Method and system for detecting abnormal slipping of electronic scale and electronic equipment

Abstract

The invention relates to the technical field of electronic scales, and discloses an electronic scale slip abnormity detection method and system and an electronic device.The feeding end of an electronic scale is provided with a metering pipe used for temporarily storing materials, and the metering pipe is provided with a first photoelectric detection device at the position of a discharging opening; the electronic scale slip anomaly detection method comprises the steps of obtaining real-time flow output by an electronic scale, and calculating instantaneous flow according to the real-time flow; detecting whether the first photoelectric detection device is shielded by the material or not, and starting timing when shielding is detected; and when the instantaneous flow is greater than a preset flow threshold value and the continuous shielding time of the first photoelectric detection device exceeds a first preset duration, determining that the electronic scale is in a slipping state. According to the method, the process stability of key procedures such as material adding and perfuming in the cigarette cut tobacco making process and the consistency of product quality are remarkably improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of electronic scales, and in particular to an electronic scale slip abnormality detection method and system and electronic equipment. BACKGROUND

[0002] In the production process of the tobacco industry, the processes of adding materials, adding flavors and blending are key links to determine the stability of tobacco flavor and the consistency of products. As the main metering equipment in the above core processes, the electronic belt scale bears the important function of accurately controlling the material conveying flow, and its metering accuracy is directly related to the accuracy of the subsequent auxiliary material addition ratio and the quality stability of the final product.

[0003] The existing electronic belt scale calculates the real-time flow and cumulative yield by collecting the material weight signal and the belt running speed signal in real time. However, in actual operation, when the tobacco material is accumulated and pressed at the metering pipe discharge port of the feeding end due to high humidity or poor flowability, a bottom blockage state is easily formed. At this time, the accumulated material continuously contacts the scale body belt, producing a constant pressure signal; at the same time, the belt is still running under the drive of the motor, and the speed pulse signal is normally output. The real-time flow calculated by the control unit is seemingly normal, but in fact no new effective material is transported to the subsequent work station, resulting in a false feeding state of the system, which seriously affects the real controllability of the process and the consistency of product quality. SUMMARY

[0004] Therefore, the electronic scale slip abnormality detection method and system and electronic equipment provided by the embodiments of the present application can effectively solve the problem of false flow of the electronic belt scale in the metering pipe discharge port due to material accumulation and blockage, which seriously affects the real controllability of the process and the consistency of product quality.

[0005] In a first aspect, the embodiments of the present application provide an electronic scale slip abnormality detection method, the feeding end of the electronic scale is provided with a metering pipe for temporarily storing materials, and the metering pipe is provided with a first photoelectric detection device at a discharge port position; The method comprises: obtaining the real-time flow output by the electronic scale, and calculating the instantaneous flow according to the real-time flow; detecting whether the first photoelectric detection device is blocked by the material, and starting timing when the blocking is detected; when the instantaneous flow is greater than a preset flow threshold, and the first photoelectric detection device is continuously blocked for more than a first preset time length, determining that the electronic scale is in a slip state.

[0006] In some embodiments, the high area of the metering pipe is provided with a second photoelectric detection device; The method further comprises: When the material entering the metering tube accumulates to the high position and shields the second photoelectric detection device, and the shielding state lasts for a second preset time length, a stop signal is generated to control the pre-sequence conveying device to stop feeding.

[0007] In some embodiments, the method further comprises: When the first photoelectric detection device is not shielded by the material, a start signal is generated to control the pre-sequence conveying device to start feeding.

[0008] In some embodiments, in the case where the slip state does not occur, the method further comprises: comparing the real-time flow with a set flow to obtain a flow deviation value; adjusting the rotation speed of the driving motor based on the flow deviation value, so that the real-time flow tends to be close to the set flow.

[0009] In some embodiments, the real-time flow is obtained according to a pressure signal and a speed pulse signal.

[0010] In some embodiments, after determining that the electronic scale is in the slip state, the method further comprises: generating a slip alarm information and displaying it by using a display interface.

[0011] In some embodiments, the first photoelectric detection device and the second photoelectric detection device are both photoelectric sensors.

[0012] In a second aspect, the embodiments of the present application provide an electronic scale slip abnormality detection system, a metering tube for temporarily storing material is arranged at the feeding end of the electronic scale, a first photoelectric detection device is arranged at the material falling port of the metering tube; the system comprises: an acquisition module, which acquires a real-time flow output by the electronic scale, and calculates an instantaneous flow according to the real-time flow; a detection module, which detects whether the first photoelectric detection device is shielded by the material, and starts timing when shielding is detected; a determination module, which determines that the electronic scale is in a slip state when the instantaneous flow is greater than a preset flow threshold value, and the time during which the first photoelectric detection device is continuously shielded exceeds a first preset time length.

[0013] In a third aspect, the embodiments of the present application provide an electronic device, which comprises a processor and a memory, the memory stores a computer program, and the processor is configured to execute the computer program to implement at least one electronic scale slip abnormality detection method described above.

[0014] The embodiments of the present application have the following beneficial effects: The feeding end of the electronic scale of the application is provided with a metering pipe for temporarily storing materials, and the metering pipe is provided with a first photoelectric detection device at the material falling port position. The electronic scale slip abnormality detection method of the application comprises the following steps: acquiring the real-time flow output by the electronic scale, and calculating the instantaneous flow according to the real-time flow; detecting whether the first photoelectric detection device is blocked by materials, and starting timing when the blocking is detected; when the instantaneous flow is greater than a preset flow threshold value, and the first photoelectric detection device is continuously blocked for more than a first preset time length, it is determined that the electronic scale is in a slip state. The application sets a first photoelectric detection device at the material falling port of the metering pipe at the feeding end of the electronic scale, and combines real-time monitoring of the instantaneous flow output by the electronic scale, to construct an intelligent judgment mechanism for material slip abnormality. When the material at the bottom of the metering pipe is blocked to continuously block the first photoelectric detection device, and the electronic scale continuously detects an instantaneous flow greater than a preset threshold value, the system determines that the belt is in a slip state, that is, the materials do not actually flow but the metering signal exists falsely. The application effectively identifies the hidden faults that are difficult to find by the traditional control unit, avoids the problem of out-of-control blending ratio caused by the inconsistency between the actual material conveying amount and the metering data, and significantly improves the process stability and product quality consistency of key processes such as material adding and flavor adding in the cigarette cut tobacco process. BRIEF DESCRIPTION OF DRAWINGS

[0015] In order to more clearly illustrate the technical solutions of the embodiments of the application, the following will briefly introduce the drawings needed to be used in the embodiments. It should be understood that the following drawings only show some of the embodiments of the application, and therefore should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can also be obtained without creative labor on the basis of these drawings.

[0016] Figure 1 A first flow diagram of the electronic scale slip abnormality detection method of the embodiment of the application is shown; Figure 2 A structural diagram of the electronic scale and the metering pipe of the embodiment of the application is shown; Figure 3 A structural diagram of the electronic scale slip abnormality detection system of the embodiment of the application is shown.

[0017] Main element symbol explanation: 10: belt; 20: idler; 30: weighing sensor; 40: metering pipe; 50: first photoelectric detection device; 60: second photoelectric detection device; 70: tobacco material; 80: belt speed sensor. DETAILED DESCRIPTION

[0018] The technical solutions in the embodiments of the application will be described clearly and completely in the following with reference to the drawings in the embodiments of the application. Obviously, the described embodiments are only some of the embodiments of the application, not all the embodiments.

[0019] The components of the application embodiments generally described and illustrated in the figures herein can be arranged and designed in a wide variety of different configurations. Therefore, the following detailed description of the embodiments of the application, as represented in the figures, is not intended to limit the scope of the application, but is merely representative of selected embodiments of the application. All other embodiments not explicitly described or shown herein are within the scope of the application.

[0020] Hereinafter, the terms "include", "have", and their conjugates, used in the various embodiments of the present application, merely indicate the presence of the features, numbers, steps, operations, elements, components, or combinations thereof, and do not exclude the possibility of the presence or addition of one or more other features, numbers, steps, operations, elements, components, or combinations thereof. Also, the terms "first", "second", "third", and the like, are used only to distinguish the description, and are not to be construed as designating or implying an order or sequence in their use, unless otherwise specified.

[0021] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which various embodiments of the present application belong. The terms, such as those defined in a generally used dictionary, are to be interpreted as having a meaning that is the same as or similar to the meaning in the context of relevant technology and will not be interpreted to an idealized or overly formal meaning unless clearly defined in various embodiments of the present application.

[0022] Some embodiments of the present application will be described below in detail with reference to the accompanying drawings. The following embodiments and features of the embodiments can be combined with each other, without conflict.

[0023] In view of the false flow caused by material accumulation and blockage at the metering tube 40 discharge port of the electronic belt scale in the prior art, which seriously affects the real controllability of the process and the consistency of the product quality, etc. The present application provides an electronic scale slip abnormality detection method, system and electronic device. The present application sets a first photoelectric detection device 50 at the metering tube 40 discharge port of the electronic scale feed end, and combines real-time monitoring of the instantaneous flow output by the electronic scale to construct an intelligent judgment mechanism for material slip abnormality. When the first photoelectric detection device 50 is continuously blocked due to material blockage at the bottom of the metering tube 40, and the electronic scale continuously detects an instantaneous flow greater than a preset threshold, the system determines that the belt 10 is in a slip state, i.e. the material is not actually flowing but the metering signal is falsely present. The present application effectively identifies the hidden faults that are difficult to find by the traditional control unit, avoids the problem of out-of-control blending ratio caused by the inconsistency between the actual material conveying amount and the metering data, and significantly improves the process stability and product quality consistency of key processes such as material addition and flavoring in the cigarette silk production process.

[0024] The electronic scale slip abnormality detection method will be described below in conjunction with some specific embodiments.

[0025] Exemplarily, the electronic scale slip abnormality detection method of the present application is applied to a tobacco silk production line, and can be executed by a segment control system in the silk production line or a control unit local to the electronic scale. The control unit can be a programmable logic controller, which realizes state monitoring and intelligent judgment of the material conveying process by running a preset program. Figure 2 The structure of the electronic scale and the metering tube 40 of the present application is shown in the schematic diagram. The electronic scale mainly includes a belt 10 carrying tobacco material 70, a carrier roller 20 supporting the belt 10, a weighing sensor 30 installed below the carrier roller 20, a belt speed sensor 80 composed of a rotary encoder for detecting the running speed of the belt 10, and an alternating current motor and a matching frequency converter for driving the belt 10 to operate. In the working process of the electronic scale, the weighing sensor 30 senses the weight of the material passing through the scale body in real time, and outputs a pressure signal proportional thereto. After being processed by an amplification circuit, the signal is converted into a voltage quantity, and then converted into a digital weight code through an A / D module; at the same time, the rotary encoder generates a periodic speed pulse signal with the rotation of the motor, and the control unit performs multiplication operation on the weight code and the speed pulse to obtain the material flow per unit time, i.e. the real-time flow.

[0026] The real-time flow is compared with the set flow to obtain a flow deviation value, and the rotational speed of the driving motor is adjusted based on the flow deviation value to make the real-time flow approach the set flow. Specifically, the control unit compares the real-time flow with a target flow set according to process requirements to obtain a flow deviation value, and generates an adjustment instruction based on the deviation value and outputs the adjustment instruction to the frequency converter to dynamically adjust the rotational speed of the driving motor, so that the actual material flow continuously approaches and stabilizes in the set flow range, ensuring that the subsequent processes such as material liquid spraying and essence adding are accurately controllable.

[0027] The feeding end of the electronic scale is provided with a metering pipe 40 for temporarily storing the material, which functions to maintain stable material supply and avoid material cutting or impact loading of the electronic scale due to uneven supply of the previous equipment. The metering pipe 40 is provided with a first photoelectric detection device 50 at the material dropping position, which is used to sense whether the material continuously drops. When the first photoelectric detection device 50 is not blocked by the material, it indicates that there is no material accumulation at the bottom of the metering pipe 40, and the metering pipe 40 is in a material shortage state. At this time, the control unit generates a start signal and sends it to the PLC of the previous conveying equipment through Ethernet communication to trigger the previous conveying equipment to start supplying material, i.e., to restart conveying the tobacco material 70, thereby ensuring continuous material supply in the subsequent production. This constitutes a typical material level linkage control mechanism, which not only ensures continuous material supply, but also prevents over-supply from causing blockage.

[0028] Further, according to actual application requirements, multiple photoelectric detection devices can be arranged at different height regions of the metering pipe 40 to form a hierarchical material level monitoring system. For example, a second photoelectric detection device 60 is arranged at a high position of the metering pipe 40. When the material entering the metering pipe 40 continuously accumulates and rises to the high position, blocking the second photoelectric detection device 60, and the blocking state lasts for a second preset time length, for example, 20 seconds, the control unit determines that the material is full, and immediately generates a stop signal to control the previous conveying equipment to stop supplying material, thereby avoiding the influence of material compaction on the smoothness of material dropping.

[0029] Demonstratively, the first photoelectric detection device 50 and the second photoelectric detection device 60 are both photoelectric sensors, which have good environmental adaptability and long-term operation stability, and are suitable for complex working conditions such as dust and humidity changes in the cigarette factory silk workshop.

[0030] Figure 1 A flowchart of an electronic scale slip abnormality detection method according to an embodiment of the present application is shown. Demonstratively, the detection method includes S101-S103: S101, acquiring the real-time flow output by the electronic scale, and calculating the instantaneous flow according to the real-time flow.

[0031] The real-time flow reflects the actual rate of current material conveying. The instantaneous flow is not a certain instantaneous limit value, but a real-time flow sampling result refreshed periodically by the control unit, which can be dynamically estimated by the difference between the real-time flows at two consecutive time points divided by the time interval in this process, for capturing short-term change trends.

[0032] The control unit obtains the change rate of the instantaneous flow by dividing the difference between the two real-time flows before and after the preset sampling time by the sampling time interval, or directly uses the latest real-time flow as the instantaneous flow for subsequent comparison and judgment. This data flow path completely relies on the existing control unit architecture, without the need to add new communication links.

[0033] S102, detecting whether the first photoelectric detection device 50 is blocked by the material, and starting the timing when the blockage is detected.

[0034] The control unit continuously scans the input point state of the first photoelectric detection device 50, and if it detects that the material enters the drop port and causes the light path to be interrupted, it triggers the timer to start accumulating time.

[0035] S103, when the instantaneous flow is greater than the preset flow threshold, and the time during which the first photoelectric detection device 50 is continuously blocked exceeds the first preset time length, it is determined that the electronic scale is in a slipping state.

[0036] The preset flow threshold is a judgment threshold for filtering small flow disturbances, for example, set to 50 kg per hour, to avoid false triggering of the alarm logic in the case of emptying or micro-residual of the scale body. The first preset time length is a time delay parameter set to exclude temporary blockage, for example, more than 20 seconds. Only when the blockage lasts more than this time length and at the same time meets the flow condition, it is determined as an abnormal working condition. These parameters can be configured through program variables, supporting flexible modification according to process adjustment in later period, enhancing the adaptability of the system.

[0037] The control unit continuously scans the input point state of the first photoelectric detection device 50, and if it detects that the material enters the drop port and causes the light path to be interrupted, it triggers the timer to start accumulating time, and if the blockage is removed during the way, the timer is automatically cleared; if the blockage persists, the timing continues to accumulate until the first preset time length is reached. This mechanism effectively avoids false judgments caused by material shaking or instantaneous contact, improving the judgment stability.

[0038] The control unit synchronously determines whether two conditions are met at the same time, i.e., the instantaneous flow is greater than the preset flow threshold and the time when the first photoelectric detection device 50 is continuously blocked exceeds the first preset time length. When both conditions are met, it is determined that the electronic scale is in a slipping state. Further, after the controller determines that the electronic scale is in a slipping state, the alarm flag bit is set, and corresponding slipping alarm information is generated and pushed to the display interface to display the electronic scale belt 10 slipping prompt information, reminding the operator to timely go to the scene to troubleshoot.

[0039] The embodiment constructs a low-invasion and high-reliability state recognition mechanism through consistency verification of the physical on-off state and the metering data. The technical effects are reflected in multiple aspects. First, the hidden fault that the material is not truly conveyed can be accurately identified under the appearance that the electric control system displays normal flow, which significantly improves the quality risk prevention and control capability. Second, the change from passive response to active early warning is realized, the dependence on manual inspection is reduced, and the autonomous decision-making level of the automatic system is improved. Third, the entire scheme is implemented based on existing sensors and control architecture, without the need to add complex hardware for deployment, and has good compatibility and promotion value. In addition, the mechanism can also be applied to other powder and particle material conveying scenes with similar slipping risks, such as re-drying lines, cut tobacco feeding, etc., to further enhance the universality and adaptability of the system.

[0040] As shown in Figure 3 Based on the method of the above embodiment, the embodiment provides an electronic scale slipping abnormality detection system. Demonstratively, the electronic scale slipping abnormality detection system 100 includes: An acquisition module 110 acquires the real-time flow output by the electronic scale and calculates the instantaneous flow according to the real-time flow; A detection module 120 detects whether the first photoelectric detection device 50 is blocked by the material, and starts timing when the blocking is detected; A determination module 130 determines that the electronic scale is in a slipping state when the instantaneous flow is greater than the preset flow threshold and the time when the first photoelectric detection device 50 is continuously blocked exceeds the first preset time length.

[0041] It can be understood that the system of the embodiment corresponds to the control method of the above embodiment, and the optional items in the above embodiment are also applicable to the embodiment, so they will not be described again here.

[0042] The application also provides an electronic device. Demonstratively, the electronic device includes a processor and a memory, wherein the memory stores a computer program, and the processor runs the computer program, so that the device executes the functions of each module in the above-mentioned electronic scale slipping abnormality detection method or the above-mentioned electronic scale slipping abnormality detection system.

[0043] The processor can be an integrated circuit chip with a processing capability of signals. The processor can be a general processor, including a central processing unit (CPU), a graphics processing unit (GPU), and a network processor (NP), a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA) or other programmable logic devices, a discrete gate or transistor logic device, a discrete hardware component, at least one of the above. The general processor can be a microprocessor or the processor can be any conventional processor, etc., which can implement or execute the disclosed methods, steps and logic block diagrams in the embodiments of the present application. Exemplarily, the processor is a programmable logic controller.

[0044] The memory can be, but is not limited to, a random access memory (RAM), a read only memory (ROM), a programmable read only memory (PROM), an erasable programmable read only memory (EPROM), an electric erasable programmable read only memory (EEPROM), etc. The memory is used to store a computer program. After receiving an execution instruction, the processor can execute the computer program accordingly.

[0045] The present application also provides a computer readable storage medium for storing the computer program used in the terminal device. For example, the computer readable storage medium can include, but is not limited to, a U disk, a mobile hard disk, a read only memory (ROM), a random access memory (RAM), a magnetic disk or an optical disk, and various media that can store program codes.

[0046] In several embodiments provided in the present application, it should be understood that the disclosed apparatus and method can also be implemented by other means. The apparatus embodiments described above are only illustrative, for example, the flowcharts and structural diagrams in the drawings show the possible implementation architecture, function and operation of the apparatus, method and computer program product according to the embodiments of the present application. In this regard, each block in the flowchart or block diagram can represent a module, a program segment or a part of code, which contains one or more executable instructions for implementing the specified logic function. It should also be noted that in alternative implementation, the functions noted in the block can also occur in different order from that noted in the drawings. For example, two consecutive blocks can actually be executed substantially in parallel, and sometimes they can be executed in reverse order, depending on the functions involved. It should also be noted that each block in the structural diagram and / or flowchart, and the combination of blocks in the structural diagram and / or flowchart, can be implemented by a dedicated hardware-based system for executing the specified function or action, or can be implemented by a combination of dedicated hardware and computer instructions.

[0047] In addition, each functional module or unit in the embodiments of the present application can be integrated together to form an independent part, or each module can exist independently, or two or more modules can be integrated to form an independent part.

[0048] If the functions are implemented in the form of software function modules and sold or used as independent products, they can be stored in a computer readable storage medium. Based on this understanding, the technical solutions of the present application can be embodied in the form of a software product, which is stored in a storage medium and includes a number of instructions for causing a computer device (which can be a smart phone, a personal computer, a server, or a network device, etc.) to execute all or part of the steps of the methods described in the embodiments of the present application.

[0049] The above describes only the specific implementation 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 in the present application, which should be covered within the protection scope of the present application.

Claims

1. An electronic scale slip abnormality detection method characterized by comprising: The feeding end of the electronic scale is provided with a metering pipe for temporarily storing materials, and the metering pipe is provided with a first photoelectric detection device at the position of a material falling port; The method comprises: acquiring real-time flow output by the electronic scale and calculating instantaneous flow according to the real-time flow; detecting whether the first photoelectric detection device is blocked by the materials or not and starting timing when the blocking is detected; determining that the electronic scale is in a slip state when the instantaneous flow is greater than a preset flow threshold and the first photoelectric detection device is continuously blocked for more than a first preset time length.

2. The electronic scale slip abnormality detection method according to claim 1, characterized by, The high area of the metering pipe is provided with a second photoelectric detection device; The method further comprises: generating a stop signal to control a previous conveying device to stop feeding when the materials entering the metering pipe accumulate to the high area and block the second photoelectric detection device and the blocking state lasts for more than a second preset time length.

3. The electronic scale slip abnormality detection method according to claim 2, characterized by, The method further comprises: generating a start signal to control the previous conveying device to start feeding when the first photoelectric detection device is not blocked by the materials.

4. The electronic scale slip abnormality detection method according to claim 1, characterized by, In the case where the slip state does not occur, the method further comprises: comparing the real-time flow with a set flow to obtain a flow deviation value; adjusting the rotating speed of a driving motor based on the flow deviation value so that the real-time flow tends to be close to the set flow.

5. The electronic scale slip abnormality detection method according to claim 1, wherein the real-time flow is obtained according to a pressure signal and a speed pulse signal.

6. The electronic scale slip abnormality detection method according to claim 1, characterized by, After determining that the electronic scale is in the slip state, the method further comprises: generating slip alarm information and displaying the information by using a display interface.

7. The electronic scale slip abnormality detection method according to claim 2, wherein the first photoelectric detection device and the second photoelectric detection device are both photoelectric sensors.

8. An electronic scale slip abnormality detection system characterized by comprising: The feeding end of the electronic scale is provided with a metering pipe for temporarily storing materials, and the metering pipe is provided with a first photoelectric detection device at the position of a material falling port; the system comprises: an acquisition module for acquiring real-time flow output by the electronic scale and calculating instantaneous flow according to the real-time flow; a detection module for detecting whether the first photoelectric detection device is blocked by the materials or not and starting timing when the blocking is detected; a determination module for determining that the electronic scale is in a slip state when the instantaneous flow is greater than a preset flow threshold and the first photoelectric detection device is continuously blocked for more than a first preset time length.

9. An electronic device, comprising: The electronic device comprises a processor and a memory, the memory stores a computer program, and the processor is used to execute the computer program to implement the electronic scale slip abnormality detection method according to any one of claims 1-7.

10. The electronic device of claim 9, wherein, The processor is a programmable logic controller.

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