Threshing and redrying processing method and system for improving tobacco module formula precision

Abstract

The invention discloses a threshing and redrying processing method and system for improving tobacco module formula precision. The method comprises the steps that layered feeding is conducted; the feeding amount is regulated and controlled in real time; primarily mixing in a bin; monitoring material processing data in real time; carrying out homogenization on-line evaluation; homogenizing process parameters are dynamically regulated and controlled; and feeding and dynamically mixing. According to the threshing and redrying processing method and system for improving the precision of the tobacco module formula, the matching precision is controlled in the source premixing stage, so that the matching error is effectively reduced, and the integrity and accuracy of the module formula are improved; in the processing process, a monitoring system is combined with a dynamic mixing control system, real-time optimization of mixing process parameters is achieved, it is guaranteed that the product processing quality meets the requirement, the quality stability and consistency of threshing and redrying finished tobacco strips are remarkably improved, the'source-process-regulation 'technical process is constructed, and the processing efficiency is improved. And a technical support is provided for intelligent management of threshing and redrying.

Description

Technical Field

[0001] This invention relates to the field of tobacco processing technology, and more specifically, to a method and system for threshing and re-drying tobacco leaves to improve the precision of tobacco leaf module formulation. Background Technology

[0002] The tobacco leaf module is the smallest quality unit of a cigarette product, and the accuracy of its formulation plays a crucial role in product quality. Current tobacco leaf blending processes have several shortcomings. The conveying and mixing methods for tobacco leaves are relatively crude, resulting in uneven initial conditions of the leaves entering the blending area. Furthermore, localized accumulation and mixing dead zones easily occur during the blending process, further increasing the difficulty of mixing and significantly reducing the accuracy of the module formulation. This affects the consistency and stability of the taste of subsequent cigarette products, making it difficult to meet the growing demand for high-quality tobacco products.

[0003] Therefore, there is an urgent need for a method and system for threshing and re-drying tobacco leaves to improve the accuracy of tobacco leaf module formulations. Summary of the Invention

[0004] The purpose of this invention is to provide a method and system for processing tobacco leaves by threshing and re-drying to improve the accuracy of tobacco leaf module formulation, so as to solve the problems in the prior art. By pre-mixing at the source of raw materials and monitoring the uniformity of the process and dynamic mixing control, the formulation deviation is greatly reduced and the quality stability and consistency of the finished tobacco leaves by threshing and re-drying are significantly improved.

[0005] This invention provides a method for improving the precision of tobacco leaf module formulation through leaf threshing and re-drying, comprising:

[0006] Layered feeding: Different grades of tobacco leaves in the formula are fed onto separate feeding conveyor belts;

[0007] Real-time control of feeding amount: The feeding amount data of each feeding belt is collected in real time, and the feeding amount of each feeding belt is controlled in real time according to the collected feeding amount data and the preset formula ratio.

[0008] Initial mixing in the silo: Materials of each grade fall into the collection belt through the corresponding feed belt, and are then transported to the feed silo by the collection belt;

[0009] Real-time monitoring of material processing data: When the tobacco leaves being processed online pass through the tobacco leaf material lifting conveyor belt at the rear end of the feed hopper, the processing data of the material is monitored in real time.

[0010] Online homogenization evaluation: Based on the monitoring results of material processing data, the homogenization of the material is evaluated online.

[0011] Dynamically adjust homogenization process parameters: dynamically adjust the mixing time of materials based on the online evaluation results of material homogenization;

[0012] Feeding and dynamic mixing: The material is sent to the mixing chamber by the material lifting conveyor belt. Under the rotation of the mixing chamber, the material is driven to make a circular motion so that the material is fully loosened and mixed.

[0013] In the above-described method for improving the precision of tobacco leaf module formulation through leaf threshing and re-drying, preferably, in the layered feeding process, the number of feeding belts is 10-20, and the speed of each feeding belt is consistent, at 3m / min-10m / min.

[0014] The leaf threshing and re-drying processing method for improving the precision of tobacco leaf module formulations as described above, preferably, involves real-time control of the feed amount, including:

[0015] Step S21: During the feeding process, the feeding amount data of single-grade tobacco leaves is collected in real time by electronic belt scales set at each feeding point of each feeding belt, and the feeding amount data is sent to the feeding control system for aggregation. Let there be n grades of tobacco leaves in the formula, and the total feeding amount of the i-th grade of tobacco leaves is denoted as x. i The feeding control system includes a PLC controller; each feeding belt has multiple feeding points and one replenishment point, with 5-10 feeding points corresponding to each feeding belt; the replenishment point is located downstream of each feeding point along the material conveying direction; an electronic belt scale is installed below each feeding point and the replenishment point on each feeding belt; a display screen of each feeding belt is installed above the corresponding replenishment point; the electronic belt scale and the display screen corresponding to each feeding point are connected to the control system.

[0016] Step S22: The feeding control system collects data on the feeding amount of each grade of tobacco leaves and calculates the maximum formula feeding base for a single feeding cycle. Specifically, this includes: combining the target proportion p of the tobacco leaf formula. i Based on the principle of the long-board theory, the maximum feed base T for a single feeding cycle is calculated using the following formula:

[0017] T= ;

[0018] Step S23: Calculate the required supplementary weight for each grade of tobacco leaf and synchronize the supplementary weight data to the display screens of the corresponding feed belts. Calculate the supplementary weight y for the i-th grade of tobacco leaf using the following formula. i :

[0019] y i = ;

[0020] Step S24: At each of the feed belts, perform weight replenishment based on the weight replenishment results displayed on the screen.

[0021] In the above-described method for improving the precision of tobacco leaf module formulation by threshing and re-drying, preferably, in the initial mixing process in the bin, the speed of the summing belt is not lower than the speed of the feeding belt, and the speed of the summing belt is set to 10m / min-15m / min.

[0022] The initial mixing in the bin includes:

[0023] The tobacco material on the conveyor belt falls into the feed hopper via a chute.

[0024] After the material falls into the feeding hopper, the tobacco material entering the feeding hopper is dispersed by an air spray device installed in the feeding hopper.

[0025] The leaf threshing and re-drying processing method for improving the precision of tobacco module formulations as described above, preferably, includes the following: Real-time monitoring of material processing data.

[0026] As the tobacco leaf material being processed online passes through the tobacco leaf material lifting conveyor belt at the rear end of the feed hopper, the processing data of the material is monitored in real time by a uniformity monitoring system. This uniformity monitoring system includes a sensor assembly on one side of the end of the material lifting conveyor belt. The sensor assembly is a near-infrared sensor, specifically comprising:

[0027] The chemical composition data of tobacco leaves is scanned using a near-infrared sensor. The near-infrared sensor is set to extract data every 5-10 minutes, for a total of n sets of data.

[0028] The method for improving the precision of tobacco leaf module formulation through threshing and re-drying, as described above, preferably includes the following: Online homogenization evaluation: Based on the monitoring results of material processing data, an online homogenization evaluation of the material is performed, including:

[0029] The sensor assembly at one end of the material lifting conveyor belt sends the collected tobacco material processing data to the mixing control system.

[0030] After receiving material processing data, the mixing control system pre-screens the collected data and obtains a total of m chemical indicators. The pre-screening includes selecting k chemical indicators from the m chemical indicators as core indicators for uniformity evaluation based on a preset core indicator screening method.

[0031] The hybrid control system sorts the selected core indicator data in ascending order of indicator value, and calculates the uniformity coefficient of each core indicator using the following formula:

[0032] Gx = ,

[0033] Where n represents the number of data sets extracted, x i This represents the i-th set of data for the core indicator x;

[0034] The overall uniformity coefficient G of tobacco sheets is calculated using the following formula:

[0035] G= ;

[0036] The hybrid control system uses a built-in standard database and analysis of variance to screen out indicators that show significant differences among samples with different homogeneity. The screened indicators are then automatically used as core indicators. The database includes sample data with known homogeneity.

[0037] The leaf threshing and re-drying processing method for improving the precision of tobacco leaf module formulations as described above, preferably, includes the following:

[0038] The mixing control system dynamically adjusts the mixing time of materials based on the online evaluation results of material homogenization, specifically including:

[0039] If G > 0.05, set the mixing time to 10 min - 15 min; if G < 0.05, set the mixing time to 5 min - 10 min.

[0040] The above-described method for improving the precision of tobacco leaf formulation through threshing and re-drying, preferably, involves the following feeding and dynamic mixing: the material is conveyed to the mixing chamber via a material lifting conveyor belt, and under the rotation of the mixing chamber, the material undergoes circular motion to ensure thorough loosening and mixing, including:

[0041] The material is conveyed to the mixing bin by the material lifting conveyor belt. The material enters the mixing bin inlet through the mixing bin chute and then enters the drum from the mixing bin inlet. Under the rotation of the drum, the material is fully stirred, turned and conveyed, which promotes the material to be fully loosened and mixed.

[0042] At the discharge port of the mixing chamber, the mixing control system controls the opening and closing of the discharge port of the mixing chamber based on the dynamic adjustment results of the material mixing time by controlling the working state of the discharge port switch control mechanism, thereby regulating the mixing time.

[0043] This invention also provides a tobacco leaf re-drying processing system for improving the precision of tobacco leaf module formulation using the above method, comprising: a conveyor platform, on which multiple feeding belts and a collection belt are provided, each feeding belt being used to receive tobacco leaf materials of different grades, and the collection belt being used to collect the tobacco leaf materials on each feeding belt; a feeding chute is provided at the end of the collection belt along an inclined direction, and the end of the feeding chute is connected to a feeding hopper; a material lifting conveyor belt is provided at the rear end of the feeding hopper, and a uniformity monitoring system is provided on one side of the end of the material lifting conveyor belt for real-time monitoring of material processing data; a mixing hopper is connected to the end of the material lifting conveyor belt, and the mixing hopper includes a rotatable roller arranged along an inclined direction, with a mixing hopper inlet and a mixing hopper outlet respectively provided at both ends of the roller; an outlet switch control mechanism is provided between the roller and the mixing hopper outlet for controlling the opening and closing of the mixing hopper outlet; the outlet switch control mechanism is connected to a mixing control system, and the mixing control system is also connected to the uniformity monitoring system.

[0044] In the tobacco leaf re-drying processing system for improving the precision of tobacco leaf module formulation as described above, preferably, each of the feeding belts has multiple feeding points and one replenishment point; the replenishment point is located downstream of each feeding point along the material conveying direction; each feeding point and the replenishment point is equipped with an independent electronic belt scale for measuring the amount of material fed; and a display screen is provided above the replenishment point.

[0045] Each of the aforementioned feeding points is connected to a feeding control system via an electronic belt scale and a display screen.

[0046] The feeding hopper includes a feeding inlet at the top of the feeding hopper and a feeding outlet at the bottom of the feeding hopper. An air spraying device is installed inside the feeding hopper. The air spraying device includes air pipes arranged vertically on both sides of the inner wall of the feeding hopper. Multiple air mixing nozzles are installed on the air pipes. The air pipes are connected to a fan.

[0047] The mixing control system is used to: obtain online evaluation results of material homogenization based on the tobacco material processing data collected by the homogenization monitoring system; dynamically adjust the mixing time of the material based on the online evaluation results of material homogenization; and control the working state of the discharge port switch control mechanism based on the dynamic adjustment results of the material mixing time, thereby controlling the opening and closing of the discharge port of the mixing chamber and adjusting the mixing time.

[0048] The roller is mounted on a roller support; a drive shaft is provided between the roller and the roller support, and multiple drive wheels are sleeved on the drive shaft, each drive wheel contacting the roller; the drive shaft is connected to a roller drive mechanism for driving the drive shaft to rotate.

[0049] The discharge port control mechanism includes a valve disposed inside the discharge port of the mixing chamber. A valve cavity is located at the top of the valve, and a switch drive mechanism is located at the top of the valve cavity. A lead screw and a threaded sleeve are arranged from top to bottom inside the valve cavity. The lead screw is located at the lower end of the switch drive mechanism, and its outer wall is threadedly connected to the inner wall of the threaded sleeve. The threaded sleeve is welded to the top of the valve. The outer diameter of the valve matches the inner diameter of the discharge port of the mixing chamber. A sealing element is provided between the valve and the discharge port of the mixing chamber.

[0050] This invention provides a method and system for improving the precision of tobacco leaf module formulations during the threshing and re-drying process. Regarding product quality assurance, by controlling the proportioning precision at the source premixing stage, it effectively reduces proportioning errors and improves the integrity and accuracy of the module formulation. During processing, a monitoring system combined with a dynamic mixing control system enables real-time optimization of mixing process parameters, ensuring that the processed product quality meets requirements and significantly improving the quality stability and consistency of threshed and re-dried products. Simultaneously, it integrates multiple technologies such as layered material distribution, online monitoring, and dynamic control to construct a "source-process-control" technical flow, providing technical support for intelligent management of threshing and re-drying. Attached Figure Description

[0051] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described below with reference to the accompanying drawings, wherein:

[0052] Figure 1 A flowchart illustrating an embodiment of the tobacco leaf threshing and re-drying processing method for improving the precision of tobacco leaf module formulations provided by the present invention;

[0053] Figure 2 This is a schematic diagram illustrating the technical principle of an embodiment of the tobacco leaf threshing and re-drying processing method for improving the precision of tobacco leaf module formulations provided by the present invention.

[0054] Figure 3 A plan view showing the positional relationship between the feed conveyor belt, the consolidation conveyor belt, and the feed hopper;

[0055] Figure 4 A top view showing the positional relationship between the feed belt, the consolidation belt, and the feed hopper;

[0056] Figure 5 This is a schematic diagram of the feed conveyor belt structure;

[0057] Figure 6 This is a simplified structural diagram of the feed hopper;

[0058] Figure 7 This is a schematic diagram of the dynamic mixing device;

[0059] Figure 8 This is a simplified schematic diagram of the switch control mechanism.

[0060] Explanation of reference numerals in the attached drawings: 1-Conveyor platform; 2-Feed belt; 3-Collecting belt; 4-Feed hopper chute; 5-Feed hopper; 6-Feeding point; 7-Replenishment point; 8-Electronic belt scale; 9-Feeding control system; 10-Display screen; 51-Feed hopper inlet; 52-Air jet device; 53-Fan; 54-Feed hopper outlet; 11-Material lifting conveyor belt; 12-Uniformity monitoring system; 13-Mixing hopper; 14-Mixing hopper chute; 15-Mixing hopper inlet; 16-Roller; 17-Roller drive mechanism; 18-Drive shaft; 19-Drive wheel; 20-Roller support; 21-Mixing hopper outlet; 22-Outlet switch control mechanism; 221-Switch drive mechanism; 222-Screw; 223-Threaded sleeve; 224-Valve; 225-Seal; 226-Valve cavity; 23-Mixing control system. Detailed Implementation

[0061] Various exemplary embodiments of the present disclosure will now be described in detail with reference to the accompanying drawings. The descriptions of the exemplary embodiments are merely illustrative and are in no way intended to limit the present disclosure or its application or use. The present disclosure may be implemented in many different forms and is not limited to the embodiments described herein. These embodiments are provided so that the present disclosure will be thorough and complete, and will fully express the scope of the disclosure to those skilled in the art. It should be noted that, unless specifically stated otherwise, the relative arrangement of components and steps, the composition of materials, numerical expressions, and values ​​set forth in these embodiments should be interpreted as exemplary only and not as limiting.

[0062] The terms “first,” “second,” and similar terms used in this disclosure do not indicate any order, quantity, or importance, but are merely used to distinguish different parts. Terms such as “including” or “contains” mean that the element preceding the term encompasses the element listed after it, and do not exclude the possibility of encompassing other elements as well. Terms such as “above” and “below” are used only to indicate relative positional relationships; when the absolute position of the described object changes, this relative positional relationship may also change accordingly.

[0063] In this disclosure, when a specific component is described as being located between a first component and a second component, an intermediary component may or may not be present between the specific component and the first or second component. When a specific component is described as connecting to other components, the specific component may be directly connected to the other components without having an intermediary component, or it may not be directly connected to the other components but may have an intermediary component.

[0064] All terms used in this disclosure (including technical or scientific terms) have the same meaning as understood by one of ordinary skill in the art to which this disclosure pertains, unless otherwise specifically defined. It should also be understood that terms defined in a general dictionary, such as a dictionary, should be interpreted as having a meaning consistent with their meaning in the context of the relevant art, and not as having an idealized or highly formalized meaning, unless expressly defined herein.

[0065] Techniques, methods, and equipment known to those skilled in the art may not be discussed in detail, but where appropriate, they should be considered part of the specification.

[0066] like Figures 1-2 As shown, this embodiment of the invention provides a method for improving the precision of tobacco leaf module formulation through threshing and re-drying. This method is based on a threshing and re-drying system for improving the precision of tobacco leaf module formulation, such as... Figures 3-8 As shown, a tobacco leaf re-drying processing system for improving the precision of tobacco leaf module formulation includes: a conveyor table 1, on which multiple feeding belts 2 and a collection belt 3 are arranged. Each feeding belt 2 is used to receive tobacco leaf materials of different grades, and the collection belt 3 is used to collect the tobacco leaf materials on each feeding belt 2. The feeding belts 2 are arranged in parallel, and the collection belt 3 is perpendicular to each feeding belt 2. A feeding chute 4 is arranged at the end of the collection belt 3 along an inclined direction, and the end of the feeding chute 4 is connected to a feeding bin 5. A material lifting conveyor belt 11 is arranged at the rear end of the feeding bin 5. A uniformity monitoring system 12 is installed at one end for real-time monitoring of material processing data. A mixing chamber 13 is connected to the end of the material lifting conveyor belt 11. The mixing chamber 13 includes a rotatable roller 16 arranged in an inclined direction. A mixing chamber inlet 15 and a mixing chamber outlet 21 are respectively provided at both ends of the roller 16. An outlet switch control mechanism 22 is provided between the roller 16 and the mixing chamber outlet 21 for controlling the opening and closing of the mixing chamber outlet 21. The outlet switch control mechanism 22 is connected to a mixing control system 23, which is also connected to the uniformity monitoring system 12.

[0067] Among them, such as Figure 5As shown, each of the feeding belts 2 has multiple feeding points 6 and a replenishing point 7 distributed on it; the replenishing point 7 is located downstream of each feeding point 6 along the material conveying direction; each feeding point 6 and the replenishing point 7 is equipped with an independent electronic belt scale 8 for measuring the amount of material fed; a display screen 10 is provided above the replenishing point 7.

[0068] Furthermore, the electronic belt scale 8 and the display screen 10 corresponding to each of the feeding points 6 are connected to a feeding control system 9.

[0069] Furthermore, such as Figure 6 As shown, the feeding bin 5 includes a feeding inlet 51 located at the top of the feeding bin 5 and a feeding outlet 54 located at the bottom of the feeding bin 5. An air spray device 52 is provided inside the feeding bin 5. The air spray device 52 includes air pipes arranged vertically on both sides of the inner wall of the feeding bin 5. Multiple air mixing nozzles are provided on the air pipes. The air pipes are connected to a blower 53.

[0070] Furthermore, the mixing control system 23 is used to: obtain the online evaluation result of material homogenization based on the tobacco material processing data collected by the homogenization monitoring system 12; dynamically adjust the mixing time of the material based on the online evaluation result of material homogenization; and control the working state of the discharge port switch control mechanism 22 based on the dynamic adjustment result of the material mixing time, control the opening and closing of the discharge port 21 of the mixing chamber, thereby adjusting the mixing time.

[0071] Furthermore, such as Figure 7 As shown, the roller 16 is mounted on the roller support 20; a drive shaft 18 is provided between the roller 16 and the roller support 20, and multiple drive wheels 19 are sleeved on the drive shaft 18, each of the drive wheels 19 contacting the roller 16; the drive shaft 18 is connected to a roller drive mechanism 17, which drives the drive shaft 18 to rotate. The roller drive mechanism 17 transmits power to the drive shaft 18, which drives the drive wheels 19 to rub against the roller 16, causing the roller 16 to rotate, tumbling, scattering, and stirring the tobacco material in the roller 16 to achieve complete mixing of the material.

[0072] Furthermore, such as Figure 8As shown, the discharge port control mechanism 22 includes a valve 224 disposed inside the discharge port 21 of the mixing chamber. A valve cavity 226 is provided at the top of the valve 224, and a switch drive mechanism 221 is disposed at the top of the valve cavity 226. A lead screw 222 and a threaded sleeve 223 are arranged from top to bottom inside the valve cavity 226. The outer diameter of the valve 224 matches the inner diameter of the discharge port 21 of the mixing chamber. Specifically, the lead screw 222 is disposed at the lower end of the switch drive mechanism 221, and the outer wall of the lead screw 222 is threadedly connected to the inner wall of the threaded sleeve 223. The threaded sleeve 223 is welded to the top of the valve 224. The control principle of the discharge port switch control mechanism 22 is that the switch drive mechanism 221 drives the lead screw 222 to rotate, and the lead screw 222 is threadedly connected to the threaded sleeve 223 through its surface thread, thereby driving the valve 224 to rise or fall, thus controlling the opening and closing of the discharge port 21 of the mixing chamber. The valve chamber 226 provides space for the valve 224 to rise. In a specific implementation, when the switch drive mechanism 221 drives the lead screw 222 to rotate clockwise, the valve 224 rises from the medium channel into the valve chamber 226, and the mixing chamber outlet 21 is in the open state; when the switch drive mechanism 221 drives the lead screw 222 to rotate counterclockwise, the valve 224 descends from the valve chamber 226 into the medium channel, and the mixing chamber outlet 21 is in the closed state.

[0073] Furthermore, a sealing element 225 is provided between the valve 224 and the discharge port 21 of the mixing chamber, so that an effective seal can be formed between the valve 224 and the discharge port 21 of the mixing chamber through the sealing element 225.

[0074] like Figure 1 and Figure 2 As shown, the leaf threshing and re-drying processing method for improving the precision of tobacco module formulations provided in this embodiment specifically includes the following steps in actual implementation:

[0075] Step S1, Layered feeding: The different grades of tobacco raw materials in the formula are fed onto separate feeding belts 2.

[0076] In step S1, different grades of tobacco raw materials in the formula are fed through independent feeding belts. Each feeding belt 2 only transports raw materials of a single grade, ensuring the accuracy and consistency of raw material feeding. Specifically, in the layered feeding process, the number of feeding belts 2 is 10-20. In actual implementation, the number of feeding belts 2 in use can be selected according to the number of grades in the formula. Furthermore, the speed of each feeding belt 2 is kept consistent at 3m / min-10m / min, ensuring that materials of all grades fall simultaneously onto the collecting belt 3.

[0077] Step S2, Real-time control of feeding amount: Collect feeding amount data of each of the feeding belts 2 in real time, and adjust the feeding amount of each of the feeding belts 2 in real time according to the collected feeding amount data and the preset formula ratio.

[0078] The feeding belt 2 of this invention is equipped with a feeding control system 9, which connects to the electronic belt scales 8 of each feeding belt 2 and a display screen 10 located above the replenishment points 7. During the feeding process, the electronic belt scales 8 at the feeding points 6 collect real-time data on the amount of tobacco leaves fed to each grade, and transmit this data to the control system 9. Based on the collected data and the built-in preset formula ratio, the feeding control system 9 quickly analyzes the difference between the actual feeding ratio and the target formula ratio for each grade of tobacco leaves, automatically calculates the required replenishment weight for each grade of tobacco leaves, and synchronizes the replenishment weight data to the display screen 10. Based on the information displayed on the display screen 10, the operator performs precise replenishment at the replenishment points 7, ensuring that the raw material ratio meets production requirements within each feeding cycle, significantly improving the accuracy of tobacco leaf feeding and the stability of production quality.

[0079] In one embodiment of the tobacco leaf layered proportioning feeding method of the present invention, step S2 may specifically include:

[0080] Step S21: During the feeding process, the feeding amount data of each grade of tobacco leaf is collected in real time by the electronic belt scale 8 installed on each of the feeding belts 2, and the feeding amount data is sent to the feeding control system 9 for aggregation. Let there be n grades of tobacco leaves in the formula, and the total feeding amount of the i-th grade of tobacco leaves is denoted as x. i .

[0081] The feeding control system 9 includes a PLC controller. It should be noted that the present invention does not specifically limit the type and model of the feeding control system 9.

[0082] Step S22: The feeding control system 9 collects data on the feeding amount of tobacco leaves of each grade and calculates the maximum formula feeding base for a single feeding cycle.

[0083] Specifically, in conjunction with the target proportion p of the tobacco leaf formulation i Based on the principle of the long-board theory, the maximum feed base T for a single feeding cycle is calculated using the following formula: T = .

[0084] Step S23: Calculate the required supplementary weight of each grade of tobacco leaves and synchronize the supplementary weight data to the display screen 10 of each of the corresponding feed belts 2.

[0085] Specifically, in step S23, the supplementary weight y of the i-th grade tobacco leaf is calculated using the following formula. i :

[0086] yi = .

[0087] Step S24: At each of the feed belt 2, add weight according to the weight display on the display screen 10.

[0088] Specifically, each of the feeding belts 2 has multiple feeding points 6 and one replenishing point 7. The number of feeding points 6 corresponding to each feeding belt 2 is 5-10. The replenishing point 7 is located downstream of each feeding point 6 along the material conveying direction. It should be noted that the present invention does not specifically limit the number and distribution of feeding points 6.

[0089] Furthermore, each of the feeding points 6 and the replenishment points 7 of the feeding belts 2 is equipped with an electronic belt scale 8 for real-time and accurate measurement of the amount of material fed at one time.

[0090] Furthermore, the display screen 10 of each of the feed belts 2 is positioned above the corresponding weight replenishment point 7, making it convenient for the weight replenishment operator to view.

[0091] Step S3, Initial mixing in the silo: Materials of each grade fall into the collection belt 3 through the corresponding feed belt 2, and are then transported to the feed silo 5 through the collection belt 3.

[0092] In step S3, the speed of the summing belt 3 is not lower than the speed of the feeding belt 2, and the speed of the summing belt 3 is set to 10m / min-15m / min. In one embodiment of the tobacco leaf stratified feeding method of the present invention, step S3 may specifically include:

[0093] Step S31: The tobacco material on the summing belt 3 falls into the feeding bin 5 via the feeding bin chute 4.

[0094] Specifically, the tobacco material on the conveyor belt 3 falls into the feed inlet 51 of the feed hopper via the feed chute 4.

[0095] Step S32: After the material falls into the feed hopper 5, the tobacco material entering the feed hopper 5 is dispersed by the air spray device 52 installed in the feed hopper 5.

[0096] An air-spraying device 52 installed inside the feeding hopper 5 disperses the tobacco leaves entering the hopper 5, facilitating thorough mixing of tobacco leaves of different grades. Air-mixing nozzles are distributed on both sides of the inner wall of the feeding hopper 5. When the material falls into the feeding hopper 5, the air-mixing nozzles disperse the incoming tobacco leaves, promoting thorough mixing of tobacco leaves of different grades. A blower 53 provides airflow to the air-spraying device 52, and the tobacco leaves exit the feeding hopper through the discharge port 54.

[0097] Step S4: Real-time monitoring of material processing data: When the tobacco leaf material being processed online passes through the tobacco leaf material lifting conveyor belt 11 at the rear end of the feed hopper 5, the processing data of the material is monitored in real time.

[0098] In step S4, as the tobacco leaf material being processed online passes through the tobacco leaf material lifting conveyor belt 11, the processing data of the material is monitored in real time by the uniformity monitoring system 12. The uniformity monitoring system 12 includes a sensor assembly on one side of the end of the material lifting conveyor belt 11, and the sensor assembly is a near-infrared sensor. Specifically, the near-infrared sensor scans the chemical composition data of the tobacco leaf material. The near-infrared sensor is set to extract data every 5-10 minutes, for a total of n sets of data.

[0099] Furthermore, in some embodiments of the present invention, steps such as leaf moistening, leaf blowing and air separation, and impurity removal are also included between steps S3 and S4.

[0100] Step S5, Online Homogenization Evaluation: Based on the monitoring results of material processing data, conduct an online evaluation of material homogenization.

[0101] In step S5, after receiving the data collected by the uniformity monitoring system 12, the mixing control system 23 performs data processing and calculation according to a preset algorithm within the mixing control system 23, thereby evaluating the uniformity of the online material. In one embodiment of the tobacco leaf stratified proportioning feeding method of the present invention, step S5 may specifically include:

[0102] Step S51: The sensor assembly on one side of the end of the material lifting conveyor belt 11 sends the collected tobacco material processing data to the mixing control system 23.

[0103] Step S52: After receiving the material processing data, the mixing control system 23 performs pre-screening on the collected data and obtains a total of m chemical indicators. The pre-screening includes: selecting k chemical indicators from the m chemical indicators as core indicators for uniformity evaluation based on a preset core indicator screening method.

[0104] Among them, chemical indicators can include conventional chemical components, pH, petroleum ether extracts, organic acids, amino acids, and aroma substances.

[0105] Step S53: The hybrid control system sorts the selected core indicator data in ascending order of indicator value, and calculates the uniformity coefficient of each core indicator using the following formula:

[0106] G x = ,

[0107] Where n represents the number of data sets extracted, x iThis represents the i-th set of data for the core indicator x.

[0108] Step S54: Calculate the overall uniformity coefficient G of the tobacco using the following formula:

[0109] G= ,

[0110] Among them, the closer the overall uniformity coefficient is to 0, the smaller the degree of differentiation of tobacco sheets and the higher the degree of homogenization.

[0111] The overall uniformity coefficient is between 0 and 0.05, indicating that the degree of homogenization is within an acceptable range.

[0112] Step S55: The hybrid control system uses a built-in standard database and variance analysis to screen out indicators that have significant differences among samples with different homogeneity, and automatically uses the screened indicators as core indicators. The standard database includes sample data with known homogeneity states.

[0113] The chemical indicators include: conventional chemical components, pH, petroleum ether extract, organic acids, amino acids, and aroma substances.

[0114] Step S6: Dynamically adjust homogenization process parameters: Based on the online evaluation results of material homogenization, dynamically adjust the mixing time of the materials.

[0115] In step S6, the homogenization evaluation result of the tobacco material from step S5 is fed back to the mixing control system 23 in real time, so that the mixing control system 23 can dynamically adjust the mixing time of the material to ensure that the homogenization of the tobacco material meets the requirements. In this invention, the mixing control system 23 dynamically adjusts the mixing time of the material based on the online homogenization evaluation result. Specifically, if G > 0.05, the mixing time is set to 10 min-15 min; if G < 0.05, the mixing time is set to 5 min-10 min.

[0116] Step S7, Feeding and Dynamic Mixing: The material is sent to the mixing chamber 13 via the material lifting conveyor belt 11. Under the rotation of the mixing chamber 13, the material is driven to make a circular motion so that the material is fully loosened and mixed.

[0117] In one embodiment of the tobacco leaf re-drying processing method for improving the precision of tobacco leaf module formulation of the present invention, step S7 may specifically include:

[0118] Step S71: The material arrives at the mixing chamber 13 via the material lifting conveyor belt 11. The material enters the mixing chamber inlet 15 via the mixing chamber chute 14 and then enters the drum 16 from the mixing chamber inlet 15. Under the rotation of the drum 16, the material is fully stirred, turned and conveyed, which promotes the material to be fully loosened and mixed.

[0119] Step S72: At the discharge port 21 of the mixing chamber, the mixing control system 23 controls the working state of the discharge port switch control mechanism 22 based on the dynamic adjustment result of the material mixing time, controls the opening and closing of the discharge port 21 of the mixing chamber, and thus regulates the mixing time.

[0120] The discharge port switch control mechanism 22 of the mixing chamber 13 is connected to the mixing control system 23. The mixing control system 23 sends a control signal to the discharge port switch control mechanism 22 to realize the timed opening and closing of the discharge port 21 of the mixing chamber, thereby regulating the mixing time and enabling precise mixing according to the set time. The discharge port switch control mechanism 22 is a gate valve.

[0121] In one embodiment of the present invention, a certain raw tobacco module A is used as the test material, and the formulation ratio of each grade of tobacco leaves in A is shown in Table 1.

[0122] Table 1 Recipe Table for Module A

[0123]

[0124] The method provided by this invention involves feeding and processing module A, specifically including the following steps:

[0125] (1) Layered feeding. Five feeding belts are activated according to the formula table, and the five grades of tobacco raw materials are fed through independent feeding belts. The feeding belt speed is set at 5m / min.

[0126] (2) Real-time control of feeding amount.

[0127] ① During a single feeding, the electronic belt scale on the feeding conveyor collects the amount of tobacco leaves fed in a single grade in real time, and the feeding control system summarizes the total amount of tobacco leaves fed for each grade. The total amount of tobacco leaves fed in a single feeding on each feeding conveyor is shown in Table 2.

[0128] Table 2 Total feed rate per feed belt

[0129]

[0130] ②Based on Tobacco Leaf Formula Table 1, and following the principle of the long-board theory, obtain the maximum formula feed base T for a single feeding cycle. The calculated maximum feed amount is 8 kg.

[0131] ③ Obtain the target feed amount based on the maximum formula feed amount, and calculate the supplementary weight y of each grade of tobacco leaves by comparing it with the actual feed amount. i = See Table 3 for details. Simultaneously, the weight replenishment information for each level will be displayed on the screens of each feed belt.

[0132] Table 3. Single replenishment weight of tobacco leaves of different grades

[0133]

[0134] ④ Operators should add weight to the corresponding key points according to the prompts on the display screen.

[0135] (3) Initial mixing in the silo. Materials of each grade fall into the collection belt via the feed belt and are transported to the feed silo, where the incoming tobacco materials are dispersed and mixed. The speed of the collection belt is set at 10 m / min.

[0136] (4) Real-time monitoring of material processing data: After the tobacco leaf material in step (3) undergoes the leaf moistening and stem separation processes, the chemical composition data of the material is scanned in real time by the uniformity monitoring system 12 above the material lifting conveyor belt 11. The sensor is set to extract data once every 10 minutes, for a total of 20 sets of data. The collected data is transmitted to the mixing control system 23.

[0137] (5) Online evaluation of homogenization: After receiving the data, the dynamic mixing control system 23 pre-screens the data and automatically selects the sugar-alkali ratio and nitrogen-alkali ratio, which have a significant impact on the uniformity of tobacco leaves in the region, as core indicators for uniformity evaluation by calling the standard database of raw materials in the region and using the variance analysis method; the data collection status of the two core indicators is shown in Table 1. The uniformity coefficients of the core indicators are calculated by the preset uniformity algorithm, and the uniformity coefficients of sugar-alkali ratio and nitrogen-alkali ratio are 0.068 and 0.073, respectively. The comprehensive uniformity coefficient of tobacco leaves is calculated to be 0.071.

[0138] Table 4 Data Collection Status of Core Evaluation Indicators

[0139]

[0140] (6) Dynamically adjust homogenization process parameters: The homogenization evaluation results of tobacco materials in step (5) are fed back to the mixing control system 23 in real time. The mixing control system 23 controls the timed opening and closing of the valve 224 of the mixing chamber outlet 21 of the drum 16 by sending control signals to the outlet switch control mechanism 22 at regular intervals. The mixing time is set at 15 min.

[0141] (7) Feeding and dynamic mixing: The material is fed to the mixing chamber 13. Under the rotation of the roller 16 in the mixing chamber 13, the material is driven to make a circular motion, which promotes the material to be fully loosened and mixed.

[0142] Meanwhile, the coefficient of variation of nicotine in the finished tobacco sheets was compared between the traditional leaf-laying method and the traditional method. The results are shown in Table 5.

[0143] Table 5 Evaluation results of mixing uniformity during the re-baking process in Module A

[0144]

[0145] As shown in Table 4, compared with the traditional leaf-laying technology, the nicotine variation coefficient of the finished tobacco obtained by the method of the present invention is reduced by 6.42 percentage points, which shows a significant improvement in processing uniformity.

[0146] The method and system for improving the precision of tobacco leaf module formulations provided in this invention, in terms of product quality assurance, effectively reduces proportioning errors and improves the integrity and accuracy of module formulations by controlling the proportioning precision at the source premixing stage. During processing, a monitoring system combined with a dynamic mixing control system enables real-time optimization of mixing process parameters, ensuring that the product processing quality consistently meets requirements and significantly improving the quality stability and consistency of threshed and re-dried products. Simultaneously, it integrates multiple technologies such as layered material distribution, online monitoring, and dynamic control to construct a "source-process-control" technical flow, providing technical support for intelligent management of threshing and re-drying.

[0147] The embodiments of this disclosure have now been described in detail. To avoid obscuring the concept of this disclosure, some details known in the art have not been described. Those skilled in the art can fully understand how to implement the technical solutions disclosed herein based on the above description.

[0148] While specific embodiments of this disclosure have been described in detail by way of examples, those skilled in the art should understand that the examples are for illustrative purposes only and not intended to limit the scope of this disclosure. Those skilled in the art should understand that modifications can be made to the above embodiments or equivalent substitutions can be made to some technical features without departing from the scope and spirit of this disclosure. The scope of this disclosure is defined by the appended claims.

Claims

1. A method for improving the precision of tobacco leaf module formulation through leaf threshing and re-drying, characterized in that, include: Layered feeding: Different grades of tobacco leaves in the formula are fed onto separate feeding conveyor belts; Real-time control of feeding amount: The feeding amount data of each feeding belt is collected in real time, and the feeding amount of each feeding belt is controlled in real time according to the collected feeding amount data and the preset formula ratio. Initial mixing in the silo: Materials of each grade fall into the collection belt through the corresponding feed belt, and are then transported to the feed silo by the collection belt; Real-time monitoring of material processing data: When the tobacco leaf material being processed online passes through the tobacco leaf material lifting conveyor belt at the rear end of the feeding hopper, the processing data of the material is monitored in real time. Online homogenization evaluation: Based on the monitoring results of material processing data, the homogenization of the material is evaluated online. Dynamically adjust homogenization process parameters: dynamically adjust the mixing time of materials based on the online evaluation results of material homogenization; Feeding and dynamic mixing: The material is sent to the mixing chamber by the material lifting conveyor belt. Under the rotation of the mixing chamber, the material is driven to make a circular motion so that the material is fully loosened and mixed.

2. The method for improving the precision of tobacco leaf module formulation by threshing and re-drying according to claim 1, characterized in that, In the layered feeding process, the number of feeding belts is 10-20, and the speed of each feeding belt is consistent, which is 3m / min-10m / min.

3. The method for improving the precision of tobacco leaf module formulation by threshing and re-drying according to claim 1, characterized in that, The real-time control of the feeding amount includes: Step S21: During the feeding process, the feeding amount data of single-grade tobacco leaves is collected in real time by electronic belt scales set at each feeding point of each feeding belt, and the feeding amount data is sent to the feeding control system for aggregation. Let there be n grades of tobacco leaves in the formula, and the total feeding amount of the i-th grade of tobacco leaves is denoted as x. i The feeding control system includes a PLC controller; each feeding belt has multiple feeding points and one replenishment point, with 5-10 feeding points corresponding to each feeding belt; the replenishment point is located downstream of each feeding point along the material conveying direction; an electronic belt scale is installed below each feeding point and the replenishment point on each feeding belt; a display screen of each feeding belt is installed above the corresponding replenishment point; the electronic belt scale and the display screen corresponding to each feeding point are connected to the feeding control system. Step S22: The feeding control system collects data on the feeding amount of each grade of tobacco leaves and calculates the maximum formula feeding base for a single feeding cycle. Specifically, this includes: combining the target proportion of the tobacco leaf formula. Based on the principle of the long-board theory, the maximum feed base T for a single feeding cycle is calculated using the following formula: T= ； Step S23: Calculate the required supplementary weight for each grade of tobacco leaf and synchronize the supplementary weight data to the display screens of the corresponding feed belts. Calculate the supplementary weight y for the i-th grade of tobacco leaf using the following formula. i : y i = ； Step S24: At each of the feed belts, perform weight replenishment according to the weight replenishment results displayed on the screen.

4. The method for improving the precision of tobacco leaf module formulation by threshing and re-drying according to claim 1, characterized in that, In the initial mixing process in the silo, the speed of the summing belt is not lower than the speed of the feed belt, and the speed of the summing belt is set to 10m / min-15m / min; The initial mixing in the bin includes: The tobacco material on the conveyor belt falls into the feed hopper via a chute. After the material falls into the feeding hopper, the tobacco material entering the feeding hopper is dispersed by an air spray device installed in the feeding hopper.

5. The method for improving the precision of tobacco leaf module formulation by threshing and re-drying according to claim 1, characterized in that, The real-time monitoring of material processing data includes: As the tobacco leaf material being processed online passes through the tobacco leaf material lifting conveyor belt at the rear end of the feed hopper, the processing data of the material is monitored in real time by a uniformity monitoring system. This uniformity monitoring system includes a sensor assembly on one side of the end of the material lifting conveyor belt, and the sensor assembly includes a near-infrared sensor, specifically comprising: The chemical composition data of the tobacco material is scanned by a near-infrared sensor. The near-infrared sensor is set to extract data every 5-10 minutes, for a total of n sets of data.

6. The method for improving the precision of tobacco leaf module formulation by threshing and re-drying according to claim 1, characterized in that, The online homogenization evaluation: Based on the monitoring results of material processing data, an online homogenization evaluation of the material is performed, including: The sensor assembly at one end of the material lifting conveyor belt sends the collected tobacco material processing data to the mixing control system. After receiving material processing data, the mixing control system pre-screens the collected data and obtains a total of m chemical indicators. The pre-screening includes selecting k chemical indicators from the m chemical indicators as core indicators for uniformity evaluation based on a preset core indicator screening method. The hybrid control system sorts the selected core indicator data in ascending order of indicator value, and calculates the uniformity coefficient of each core indicator using the following formula: G x = ， Where n represents the number of data sets extracted, x i This represents the i-th set of data for the core indicator x; The overall uniformity coefficient G of tobacco sheets is calculated using the following formula: G= ； The hybrid control system uses a built-in standard database and analysis of variance to screen out indicators that show significant differences among samples with different homogeneity. The screened indicators are then automatically used as core indicators. The standard database includes sample data with known homogeneity states.

7. The method for improving the precision of tobacco leaf module formulation by threshing and re-drying according to claim 1, characterized in that, The dynamic adjustment of homogenization process parameters includes: The mixing control system dynamically adjusts the mixing time of materials based on the online evaluation results of material homogenization, specifically including: If G > 0.05, set the mixing time to 10 min - 15 min; if G < 0.05, set the mixing time to 5 min - 10 min.

8. The method for improving the precision of tobacco leaf module formulation by threshing and re-drying according to claim 1, characterized in that, The feeding and dynamic mixing process involves the material being conveyed to the mixing chamber via a material lifting conveyor belt. The rotation of the mixing chamber causes the material to move in a circular motion, ensuring thorough loosening and mixing. This includes: The material is conveyed to the mixing bin by the material lifting conveyor belt. The material enters the mixing bin inlet through the mixing bin chute and then enters the drum from the mixing bin inlet. Under the rotation of the drum, the material is fully stirred, turned and conveyed, which promotes the material to be fully loosened and mixed. At the discharge port of the mixing chamber, the mixing control system controls the opening and closing of the discharge port of the mixing chamber based on the dynamic adjustment results of the material mixing time by controlling the working state of the discharge port switch control mechanism, thereby regulating the mixing time.

9. A leaf-pounding and re-drying processing system for improving the precision of tobacco leaf module formulation using the method described in any one of claims 1-8, characterized in that, include: The conveyor platform is equipped with multiple feeding belts and a collection belt. Each feeding belt receives tobacco leaf materials of different grades, and the collection belt collects the tobacco leaf materials from each feeding belt. A feeding chute is inclined at the end of each collection belt, and a feeding hopper is connected to the end of the feeding chute. A material lifting conveyor belt is located at the rear end of the feeding hopper, and a uniformity monitoring system is installed on one side of the end of the material lifting conveyor belt to monitor the processing data of the material in real time. A mixing chamber is connected to the end of the material lifting conveyor belt. The mixing chamber includes a rotatable roller inclined in the direction of inclination. A mixing chamber inlet and a mixing chamber outlet are respectively located at both ends of the roller. An outlet switch control mechanism is installed between the roller and the mixing chamber outlet to control the opening and closing of the mixing chamber outlet. The outlet switch control mechanism is connected to a mixing control system, which is also connected to the uniformity monitoring system.

10. The tobacco leaf threshing and re-drying processing system for improving the precision of tobacco leaf module formulation according to claim 9, characterized in that, Each of the feeding belts has multiple feeding points and one replenishment point; the replenishment point is located downstream of each feeding point along the material conveying direction; each feeding point and the replenishment point is equipped with an independent electronic belt scale for measuring the amount of material fed; a display screen is installed above the replenishment point. Each of the aforementioned feeding points is connected to a feeding control system via an electronic belt scale and a display screen. The feeding hopper includes a feeding inlet at the top of the feeding hopper and a feeding outlet at the bottom of the feeding hopper. An air spraying device is installed inside the feeding hopper. The air spraying device includes air pipes arranged vertically on both sides of the inner wall of the feeding hopper. Multiple air mixing nozzles are installed on the air pipes. The air pipes are connected to a fan. The mixing control system is used to: obtain online evaluation results of material homogenization based on the tobacco material processing data collected by the homogenization monitoring system; and dynamically adjust the mixing time of the material based on the online evaluation results of material homogenization. Based on the dynamic adjustment results of material mixing time, the working state of the discharge port switch control mechanism is controlled to control the opening and closing of the discharge port of the mixing chamber, thereby regulating the mixing time; The roller is mounted on a roller support; a drive shaft is provided between the roller and the roller support, and multiple drive wheels are sleeved on the drive shaft, each drive wheel contacting the roller; the drive shaft is connected to a roller drive mechanism for driving the drive shaft to rotate. The discharge port control mechanism includes a valve disposed inside the discharge port of the mixing chamber. A valve cavity is located at the top of the valve, and a switch drive mechanism is located at the top of the valve cavity. A lead screw and a threaded sleeve are arranged from top to bottom inside the valve cavity. The lead screw is located at the lower end of the switch drive mechanism, and its outer wall is threadedly connected to the inner wall of the threaded sleeve. The threaded sleeve is welded to the top of the valve. The outer diameter of the valve matches the inner diameter of the discharge port of the mixing chamber. A sealing element is provided between the valve and the discharge port of the mixing chamber.

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