Valve sensor data visualization method for tobacco primary processing production line
By employing analog sensors and network communication technology in the tobacco processing production line, the visualization and intelligent monitoring of valve sensor data have been achieved, solving the problems of data resource waste and maintenance difficulties, and improving equipment maintenance efficiency.
Patent Information
- Application Number
- CN202511151062.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-08-18
- Publication Date
- 2025-11-28
AI Technical Summary
Valve sensor data in tobacco processing production lines are not fully visualized, lacking intelligent monitoring and maintenance support, resulting in wasted data resources and maintenance difficulties.
Analog sensors are used to replace digital sensors. Valve sensors are connected to the master station via Ethernet and IO/LINK. PLC is used for data scanning and anomaly analysis, and monitoring software provides visualization output. Detailed data display is achieved by combining industrial Profinet network communication and WINCC software.
It enables detailed display of valve sensor data in the tobacco processing production line, facilitating inspection and maintenance by maintenance workers and monitoring by operators, thereby improving equipment maintenance efficiency.
Smart Images
Figure CN121026221A_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The present application relates to the technical fields of tobacco production and data processing, and more particularly to a valve sensor data visualization method for a tobacco primary processing production line. BACKGROUND
[0002] At present, a large number of field valve sensors are used in the tobacco primary processing production line, which play a very important role in production control. Today, with the rapid use and development of Ethernet, the running data of each end executor is analyzed by a CPU processor, and the production logic of the host device is established. The difference in the internal data operation mode of the existing valve sensor causes the single application mode of the sensor data collection, and the multi-level information in the internal sensor is still in the hidden stage without visualization. In the process of equipment maintenance, there is a lack of sufficient theory and data support.
[0003] Take the valve sensor used in the tobacco primary processing production line as an example to illustrate the single and defects of the data:
[0004] The valve sensor used in the tobacco primary processing production line only uses its basic simple function, and the field valve system data lacks secondary development of intelligent collection and collection. At present, the information of 0 and 1 provided by the switch quantity cannot meet the requirements of intelligent monitoring, and the data information provided is only a small part of the design capacity, which has gradually become unsuitable for the needs of the high-speed development of enterprises to further collect, arrange and apply the internal data, and is not convenient for maintenance workers to check and repair and operators to check and monitor.
[0005] With the development of intelligent and digital tobacco primary processing equipment, the tobacco primary processing control system needs to monitor the real-time data of the device control layer components, and the terminal data needs to be called and operated in the program logic. The data information of the valve sensor at the end of the tobacco primary processing equipment urgently needs to be fully analyzed, arranged and effectively developed. Therefore, it is urgent to provide a valve sensor data visualization method to make the valve sensor data visualized, transparent and intelligent, so as to facilitate maintenance workers to check and repair and operators to check and monitor. SUMMARY
[0006] Therefore, the present application provides a valve sensor data visualization method for a tobacco primary processing production line, which can visualize the valve sensor data of the tobacco primary processing production line, display more detailed data information, and facilitate maintenance workers to check and repair and operators to check and monitor.
[0007] To achieve the above purpose, the technical scheme adopted by the present application is as follows:
[0008] In a first aspect, the present application provides a valve sensor data visualization method for a tobacco primary processing production line, which comprises the following steps:
[0009] The valve sensor of the tobacco cut tobacco production line is connected with an Ethernet and an IO / LINK master station, and the running data of the valve sensor is transmitted to a control system; wherein the valve sensor is an analog sensor.
[0010] The control system scans the running data of the valve sensor, establishes a variable table for monitoring, and performs data processing and abnormality analysis on the running data of the valve sensor.
[0011] The running data of the valve sensor and the analysis result of the control system are visually output and displayed through the monitoring software.
[0012] Further, the analog sensor comprises a photoelectric detection sensor, a distance detection sensor, a displacement detection sensor and a proximity switch.
[0013] Further, the data parameters detected by the sensor are transmitted to the processor inside the control system through industrial profinet network communication.
[0014] Further, the control system is a programmable logic controller (PLC).
[0015] Further, the data processing and abnormality analysis on the running data of the valve sensor comprise: converting the data format, converting the angle data into double integers by using I_DI instruction, then converting the double integers into real numbers by using DI_R instruction, and comparing with the limit threshold set in the program, if exceeding the set range, outputting a pre-warning signal.
[0016] Further, the monitoring software is WINCC.
[0017] In a second aspect, the present application further provides a valve sensor data visualization system of a tobacco cut tobacco production line, which comprises a detection device, a data transmission device, a data processing device and a display device, and when applied, executes the above-mentioned valve sensor data visualization method of a tobacco cut tobacco production line, and realizes the valve sensor data visualization of the tobacco cut tobacco production line.
[0018] In a third aspect, the present application further provides an electronic device comprising a processor and a memory, wherein the memory stores machine executable instructions capable of being executed by the processor, and the processor executes the machine executable instructions to realize the valve sensor data visualization method of a tobacco cut tobacco production line.
[0019] According to the above technical solution, the present application provides a valve sensor data visualization method of a tobacco cut tobacco production line, and compared with the prior art, the present application has at least the following beneficial effects:
[0020] The present application can realize data extraction and visualization of valve sensor on site of a tobacco primary processing line, can show more detailed data information, and is convenient for maintenance workers to check, maintain and operation workers to monitor.
[0021] Other features and advantages of the present application will be set forth in the following description, and in part will become apparent to those skilled in the art from the description, or can be learned by practice of the present application. The objects and other advantages of the present application can be realized and attained by means of the instrumentalities particularly pointed out in the written description and claims hereof.
[0022] The technical solutions of the present application are described in further detail below with the help of the accompanying drawings and examples. BRIEF DESCRIPTION OF DRAWINGS
[0023] In order to more clearly illustrate the technical solutions of the embodiments of the present application or the prior art, the drawings needed to be used in the embodiments or the prior art description will be briefly introduced. Obviously, the drawings in the following description are some embodiments of the present application, and those skilled in the art can also obtain other drawings according to these drawings without creative labor.
[0024] The accompanying drawings are used to provide a further understanding of the present application, and constitute a part of the specification, and are used to explain the present application together with the embodiments of the present application, and do not constitute a limitation on the present application.
[0025] Figure 1 A flowchart of a valve sensor data visualization method of a tobacco primary processing line provided by the present application.
[0026] Figure 2 An IFM intelligent sensor and its data byte schematic diagram provided by the present application.
[0027] Figure 3 A variable monitoring representation diagram provided by the present application.
[0028] Figure 4 A valve sensor angle acquisition test schematic diagram provided by the present application.
[0029] Figure 5 A valve sensor angle data and IO-link communication schematic diagram provided by the present application.
[0030] Figure 6 A sensor position definition schematic diagram provided by the present application.
[0031] Figure 7 A data conversion program schematic diagram provided by the present application.
[0032] Figure 8 A data processing flow schematic diagram provided by the present application.
[0033] Figure 9 The valve sensor visualization schematic provided by the present application.
[0034] Figure 10 The electronic device structure schematic provided by the present application. DETAILED DESCRIPTION
[0035] In order to make the purpose, technical solutions and advantages of the embodiments of the present application clearer, the technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only some of the embodiments of the present application, not all the embodiments.
[0036] In the description of the present application, it should be noted that in some processes described in the specification and drawings, a plurality of operations appear in a specific order, but it should be clearly understood that these operations can be executed or performed in parallel without the order appearing in the text. In addition, various serial numbers are only for description purposes and cannot be understood as indicating or implying relative importance.
[0037] Therefore, the following detailed description of the embodiments of the present application provided in the drawings is not intended to limit the scope of the claimed present application, but only represents selected embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative labor are within the scope of protection of the present application.
[0038] At present, the end effector of the tobacco flavoring system of the tobacco cut tobacco production line is a valve system; the control system PLC receives the signal feedback of the valve sensor, performs logical operation processing, and issues instructions to the valve island, thereby controlling the on-off state of the valve system to form a control closed loop. In this process, the PLC only collects the basic binary data of the sensor, i.e. "0" and "1", the data structure is single, and all information in the sensor is not systematically processed, resulting in waste of data resources, and the valve sensor data is not better visualized to display more detailed data information to facilitate maintenance workers to check and repair and operators to check and monitor.
[0039] Referring to Figure 1 The present application provides a valve sensor data visualization method for a tobacco cut tobacco production line, which mainly comprises the following steps:
[0040] S1: connecting the valve sensor of the tobacco cut tobacco production line through Ethernet and IO / LINK master station, and transmitting the running data of the valve sensor to the control system; wherein the valve sensor is an analog sensor;
[0041] S2: the control system scans the running data of the valve sensor, establishes a variable table for monitoring, and processes and analyzes the running data of the valve sensor;
[0042] S3: the running data of the valve sensor and the analysis results of the control system are visualized and output displayed by the monitoring software.
[0043] The specific embodiments of the present application are described in detail as follows:
[0044] The present application first improves the hardware of the tobacco valve control system equipment, replaces the digital sensor with an analog sensor, changes the digital signals "0" and "1" as switching values to continuous values "-180° to 180°" analog data signals. Through comprehensive collection, analysis, transformation, development and application of the internal running data of the sensor, the network architecture of one network to the end is used to open the path between the central control and the field devices and sensors, and realize seamless integration of field data into the central control system. Through the connection of field components and valve sensors by Ethernet and IO / LINK master station, data extraction and intelligent analysis of field sensors are realized, and visual display is carried out.
[0045] In one specific embodiment, the valve sensor detection signal on-off, position data, early warning value and other data parameters are transmitted to the PLC processor inside by using industrial profinet network communication, the sensor detection is updated by using IO-LINK technology, the variable table is established for the internal data, the sensor detection component information is read out by writing program, further, data diagnosis, production control, feedback and the like are carried out, and intelligent diagnosis is carried out on the sensor state data; for example, the sensor running data is scanned, a variable table is established for monitoring, the extracted data is converted in format, for example, the data is A, and the limit threshold set in the program is compared, for example, the threshold range is A1-A10, if it is out of the set range, that is, A
[0046] Referring to Figure 2 In this embodiment, the IFM valve position sensor is taken as an example, the valve initial position determination, switch position determination, valve action execution information and the like can be carried out, the program point position is collected angle information, 32-bit point position corresponding SSC1 and SSC2 information (SSC1 is the sensor opening position signal, and SSC2 is the closing position signal) is read. At the same time, a variable table is established in S7 (Siemens programmable logic controller PLC) for monitoring, the variable monitoring table is shown inFigure 3 As shown, the valve position sensor valve angle data is acquired, the valve signal transmission and the upper operation interface valve state are realized through the self-checking system.
[0047] The main technical means in the embodiment of the application are as follows:
[0048] 1. Valve sensor angle data acquisition:
[0049] Through the above method for data acquisition, the valve sensor carries out a comparison test between the digital sensor and the analog sensor, and the test results are as shown in Figure 4 In the figure, A and B represent the digital sensor and the analog sensor respectively. Through comparison, the new analog position sensor can output 0-+-90° continuous data. At the same time, most of the data in the sensor operation can be collected and read through the S7 program, and post-processing is carried out.
[0050] 2. Sensor early warning data acquisition and extraction:
[0051] The hardware pin reading needs to reconfigure the hardware, reconfigure the output position through IO-link, read the valve sensor output angle through the program, redefine the output angle position, and realize real-time communication data acquisition. The sensor position definition is as shown in Figure 6 SP represents the set point, HYS represents the hysteresis, interval ① is the tolerance range, and the early warning position is defined as interval ②.
[0052] 3. Sensor data processing:
[0053] Through the data conversion program, the valve angle data is scanned and uploaded, the DB standard block is established, and the angle data is read. The data format is converted, the angle data is converted into double integer by I_DI instruction, then the double integer is converted into real number by DI_R instruction, and then the data is operated and processed by S7 instruction. Here, the S7 instruction specifically refers to some mathematical operation instructions, including ABS (absolute value), DIV (division operation), CMP (comparison instruction) and the like. The operation process is that the converted real data is first taken as an absolute value, the obtained data is divided by 10 to obtain the actual valve angle, the actual angle is compared with the defined leakage threshold value, and the output determination result is output. In the embodiment, the data conversion program flow is shown in Figure 7 The data processing flow is as shown in Figure 8 .
[0054] 4. Establishment of valve sensor data visualization:
[0055] In the control program, a DB data block is established for data reading and storage, and it is associated with the upper-level WinCC data module to establish an upper-level data association point. Communication with the upper-level WinCC variable module is established through IO-LINK technology, dedicated communication data is established, and data synchronization with WinCC variables is performed.
[0056] Valve system data is collected, displayed at the associated points on the upper-level interface, and visualized in the WinCC interface. Sensor angle data is written into the communication data block, and a real-time display of the valve system angle is added to the upper-level WinCC interface. Valve system angle data is processed in the WinCC variable management system. The valve sensor visualization results are as follows: Figure 9 As shown, after data visualization, the control screen not only indicates the valve's on / off state, but also collects the valve angle and has a valve leakage detection function. When the valve is closed, the angle should be 0 degrees. If it exceeds plus or minus two degrees, an early warning will be issued, which is convenient for maintenance workers to check and maintain, and for operators to inspect and monitor.
[0057] As described in the above embodiments, those skilled in the art will understand that the present invention proposes a method for visualizing valve sensor data in a tobacco processing production line. This method can realize the extraction and visualization of data from valve sensors on-site in the tobacco processing production line, and can display more detailed data information, making it convenient for maintenance workers to inspect and maintain the equipment, and for operators to check and monitor it.
[0058] Furthermore, this embodiment of the invention also provides a valve sensor data visualization system for a tobacco processing production line. The system includes a detection device, a data transmission device, a data processing device, and a display device. When applied, it executes the above-described valve sensor data visualization method for a tobacco processing production line to realize the visualization of valve sensor data in the tobacco processing production line.
[0059] The valve sensor data visualization system for a tobacco processing production line provided in this embodiment of the invention has the same implementation principle and technical effects as the aforementioned method embodiment. For the sake of brevity, any parts not mentioned in this embodiment can be referred to the corresponding content in the aforementioned method embodiment, and will not be repeated here.
[0060] Furthermore, refer to Figure 10 As shown, this embodiment of the invention also provides an electronic device that can execute the above-described methods and systems for visualizing valve sensor data in a tobacco processing production line. The electronic device may include a processor 10, a memory 11, a communication bus 12, and a communication interface 13, and may also include a computer program stored in the memory 11 and capable of running on the processor 10.
[0061] The processor 10 can be composed of integrated circuits in some embodiments, for example, can be composed of a single packaged integrated circuit, or can be composed of multiple packaged integrated circuits with the same function or different functions, including one or more combinations of central processing units (CPUs), microprocessors, digital processing chips, graphics processors, and various control chips. The processor 10 is the control core of the electronic device, connects various components of the electronic device through various interfaces and lines, and executes programs or modules stored in the memory 11 and calls data stored in the memory 11 to perform various functions and process data of the electronic device
[0062] Those skilled in the art should understand that the embodiments of the present application can be provided as a method, a system, a device or a computer program product, etc. Therefore, the present application can be in the form of a complete hardware embodiment, a complete software embodiment, or an embodiment combining software and hardware aspects. Moreover, the present application can be in the form of a computer program product implemented on one or more computer usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) containing computer usable program code.
[0063] It should be noted that the word "comprising" does not exclude the presence of components or steps not listed in the claims. The word "a" or "an" preceding the components does not exclude the presence of a plurality of such components. The present application can be implemented by means of hardware comprising several distinct components, and by means of a suitably programmed computer.
[0064] Each embodiment in the specification is described in a progressive manner, and each embodiment focuses on the differences from other embodiments. The same or similar parts between each embodiment can be referred to each other.
[0065] The above description of the disclosed embodiments enables a person skilled in the art to implement or use the present application. The above description is only a specific embodiment of the present application, but the protection scope of the present application is not limited thereto. Any person skilled in the art can easily think of changes or replacements within the technical range disclosed by the present application, which should be covered within the protection scope of the present application.
Claims
1. A method for visualizing valve sensor data in a tobacco processing production line, characterized in that, The method includes the following steps: The valve sensors of the tobacco processing production line are connected via Ethernet and IO / LINK master station, and the operation data of the valve sensors are transmitted to the control system; wherein, the valve sensors are analog sensors; The control system scans the operating data of the valve sensors, establishes a variable table for monitoring, and performs data processing and anomaly analysis on the operating data of the valve sensors. The monitoring software visualizes and displays the operating data of the valve sensors and the analysis results of the control system.
2. The method for visualizing valve sensor data in a tobacco processing production line according to claim 1, characterized in that, The analog sensors include: a photoelectric detection sensor, a distance detection sensor, a displacement detection sensor, and a proximity switch.
3. The method for visualizing valve sensor data in a tobacco processing production line according to claim 2, characterized in that, The data parameters detected by the sensors are transmitted to the processor of the control system through industrial Profinet network communication.
4. The method for visualizing valve sensor data in a tobacco processing production line according to claim 1, characterized in that, The control system is a programmable logic controller (PLC).
5. The method for visualizing valve sensor data in a tobacco processing production line according to claim 4, characterized in that, Data processing and anomaly analysis of valve sensor operating data include: converting the data format, converting angle data into double integers using the I_DI instruction, then converting the double integers into real numbers using the DI_R instruction, and comparing them with the limit thresholds set in the program. If the data exceeds the set range, an early warning signal is output.
6. The method for visualizing valve sensor data in a tobacco processing production line according to claim 1, characterized in that, The monitoring software is WINCC.
7. A valve sensor data visualization system for a tobacco processing production line, characterized in that, The system includes a detection device, a data transmission device, a data processing device, and a display device. When applied, it executes a valve sensor data visualization method for a tobacco processing production line as described in any one of claims 1 to 6, thereby realizing the visualization of valve sensor data in the tobacco processing production line.
8. An electronic device, characterized in that, It includes a processor and a memory, the memory storing machine-executable instructions that can be executed by the processor, the processor executing the machine-executable instructions to implement a valve sensor data visualization method for a tobacco processing production line as described in any one of claims 1 to 6.