points at the outlet of the cut tobacco blending and flavoring process, the inlet of the flexible cut tobacco distribution process, and the finished cigarette running strip process, and correlate the detection data of the foregoing detection points and the information of the cut tobacco manufacturing process section through the MES system;

[0013] Step (2): At the on-line moisture detection points at the outlet of the cut tobacco blending and flavoring process, the inlet of the flexible cut tobacco distribution process, and the finished cigarette running strip process, take samples of the cut tobacco at a preset cycle, and use the oven method to re-inspect the moisture content of each batch of samples. Preferably, the same oven is used for re-inspection;

[0014] Step (3): Synchronously collect the on-line detection data and the oven detection value, and perform dynamic calibration and deviation compensation on the on-line detection data based on the oven detection value;

[0015] Step (4) performs real-time evaluation of the moisture content distribution of the tobacco based on the calibrated data, and accordingly infers and accurately adjusts the tobacco making process and / or the ambient temperature and humidity settings to ensure that the moisture content is always maintained within a preset target range.

[0016] Preferably, the preset cycle in step (2) is immediately executed when any of the following events occurs: a. raw material batch replacement;

[0017] b. Production shift handover;

[0018] c. Sudden changes in ambient temperature and humidity;

[0019] d. The equipment runs continuously for more than 8 hours;

[0020] e. The rolling and packaging equipment malfunctioned and stopped working, and the tobacco was not delivered for a long time.

[0021] Considering that tobacco has obvious moisture absorption and release characteristics, once the packaging link fails, the tobacco in the distribution process will be exposed to the change of environmental humidity for a long time in the buffer zone, and it is easy to absorb moisture and cause the moisture content to exceed the standard. Since the information between the silk-making workshop and the packaging workshop cannot be communicated in real time, when the packaging equipment is shut down or the buffer zone accumulates materials, the silk-making workshop still continues to transport tobacco as planned and cannot adjust the production rhythm in time. The above-mentioned tobacco maintains the initial moisture content during the failure period, but absorbs moisture and increases water in the stagnant environment, and the moisture content exceeds the design range when it is finally delivered to the packaging link. To this end, the present invention installs an online moisture meter at the key node of the distribution section to monitor the moisture content of tobacco in real time. Once the detection value exceeds the set range, the storage room staff can recycle the batch of tobacco into the constant humidity storage cabinet for moisture balance treatment, and at the same time guide the production personnel to adjust the tobacco distribution status and moisture content in time, and completely eliminate the quality risks and material waste caused by upstream and downstream information islands.

[0022] Preferably, in step (3), the dynamic calibration and deviation compensation are performed by correcting the historical data of the online moisture detection point with the mean of the parallel oven tests, according to the formula: correction value = online detection value + (oven mean - online mean) × K, where the compensation coefficient K = 0.8-1.2.

[0023] Preferably, if the detected values ​​for three consecutive cycles deviate from the central value by ±0.4%, a process parameter adjustment instruction is triggered, wherein the central value is the target moisture content reference value set for the process.

[0024] The second aspect of this law provides a system for implementing the method described in the first aspect. The system includes: an on-line infrared moisture meter, a microwave moisture meter, an MES system, and data processing software. The data processing software integrates at least data acquisition, calibration, data association, visualization, and regulation suggestion generation modules. The moisture data collected at each on-line detection point is first received by the MES system, and is associated with information such as batch number and machine number in the cut tobacco processing section. The complete associated data is then analyzed by the data processing software, and finally visualized charts and regulation suggestions are generated.

[0025] Preferably, the on-line infrared moisture meters are respectively arranged at the outlet end of the cut tobacco blending and flavoring process and the inlet end of the flexible cut tobacco distribution process, and the microwave moisture meter is arranged at the outlet end of the finished cigarette running process.

[0026] Compared with the prior art, the present invention has the following beneficial effects:

[0027] 1. By synchronously arranging on-line moisture detectors and re-inspecting with the unified oven method at multiple key nodes such as the outlet of cut tobacco blending and flavoring, the inlet of flexible cut tobacco distribution, and the outlet of the running process, the present invention uses a dynamic calibration algorithm to eliminate the systematic deviation between different detection principles, realizes the high-precision fusion of on-line data and off-line data, and significantly improves the accuracy of moisture content monitoring.

[0028] 2. Compared with the traditional method of only taking a small number of samples at the end of the process or in the packaging stage, the present invention sets up points at multiple points in the whole process and automatically takes samples for re-inspection according to the preset event cycle (such as batch change, shift handover, environmental mutation, long-term equipment operation), ensuring comprehensive coverage and continuous monitoring of the moisture content distribution of the whole batch of cut tobacco.

[0029] 3. Based on the full-process data association and real-time exchange of the MES system, and combined with the method of dynamic calibration compensation, the present invention can identify the deviation trend in the first time and trigger the automatic adjustment instruction of process parameters (such as triggering by continuous three-cycle deviation), quickly respond to the fluctuations in the production site, and reduce the generation of defective products.

[0030] 4. Further, the present invention associates the batch number, machine number, and real-time moisture data of each detection point in the MES system. Subsequently, by establishing a moisture content distribution model and a batch traceability database, the whole-process visualization monitoring and traceability from raw materials to finished products can be realized, providing a reliable basis for quality analysis and problem traceability.

[0031] 5. In addition, the present invention arranges on-line moisture detectors at the key nodes of each process, and real-time feedbacks the detection data through a two-way information sharing mechanism, which can timely detect the cut tobacco with abnormal moisture content, accurately guide the production personnel to adjust the distribution rhythm and moisture state, thus eliminating the quality hidden dangers brought by information islands and avoiding the generation of a large number of unqualified products. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Figure 1 It is a layout schematic diagram of each on-line moisture detection point in the specific implementation manner;

[0033] Figure 2 It is a schematic diagram of the data processing flow of the moisture content of cut tobacco in the specific implementation manner. Specific implementation manner

[0034] The present application will be further described in detail below in conjunction with the embodiments.

[0035] Embodiment 1

[0036] As Figure 1 shown, this embodiment takes a certain cigarette production workshop as an example object, and provides a method for controlling the moisture content of cut tobacco in the cigarette production process. The control method includes the following steps:

[0037] Step (1), on-line moisture detection points are set at the outlet of the cut tobacco blending and flavoring process, the inlet of the flexible cut tobacco distribution process, and the finished cigarette running strip process, and the detection data of the foregoing detection points and the information of the cut tobacco processing section are associated through the MES system;

[0038] Step (2), at the on-line moisture detection points of the outlet of the cut tobacco blending and flavoring process, the inlet of the flexible cut tobacco distribution process, and the finished cigarette running strip process, samples of cut tobacco are taken at a preset cycle, and the moisture content of each batch of samples is re-inspected by the oven method. Preferably, the same oven is used for re-inspection;

[0039] Step (3), synchronously collect the on-line detection data and the oven detection value, and dynamically calibrate and compensate the deviation of the on-line detection data based on the oven detection value;

[0040] Step (4), based on the calibrated data, conduct a real-time evaluation of the moisture content distribution of cut tobacco, and accordingly inversely deduce and accurately adjust the cut tobacco processing technology and / or the environmental temperature and humidity settings to ensure that the moisture content is always maintained within the preset target range.

[0041] The preset cycle in step (2) is immediately executed when any of the following events occurs: a. The raw material batch is changed;

[0042] b. The production shift is handed over;

[0043] c. The environmental temperature and humidity suddenly change;

[0044] d. The equipment runs continuously for more than 8 hours;

[0045] e. The cigarette making and packing equipment breaks down and stops, and the cut tobacco is not delivered for a long time.

[0046] In step (3), the dynamic calibration and deviation compensation correct the historical data of the on-line moisture detection points based on the average value of the oven parallel tests. According to the formula: correction value = on-line detection value + (oven average value - on-line average value) × K, where the compensation coefficient K = 0.8 - 1.2, the dynamic calibration and deviation compensation are carried out.

[0047] If the detection values deviate from the central value by ±0.4% for three consecutive cycles, a process parameter adjustment instruction is triggered, where the central value is the target moisture content reference value set by the process.

[0048] Meanwhile, this embodiment also provides a system for implementing the above method. The system includes: an on-line infrared moisture meter, a microwave moisture meter, an MES system, and data processing software. The data processing software at least integrates data acquisition, calibration, data association, visualization, and regulation suggestion generation modules. The moisture data collected at each on-line detection point is first received by the MES system and associated with information such as the batch number and machine number of the cigarette making process section. The complete associated data is then analyzed by the data processing software to finally generate a visualization chart and regulation suggestions.

[0049] The on-line infrared moisture meter at the outlet end of the cut tobacco blending and flavoring process is installed at a position 1 m away from the outlet end of the cut tobacco blending and flavoring process; the on-line infrared moisture meter at the inlet end of the flexible tobacco feeding process is installed at a position 0.5 m upstream of the metering pipe of the flexible tobacco feeder; the microwave moisture meter is arranged adjacent to the microwave detection component of the microwave weight control system in the finished cigarette running process.

[0050] To more detailedly demonstrate the application of the solution of this embodiment in daily production, next, the historical data of a certain brand and a certain batch is taken as an example. Table 1 shows the associated information of the cigarette making batch in the wrapping work order:

[0051]

[0052] The corresponding Table 2 intercepts the on-line moisture content detection values at a certain time period during the distribution and transportation of the cut tobacco in the cigarette making section of Table 1, as shown in the following table:

[0053] Table 2 On-line moisture content detection situation

[0054]

[0055]

[0056] Meanwhile, the detection personnel record the display values of the detection instruments at a certain time period and take cut tobacco samples (3 parallel samples are taken at each detection point) at the corresponding time period for detection by the oven method. The specific values are shown in Table 3 below:

[0057] Table 3 Detection values by the oven method and display values of the detection instruments

[0058]

[0059] As shown in Table 3 above, when the difference between the detected value shown by the detection instrument and the average detected value of the oven is within 0.2% (including 0.2%), no manual intervention is carried out, and the data processing software conducts statistical analysis on the historical data collected by MES at the detection point: mean, maximum value, minimum value, standard deviation, etc.

[0060] When the difference between the detected value of the display value and the absolute value of the detected value is outside 0.2%, it is necessary for the operator to input the sampling time point of a certain batch of cut tobacco into the data processing software. The data before the sampling time point is processed according to the correction value = on-line detected value + (oven average value - on-line average value) × K, and the data after the sampling time point is calculated without adding the correction value, and then the true statistical value of this batch is synthesized.

[0061] Suppose that when the average moisture content of the cut tobacco at the outlet of the cut tobacco blending and flavoring process is within the set central value range and there is no obvious abnormality, while the average moisture content of the cut tobacco in the flexible cut tobacco feeding process is relatively low, then according to the regulation suggestions calculated by the data software, for example, increase the storage temperature of the cut tobacco by 2 - 5 degrees and the relative humidity by 5 - 6%, and vice versa, reduce the temperature and humidity.

[0062] When the average moisture content of the cut tobacco at the outlet of the cut tobacco blending and flavoring process and the average moisture content of the cut tobacco at the inlet of the flexible cut tobacco feeding process are both within the set central value range and there is no obvious abnormality, while the moisture content of the cigarette running strip process is relatively low, then according to the regulation suggestions calculated by the data software, for example, the temperature of the cigarette packing workshop can be increased by 2 - 5 degrees and the relative humidity by 2 - 3%, and vice versa, reduce the temperature and humidity.

[0063] When the average moisture content of the cut tobacco at the outlet of the cut tobacco blending and flavoring process, the average moisture content of the cut tobacco at the inlet of the flexible cut tobacco feeding process, and the average moisture content of the cigarette running strip process are all relatively low, then according to the regulation suggestions calculated by the data software, through the moisture loss of each process, the moisture is regulated (increase moisture) starting from the loose and re-drying process.

[0064] When the average moisture content of the cut tobacco at the outlet of the cut tobacco blending and flavoring process, the average moisture content of the cut tobacco at the inlet of the flexible cut tobacco feeding process, and the average moisture content of the cigarette running strip process are all relatively high, then according to the regulation suggestions calculated by the data software, through the moisture loss of each process, the moisture is regulated (reduce moisture) starting from the loose and re-drying process.

[0065] It should be noted that the specific algorithm for the regulation suggestions calculated by the data software can refer to the existing technology.

[0066] Those skilled in the art will understand that the following embodiments are only used to illustrate the present application and should not be construed as limiting the scope of the present application. For those embodiments in which specific techniques or conditions are not indicated, the techniques or conditions described in the literature in the art or according to the product specifications shall be followed. For those materials or equipment whose manufacturers are not indicated, they are all conventional products that can be obtained by purchase.

Claims

1. A method for controlling the moisture content of shredded tobacco in a cigarette production process, characterized in that: The control method comprises the following steps: Step (1), setting online moisture detection points at the outlet of the blending and flavoring process, the entrance of the flexible matching process and the finished cigarette strip running process, and associating the detection data of the aforementioned detection points with the information of the silk making process section through the MES system; Step (2), sampling the shredded tobacco at the outlet of the blending and flavoring process, the entrance of the flexible blending process, and the online moisture detection point of the finished cigarette strip running process according to a preset cycle, and retesting the moisture content of each batch of samples by using an oven method; Step (3) synchronously collects online detection data and oven detection values, and dynamically calibrates and compensates for deviations of the online detection data based on the oven detection values; Step (4) performs real-time evaluation of the moisture content distribution of the tobacco based on the calibrated data, and accordingly infers and accurately adjusts the tobacco making process and / or the ambient temperature and humidity settings to ensure that the moisture content is always maintained within a preset target range.

2. The method for controlling the moisture content of shredded tobacco in the cigarette production process according to claim 1, characterized in that: The preset period in step (2) is to be executed immediately when any of the following events occurs: a. Raw material batch replacement; b. Production shift handover; c. Sudden changes in ambient temperature and humidity; d. The equipment runs continuously for more than 8 hours; e. The rolling and packaging equipment malfunctioned and stopped, and the tobacco was not delivered for a long time.

3. The method for controlling the moisture content of shredded tobacco in the cigarette production process according to claim 1, characterized in that: The dynamic calibration and deviation compensation in step (3) is to correct the historical data of the online moisture detection point with the average value of the parallel test of the oven, according to the formula: correction value = online detection value + (oven average value - online average value) × K, where the compensation coefficient K = 0.8-1.2, to perform dynamic calibration and deviation compensation.

4. The method for controlling the moisture content of shredded tobacco in the cigarette production process according to claim 1, characterized in that: If the detected values ​​deviate from the central value by ±0.4% for three consecutive cycles, a process parameter adjustment instruction is triggered, wherein the central value is the target moisture content reference value set for the process.

5. A system for implementing any method of claims 1-4, characterized in that: The system includes: the system includes an online infrared moisture meter, a microwave moisture meter, an MES system and data processing software, and the data processing software at least integrates data acquisition, calibration, data association, visualization and control suggestion generation modules.

6. The system according to claim 5, characterized in that The online infrared moisture meter is arranged at the outlet end of the blending and flavoring process and the inlet end of the flexible matching process, and the microwave moisture meter is arranged at the outlet end of the finished cigarette strip running process.

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