Filter stick production line fault diagnosis and maintenance guidance method and application thereof

Abstract

The invention provides a filter stick production line fault diagnosis and maintenance guidance method and application thereof, and the method comprises the following steps: detecting a circumference variation coefficient, a weight variation coefficient CVm and a voltage drop SD value [delta] Psd of a to-be-detected filter stick, the method provided by the invention can quickly and effectively diagnose and position fault sites in a lossless manner, guides field workers to quickly position and solve machine faults, is simple and quick in operation, only uses conventional detection data, is simple in calculation, is low in professional requirement, and is suitable for common front-line operators.

Description

Technical Field

[0001] This invention belongs to the field of filter rod manufacturing technology, specifically relating to a method for diagnosing and repairing filter rod production line faults and its application. Background Technology

[0002] As a crucial component of cigarettes, the performance of the filter rod significantly impacts the comfort of the smoking experience and the quality of the cigarette. Among the key parameters for evaluating filter rod quality is the stability of draw resistance. However, in actual production, the stability of filter rod pressure drop is often affected by multiple factors, including coupled process parameters and dynamic fluctuations in equipment, leading to a standard deviation of pressure drop exceeding process requirements. When significant fluctuations occur in the pressure drop value of the filter rod, the forming machine operator typically uses empirical methods to adjust production parameters to control these fluctuations. For example, Li Chenqiao et al. proposed a composite rod pressure drop prediction method and device, which constructed filter rod models corresponding to several filter rod models through CFD fluid simulation and conducted simulation analysis (202410890831.4); Wang Jie et al. proposed an ISO suction mode, which described a rapid method for measuring filter rod pressure drop during suction. By fitting the pressure drop at the inlet and outlet ends, the pressure drop at any position was calculated using the proportional segmentation method (201911080134.8); Gao Duanjiang et al. studied a quantitative evaluation method for the internal pressure drop stability of a filter rod, using a microwave moisture density meter to detect the density (202411800064.X); Wang Hongsu et al. used correlation analysis and multiple regression as technical means to conduct statistical analysis on the pressure drop, various physical indicators, process parameters and tobacco structure of conventional brand cigarettes (Wang Hongsu, Zhao Haiyang, Zhao Changjiu et al., Mathematical Model and Application of Cigarette Suction Resistance Based on Multiple Regression [J]. Food Industry, 2022, 43(05):60-64). However, the methods mentioned above either only provide a theoretical basis and approach for adjustments in actual production, and often suffer from insurmountable objective factors that make it difficult to clearly define many factors in actual production, or involve too many complex basic experiments that are difficult to reproduce; or they are purely theoretical analyses, too far removed from the operations of front-line production workers, resulting in many things remaining at the level of "personal subjective feelings" of operators or maintenance personnel, lacking universal operability. Furthermore, if the pressure drop standard deviation of the filter rods does not improve significantly after the molding machine operator adjusts the relevant parameters, the molding machine maintenance worker needs to calibrate the molding machine equipment.

[0003] Currently, most molding machine repairmen are young people with insufficient practical repair experience. Furthermore, due to individual differences, their repair and adjustments are highly random, resulting in varying degrees of effectiveness, wasting time and effort, and sometimes yielding little result. Therefore, providing a more precise guidance method to offer reference opinions, making repair work a technical reference and improving work efficiency, has become an urgent problem to be solved. Summary of the Invention

[0004] To address the shortcomings of existing technologies, the present invention aims to provide a method for diagnosing and repairing filter rod production line faults and its application. The method provided by this invention can non-destructively, quickly, and effectively diagnose and locate fault sites, guiding on-site workers to quickly locate and resolve machine faults. Furthermore, it is simple and fast to operate, using only conventional test data, with simple calculations and low professional requirements, making it suitable for ordinary frontline operators.

[0005] To achieve this objective, the present invention adopts the following technical solution:

[0006] On one hand, the present invention provides a method for diagnosing and repairing filter rod production line faults, the method comprising the following steps:

[0007] Detecting the circumferential variation coefficient of the filter rod under test Coefficient of variation (CV) m And the voltage drop SD value (standard deviation of voltage drop) ΔP sd Diagnosis and repair will be carried out based on the test results.

[0008] If the circumferential variation coefficient is satisfied Not greater than 0.3, coefficient of variation (CV) m Not greater than 0.7 and ΔP sd If the value is less than 70, no repair is required.

[0009] If the coefficient of variation of the circumference Greater than 0.3 and the coefficient of variation of weight (CV) m If the value is not greater than 0.7, check and repair the smoke tongue, cooling strip, inner and outer pressure plates, etc.

[0010] If the coefficient of variation of weight CV m Greater than 0.7 and circumferential coefficient of variation If the value is not greater than 0.3, check whether the opening ratio is correct, whether the opening roller is working properly, and repair it.

[0011] If the coefficient of variation of weight CV m Greater than 0.7 and circumferential coefficient of variation If the value is greater than 0.3, all machines should be inspected and repaired.

[0012] If ΔP is not satisfied sd Less than 70, and the coefficient of variation around the circumference Not greater than 0.3, coefficient of variation (CV) m If the value is not greater than 0.7, then substitute it into the following formula for calculation:

[0013]

[0014] In the formula, FLI is the fault location index, α is the longitudinal distribution coefficient, β is the axial distribution coefficient, and γ is the lateral distribution coefficient;

[0015] If FLI > 2.0, check the input air value of the high-pressure air nozzle and check the air pressure stability. If necessary, add or remove the adjusting shims of the high-pressure air nozzle and adjust the opening ratio.

[0016] If 1.5≤FLI≤2.0, check whether the pressure of the opening roller pair is normal and whether the opening roller pair is worn. If necessary, adjust the opening ratio.

[0017] If FLI < 1.5, check whether the fiber blowing system, fiber spread range and opening plate gap are blocked, and adjust the opening ratio if necessary.

[0018] Filter rods are made by cutting filter strips to specific lengths. Given a fixed length and circumference, the pressure drop of a filter rod is primarily determined by the filament bundles within it, including the state of the individual filaments, the packing density, and their distribution. Therefore, the ideal distribution of filament bundles in a filter rod should theoretically possess the following characteristics: uniform lateral and longitudinal distribution, meaning the filament bundles are uniformly distributed both laterally and longitudinally, with equal density throughout the longitudinal section. Different packing densities in the cross-section lead to significant differences in the mass and pressure drop of different filter rods. Furthermore, differences in the state and distribution of individual filaments across the cross-section can not only cause significant differences in mass and pressure drop but also result in filter rods with the same weight exhibiting substantial differences in pressure drop. Since the pressure drop of a filter rod mainly depends on the uniformity of its axial cross-sectional density, it can be simplified as an axially uniform cylinder.

[0019] However, in actual production, due to mechanical reasons, radial unevenness can occur, and there can be significant differences in pressure drop even for filter rods of the same weight. In fact, the instability model of filter rods should also include a mixed type of transverse and longitudinal unevenness, making the situation even more complex. Therefore, axial uniformity alone cannot be considered; radial factors must be incorporated. To achieve the goal of guiding process adjustments using only conventional test data (weight, pressure drop) on the production floor, we incorporated the circumferential coefficient of variation and the weight coefficient of variation into the model. We used the ratio method to quickly determine the direction of the main cause, using the circumferential coefficient of variation from the conventional test report... and weight variation coefficient CV m and pressure drop ΔP sd Three readily available detection parameters can be used to quantify the complex problem of filament distribution. For example, the weight variation coefficient (CV) can be added. mAs a secondary characterization of the weight dispersion of the sample population, it represents the degree of openness of the fiber bundle. Its effect on pressure drop is non-linear, quantifying the physical phenomenon that "the more severe the weight variation, the non-linear amplification of the pressure drop deviation." Through normalization and weight allocation, a single fault location index (FLI) is generated to facilitate the location of faults. Therefore, the above method can non-destructively, quickly, and effectively diagnose and locate fault locations, guiding on-site workers to quickly locate and resolve machine faults. It is also simple and fast to operate, using only conventional test data, with simple calculations and low professional requirements, making it suitable for ordinary front-line operators.

[0020] Preferably, there are at least 30 filter rods to be tested.

[0021] Preferably, the value of α is 0.5-0.7, such as 0.5, 0.55, 0.6, 0.65 or 0.7, but is not limited to the values ​​listed above. Other unlisted values ​​within the above range are also applicable.

[0022] Preferably, the value of α is 0.55-0.65.

[0023] Preferably, the value of β is 1.1-1.3, such as 1.1, 1.15, 1.2, 1.25 or 1.3, but is not limited to the values ​​listed above. Other unlisted values ​​within the above range are also applicable.

[0024] Preferably, the value of β is 1.15-1.25.

[0025] Preferably, the value of γ is 0.3-0.5, such as 0.3, 0.35, 0.4, 0.45 or 0.5, but is not limited to the values ​​listed above. Other unlisted values ​​within the above range are also applicable.

[0026] Preferably, the value of γ is 0.35-0.45.

[0027] On the other hand, the present invention also provides the application of the method for diagnosing and repairing filter rod production line faults as described above in filter rod production.

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

[0029] This invention provides a method for diagnosing and repairing faults in a filter rod production line. It can diagnose and locate fault locations in a non-destructive, rapid and effective manner, guide on-site workers to quickly locate and resolve machine faults, and is simple and quick to operate, using only conventional test data, with simple calculations and low professional requirements, making it suitable for ordinary front-line operators. Detailed Implementation

[0030] To further illustrate the technical means and effects of the present invention, the following describes the technical solution of the present invention in conjunction with preferred embodiments of the present invention. However, the present invention is not limited to the scope of the embodiments.

[0031] Example 1

[0032] This embodiment provides a method for diagnosing and repairing filter rod production line faults. The specific steps are as follows:

[0033] Thirty filter rods from the same production line and batch were selected and tested using the QTM (cerulean) integrated testing platform to obtain the CV (conductivity) results. m , and ΔP sd They are respectively CV m =0.610, ΔP sd =69.173. After that, observe the shape of the filter rod. The maintenance worker should first check the height of the smoke tongue, the height of the cooling strip, and the position of the inner and outer pressure plates and make adjustments to make them meet the installation and adjustment requirements.

[0034] The same production line, after repair, was used to produce 30 filter rods again. These rods were then tested using the QTM (Cerulean) integrated testing bench, and the CV results were obtained. m , and ΔP sd They are respectively CV m =0.592, ΔP sd =43.031, which meets the requirements, indicating that the repair was successful.

[0035] Example 2

[0036] This embodiment provides a method for diagnosing and repairing filter rod production line faults. The specific steps are as follows:

[0037] Thirty filter rods from the same production line and batch were selected and tested using the QTM (cerulean) integrated testing platform to obtain the CV (conductivity) results. m , and ΔP sd They are respectively CV m =0.754, ΔP sd =80.247. After that, first observe whether the weight of a single filter rod is too high or too low, check whether the opening ratio is correct, whether the opening roller moves after ventilation, whether the filament bundle is poorly opened, and if necessary, clean and disassemble the plasticizer nozzle to make the weight of the filter rod within the normal range.

[0038] The same production line, after repair, was used to produce 30 filter rods again. These rods were then tested using the QTM (Cerulean) integrated testing bench, and the CV results were obtained. m , and ΔP sd They are respectively CV m =0.611, ΔP sd =59.110, which meets the requirements, indicating that the repair was successful.

[0039] Example 3

[0040] This embodiment provides a method for diagnosing and repairing filter rod production line faults. The specific steps are as follows:

[0041] Thirty filter rods from the same production line and batch were selected and tested using the QTM (cerulean) integrated testing platform to obtain the CV (conductivity) results. m , and ΔP sd They are respectively CV m =0.725, ΔP sd =97.078. After that, first check the height of the smoke tongue, the height of the cooling strip, and the position of the inner and outer pressure plates and adjust them to make the circumference of the filter rod fluctuate less. Then check the opening of the filament bundle and whether the opening rollers at each stage are worn. Check the plasticizer spraying. When starting the machine, adjust the opening ratio appropriately to make the weight of the filter rod meet the standard.

[0042] The same production line, after repair, was used to produce 30 filter rods again. These rods were then tested using the QTM (Cerulean) integrated testing bench, and the CV results were obtained. m , and ΔP sd They are respectively CV m =0.521, ΔP sd =37.296, which meets the requirements, indicating that the repair was successful.

[0043] Example 4

[0044] This embodiment provides a method for diagnosing and repairing filter rod production line faults. The specific steps are as follows:

[0045] Thirty filter rods from the same production line and batch were selected and tested using the QTM (cerulean) integrated testing platform to obtain the CV (conductivity) results. m , and ΔP sd They are respectively CV m =0.664, ΔP sd=81.918, then substitute the above data into the formula to calculate FLI=0.6×(0.664 / 0.7)+1.2×(81.918 / 70)+0.4×(0.132 / 0.3)=2.1493. Based on the results, check the input air value of the high-pressure air nozzle and check the air pressure stability. If necessary, add or remove the adjusting shims of the high-pressure air nozzle, and adjust the opening ratio if necessary.

[0046] The same production line, after repair, was used to produce 30 filter rods again. These rods were then tested using the QTM (Cerulean) integrated testing bench, and the CV results were obtained. m , and ΔP sd They are respectively CV m =0.412, ΔP sd =42.444, which meets the requirements, indicating that the repair was successful.

[0047] Example 5

[0048] This embodiment provides a method for diagnosing and repairing filter rod production line faults. The specific steps are as follows:

[0049] Thirty filter rods from the same production line and batch were selected and tested using the QTM (cerulean) integrated testing platform to obtain the CV (conductivity) results. m , and ΔP sd They are respectively CV m =0.414, ΔP sd =74.271, then substitute the above data into the formula to calculate FLI=0.6×(0.414 / 0.7)+1.2×(74.271 / 70)+0.4×(0.158 / 0.3)=1.83866. Based on the results, check whether the pressure of each opening roller pair is normal, whether there is any movement, and check whether the opening roller pair is worn. If necessary, replace the opening roller and adjust the opening ratio.

[0050] The same production line, after repair, was used to produce 30 filter rods again. These rods were then tested using the QTM (Cerulean) integrated testing bench, and the CV results were obtained. m , and ΔP sd They are respectively CV m =0.595, ΔP sd =47.928, which meets the requirements, indicating that the repair was successful.

[0051] Example 6

[0052] This embodiment provides a method for diagnosing and repairing filter rod production line faults. The specific steps are as follows:

[0053] Thirty filter rods from the same production line and batch were selected and tested using the QTM (cerulean) integrated testing platform to obtain the CV (conductivity) results. m , and ΔP sd They are respectively CV m =0.122, ΔP sd =72.250, then substitute the above data into the formula to calculate FLI=0.6×(0.122 / 0.7)+1.2×(72.250 / 70)+0.4×(0.115 / 0.3)=1.4979. Based on the results, check whether the filament blowing system, filament unfolding range and opening plate gap are blocked, and adjust the opening ratio if necessary.

[0054] The same production line, after repair, was used to produce 30 filter rods again. These rods were then tested using the QTM (Cerulean) integrated testing bench, and the CV results were obtained. m , and ΔP sd They are respectively CV m =0.508, ΔP sd =55.455, which meets the requirements, indicating that the repair was successful.

[0055] The above embodiments fully demonstrate that the method provided by the present invention can diagnose and locate fault sites non-destructively, quickly and effectively, guide on-site workers to quickly locate and resolve machine faults, and is suitable for ordinary front-line operators.

[0056] The applicant declares that this invention illustrates the method for diagnosing and repairing filter rod production line malfunctions and its application through the above embodiments. However, this invention is not limited to the above embodiments, meaning that this invention does not necessarily rely on the above embodiments for implementation. Those skilled in the art should understand that any improvements to this invention, equivalent substitutions of raw materials, additions of auxiliary components, and selection of specific methods, etc., all fall within the protection and disclosure scope of this invention.

[0057] The preferred embodiments of the present invention have been described in detail above. However, the present invention is not limited to the specific details in the above embodiments. Within the scope of the technical concept of the present invention, various simple modifications can be made to the technical solution of the present invention, and these simple modifications all fall within the protection scope of the present invention.

[0058] It should also be noted that the various specific technical features described in the above specific embodiments can be combined in any suitable manner without contradiction. In order to avoid unnecessary repetition, the present invention will not describe the various possible combinations separately.

Claims

1. A method for diagnosing and guiding the repair of filter rod production line faults, characterized in that, The diagnostic and repair guidance method for filter rod production line faults includes the following steps: Detecting the circumferential variation coefficient of the filter rod under test Coefficient of variation (CV) m and voltage drop SD value ΔP sd Diagnosis and repair will be carried out based on the test results. If the circumferential variation coefficient is satisfied Not greater than 0.3, coefficient of variation (CV) m Not greater than 0.7 and ΔP sd If the value is less than 70, no repair is required. If the coefficient of variation of the circumference Greater than 0.3 and the coefficient of variation of weight (CV) m If the value is not greater than 0.7, check and repair the smoke tongue, cooling strip, inner and outer pressure plates, etc. If the coefficient of variation of weight CV m Greater than 0.7 and circumferential coefficient of variation If the value is not greater than 0.3, check whether the opening ratio is correct, whether the opening roller is working properly, and repair it. If the coefficient of variation of weight CV m Greater than 0.7 and circumferential coefficient of variation If the value is greater than 0.3, all machines should be inspected and repaired. If ΔP is not satisfied sd Less than 70, and the coefficient of variation around the circumference Not greater than 0.3, coefficient of variation (CV) m If the value is not greater than 0.7, then substitute it into the following formula for calculation: In the formula, FLI is the fault location index, α is the longitudinal distribution coefficient, β is the axial distribution coefficient, and γ is the lateral distribution coefficient; If FLI > 2.0, check the input air value of the high-pressure air nozzle and check the air pressure stability. If necessary, add or remove the adjusting shims of the high-pressure air nozzle and adjust the opening ratio. If 1.5≤FLI≤2.0, check whether the pressure of the opening roller pair is normal and whether the opening roller pair is worn. If necessary, adjust the opening ratio. If FLI < 1.5, check whether the fiber blowing system, fiber spread range and opening plate gap are blocked, and adjust the opening ratio if necessary.

2. The method for diagnosing and repairing filter rod production line faults according to claim 1, characterized in that, The number of filter rods to be tested is at least 30.

3. The method for diagnosing and repairing filter rod production line faults according to claim 1 or 2, characterized in that, The value of α is 0.5-0.

7.

4. The method for diagnosing and repairing filter rod production line faults according to claim 3, characterized in that, The value of α is 0.55-0.

65.

5. The method for diagnosing and guiding the repair of filter rod production line faults according to any one of claims 1-4, characterized in that, The value of β is 1.1-1.

3.

6. The method for diagnosing and repairing filter rod production line faults according to claim 5, characterized in that, The value of β is 1.15-1.

25.

7. The method for diagnosing and guiding the repair of filter rod production line faults according to any one of claims 1-6, characterized in that, The value of γ is 0.3-0.

5.

8. The method for diagnosing and repairing filter rod production line faults according to claim 7, characterized in that, The value of γ is 0.35-0.

45.

9. The application of a method for diagnosing and repairing filter rod production line faults according to any one of claims 1-8 in filter rod production.

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