Self-adaptive deviation correction system for double-channel cigarette paper and control method

Abstract

The system comprises a detection mechanism, a controller and a deviation correction execution mechanism, the detection mechanism is used for collecting images of the cigarette paper in the conveying process, the controller calculates the deviation value of the cigarette paper in the conveying process according to the collected images, and the deviation value of the cigarette paper in the conveying process is calculated according to the deviation value. And according to the deviation value, the axial adjustment amount of the cigarette paper guide block is iteratively calculated for multiple times through a self-adaptive step length gradient descent algorithm, the deviation correction execution mechanism drives the cigarette paper guide block to carry out axial position adjustment on the cigarette paper according to the received axial adjustment amount, redundant deviation correction is carried out if deviation correction is not successful every time, and an alarm is given if three times of deviation correction are not successful. According to the cigarette paper deviation correcting device, the cigarette paper deviation situation can be detected in real time in the cigarette paper conveying process, accurate deviation correcting is conducted on the cigarette paper, and therefore the dependence of the cigarette paper deviation correcting process on manpower can be reduced, an alarm is given in time to prevent defective products from flowing into the next procedure, and meanwhile the mechanical efficiency is improved.

Description

Technical Field

[0001] This invention belongs to the field of industrial automation control technology, specifically relating to an adaptive correction system and control method for dual-track cigarette paper. Background Technology

[0002] The ZJ-116 cigarette rolling machine is a commonly used model for cigarette rolling. During the cigarette rolling process, after the cigarette paper is unrolled, it is conveyed to the circular cutter via conveyor rollers. The circular cutter cuts the cigarette paper into two strips of equal width. The cut cigarette paper is then conveyed to the next process via the cigarette paper conveyor chute. During production, the position of the cigarette paper on the conveyor rollers may shift. If the position of the cigarette paper shifts before entering the circular cutter, it will result in inconsistent widths between the two strips of cigarette paper, ultimately affecting the quality of the finished cigarette.

[0003] After the circular cutter cuts the cigarette paper, the operator observes the gap between the edge of the cut cigarette paper and the inner wall of the conveyor chute to determine if the cigarette paper has shifted, and thus to determine if there is a width inconsistency between the two layers of cigarette paper. When the widths of the inner and outer layers of cigarette paper are inconsistent, the operator manually adjusts the axial position of the cigarette paper guide block by rotating the adjustment knob, relying on the internal thread structure. The cigarette paper guide block corrects the position of the cigarette paper, thereby ensuring that the widths of the inner and outer layers of cigarette paper are consistent.

[0004] The existing adjustment method has significant drawbacks: First, the process is severely delayed and repetitive, making it impossible to adjust the cigarette paper position in a timely manner; second, the adjustment process is highly dependent on the operator's experience, and manual operation makes it difficult to ensure the stability of the correction. Furthermore, manual inspection and adjustment are not only inefficient but also introduce additional labor costs and quality risks in mass production. Summary of the Invention

[0005] The purpose of this invention is to provide an adaptive correction system and control method for double-track cigarette paper, which aims to detect the deviation of cigarette paper in real time during the cigarette paper conveying process and to accurately correct the deviation of the cigarette paper, thereby reducing the dependence on manual labor in the cigarette paper correction process, ensuring product quality, and improving mechanical efficiency.

[0006] To achieve the above-mentioned objectives, the present invention adopts the following technical solution: The automatic correction system for double-track cigarette paper of the present invention is characterized by comprising: a detection mechanism, a controller, and a correction execution mechanism; The testing mechanism includes: a frame, a mounting frame, a binocular camera, and a cigarette paper conveying guide trough; The correction mechanism includes: cigarette paper guide block, guide roller assembly, servo motor, and circular cutter; A guide roller assembly is fixedly installed on one side of the bottom front of the frame. The guide roller assembly is covered with cigarette paper and is used to guide the conveying direction of the cigarette paper. The cigarette paper conveying guide groove is provided on the frame and downstream of the guide roller assembly for conveying the slit cigarette paper. A cigarette paper guide block is provided on the frame and upstream of the guide roller assembly; A circular cutter is provided between the cigarette paper guide block and the cigarette paper conveying guide groove; The mounting frame is provided on the frame and above the cigarette paper conveying guide groove, and the binocular camera is fixedly installed in the inner cavity of the mounting frame 2; When the cigarette rolling machine starts running, the controller controls the servo motor to drive the cigarette paper guide block to adjust its axial position, so as to adjust the axial position of the cigarette paper during the conveying process. The controller sends an optocoupler signal to the binocular camera to trigger the binocular camera to start acquiring images of cigarette paper in the cigarette paper conveying guide groove; The controller corrects the deviation of the cigarette paper conveying guide groove based on the cigarette paper image.

[0007] The automatic correction system for double-track cigarette paper described in this invention is characterized in that the binocular camera consists of two industrial cameras, which are symmetrically installed on both sides of the cigarette paper conveying guide groove and form a 45° angle with the surface of the cigarette paper in the cigarette paper conveying guide groove.

[0008] The control method of the automatic correction system based on the aforementioned double-track cigarette paper is characterized by correcting the cigarette paper conveying guide groove according to the following steps: S1, Define and initialize the number of corrections N=0; S2, the controller calculates the Nth deviation of the cigarette paper based on the currently acquired cigarette paper image. ,like If the threshold is exceeded, proceed to step S3; otherwise, return to S2. S3, the controller calculates the Nth adjustment amount of the cigarette paper guide block. This drives the servo motor to axially adjust the position of the cigarette paper guide block, thereby performing the Nth correction on the cigarette paper. S4, after the controller activates the binocular camera to acquire an image of the cigarette paper conveying guide trough after the Nth correction, it calculates the deviation of the cigarette paper after the Nth correction based on the image of the cigarette paper after the Nth correction. ,like If the threshold is exceeded, proceed to step S5; otherwise, return to S1. S5, the controller initiates the redundancy correction mode: calculates the adjustment amount for the Nth redundancy correction of the cigarette paper guide block. This drives the servo motor to adjust the position of the cigarette paper guide block axially, thereby performing the Nth redundant correction of the cigarette paper. S6, after the controller activates the binocular camera to acquire images of the cigarette paper conveying guide trough after the Nth redundant correction, it calculates the deviation of the cigarette paper after the Nth redundant correction. ,like If the threshold is exceeded, proceed to step S6; otherwise, return to S1. S7: Assign N+1 to N, check if N=Nmax is true. If true, indicate that the correction failed and issue an alarm; otherwise, return to S2.

[0009] The control method of the automatic correction system for double-track cigarette paper described in this invention is also characterized in that, in step S2, the calculation is performed according to the following steps. : S2.1, Denoise and radial distortion correction are performed on the currently acquired cigarette paper image, and the sub-pixel coordinates of the cigarette paper edge in the corrected left and right images are extracted using the dual-threshold adaptive Canny edge detection operator and the Sobel gradient direction interpolation algorithm. S2.2, Based on the sub-pixel coordinates of the cigarette paper edge from each viewpoint, a semi-global matching algorithm combined with edge line constraints is used to calculate the disparity of the corrected left and right images, obtaining the left and right gaps between the cigarette paper edge and the inner wall of the cigarette paper conveying guide 4, and taking the smaller value. As the Nth reference value; S2.3, will and target value By comparison, the deviation of the cigarette paper was obtained. .

[0010] Furthermore: In S3, the Nth adjustment amount of the cigarette paper guide block is calculated according to the following steps. : S3.1, Define and initialize the current iteration number k=1; define the maximum iteration number as K and the decay coefficient as... Randomly initialize the adjustment amount for the Nth iteration in the kth iteration. Randomly initialize the adjustment step size in the k-th iteration. ; S3.2, Establish and Feedback curves between And calculate the gradient of the Nth adjustment loss function in the kth iteration. ,in, These are constants defined by experience. S3.3, Calculate the adjustment step size in the (k+1)th iteration. ; S3.4, Calculate the Nth adjustment amount in the (k+1)th iteration. ; S3.5, when When, it means that the first time is obtained. The Nth adjustment amount in the next iteration And as Otherwise, assign k+1 to Then, return to S3.2.

[0011] Further: In the redundant correction mode, the adjustment step size when k=1 is... After halving the number of iterations and increasing the maximum number of iterations K, the process is executed according to S3.

[0012] Compared with the prior art, the beneficial effects of the present invention are as follows: 1. This invention uses a binocular camera to collect images of the cigarette paper conveying process in real time to judge the deviation of the cigarette paper. When the cigarette paper is deviated, it is adjusted in time. If the deviation persists after multiple adjustments, an alarm is triggered in time to prevent defective cigarettes from flowing into the next production stage.

[0013] 2. This invention calculates the precise adjustment amount through multiple iterations. The combination of correction and redundant correction steps accurately achieves the task of correcting the axial position of cigarette paper, thereby solving the drawback of unstable adjustment amount in the traditional manual correction mode that relies on work experience.

[0014] 3. This invention corrects the axial position of cigarette paper during the feeding process by using a correction actuator, which reduces the waste of mechanical efficiency caused by the need to stop the machine to make adjustments in the traditional manual correction mode.

[0015] 4. The present invention has a simple structure, stable operation, and requires little maintenance. Attached Figure Description

[0016] Figure 1 This is a flowchart of the adaptive correction method for double-track cigarette paper of the present invention; Figure 2 This is a flowchart illustrating the process of obtaining the deviation of cigarette paper in this invention. Figure 3 This is a flowchart of the adaptive step-size gradient descent algorithm of the present invention; Figure 4 This is a front view of the adaptive correction system for the double-track cigarette paper of the present invention. Figure 5 This is a schematic side view of the adaptive correction system for dual-track cigarette paper of the present invention.

[0017] The numbers in the diagram are: 1-frame, 2-mounting bracket, 3-binocular camera, 4-double-track cigarette paper conveying guide, 5-controller, 6-manual adjuster, 7-cigarette paper guide block, 8-guide roller assembly, 9-servo motor, 10-circular cutter. Detailed Implementation

[0018] In this embodiment, as Figure 4 and Figure 5 As shown, an automatic correction system for double-track cigarette paper includes: a detection mechanism, a controller, and a correction execution mechanism; The testing equipment includes: frame 1, mounting frame 2, binocular camera 3, and cigarette paper conveying guide 4; The correction mechanism includes: cigarette paper guide block 7, guide roller assembly 8, servo motor 9, and circular cutter 10.

[0019] A guide roller assembly 8 is fixedly installed on one side of the bottom front of the frame 1. Cigarette paper is wrapped around the guide roller assembly 8 to guide the conveying direction of the cigarette paper. The guide roller assembly 8 has a fixed rotation direction, and the cigarette paper is conveyed forward along the rotation direction of the guide roller assembly 8. A cigarette paper conveying guide trough 4 is provided on the frame 1 and downstream of the guide roller assembly 8 for conveying the slit cigarette paper; A cigarette paper guide block 7 is provided on the frame 1 and upstream of the guide roller assembly 8.

[0020] A circular cutter 10 is provided between the cigarette paper guide block 7 and the cigarette paper conveying guide groove 4. After passing through the circular cutter 10, the cigarette paper will be cut into two parts along the axis of the circular cutter. The cut cigarette paper continues to be conveyed forward through the conveying guide groove 4. If the position of the cigarette paper is offset, the width of the two cut cigarette papers cannot be equal, which will affect the quality of the cigarette. A mounting frame 2 is provided on the frame 1 and above the cigarette paper conveying guide 4. A binocular camera 3 is fixedly installed in the inner cavity of the mounting frame 2. The binocular camera 3 consists of two industrial cameras. The two industrial cameras are symmetrically installed on both sides of the cigarette paper conveying guide 4, forming a 45° angle with the cigarette paper plane, to ensure that the image acquisition area completely covers the cigarette paper conveying guide 4.

[0021] When the cigarette machine starts running, the controller 5 controls the servo motor 9 to drive the cigarette paper guide block 7 to adjust its axial position and push the cigarette paper inside the cigarette paper guide block 7 to adjust the axial position of the cigarette paper during the conveying process. When the cigarette machine starts running, the controller 5 sends an optocoupler signal to the binocular camera 3 to trigger the binocular camera 3 to start acquiring images of the cigarette paper in the cigarette paper conveying guide 4. The controller 5 calculates the deviation of the cigarette paper and the adjustment amount required to return the cigarette paper to the correct position based on the cigarette paper image, and outputs the adjustment amount to the servo motor 9. The servo motor 9 drives the cigarette paper guide block 7 to correct the deviation of the cigarette paper conveying guide groove 4.

[0022] In this embodiment, as Figure 1 and Figure 2 As shown, a control method for an automatic correction system for double-track cigarette paper involves correcting the cigarette paper conveying guide 4 according to the following steps: S1, Define and initialize the number of corrections N=0; S2, Controller 5 calculates the Nth deviation of the cigarette paper based on the currently acquired image of the cigarette paper. ,like If the threshold is exceeded (this threshold is set differently depending on the cigarette paper currently being used), then proceed to step S3; otherwise, return to S2. S2.1, Denoise and radial distortion correction are performed on the currently acquired cigarette paper image, and the sub-pixel coordinates of the cigarette paper edges in the corrected left and right images are extracted using the dual-threshold adaptive Canny edge detection operator and the Sobel gradient direction interpolation algorithm.

[0023] S2.2, Based on the sub-pixel coordinates of the cigarette paper edge from each viewpoint, a semi-global matching algorithm combined with edge line constraints is used to calculate the disparity of the corrected left and right images, obtaining the left and right gaps between the cigarette paper edge and the inner wall of the cigarette paper conveying guide 4, and taking the smaller value. As the Nth reference value, since the cigarette paper is wrapped around the guide roller assembly 8 during the conveying process, the slit cigarette paper will not overlap or separate during the conveying process. The deviation of the cigarette paper from the correct position can be reflected by comparing the left and right gaps between the edge of the cigarette paper and the inner wall of the cigarette paper conveying guide groove 4 with the threshold. S2.3, will and target value Compare (target values ​​vary depending on the specifications of the cigarette paper currently used) For different settings), the cigarette paper deviation is obtained. .

[0024] S3, Controller 5 calculates the Nth adjustment amount of the cigarette paper guide block 7. The servo motor 9 is used to axially adjust the position of the cigarette paper guide block 7, thereby performing the Nth correction on the cigarette paper.

[0025] In this embodiment, as Figure 3 The figure shows the Nth adjustment amount of the cigarette paper guide block 7 calculated according to the following steps. : S3.1, Define and initialize the current iteration count k=1; define the maximum iteration count as K, generally K=7, and the decay coefficient is... Under normal circumstances =0.95; Randomly initialize the Nth adjustment amount in the kth iteration. Randomly initialize the adjustment step size in the k-th iteration. ; S3.2, Establish and Feedback curves between And calculate the gradient of the Nth adjustment loss function in the kth iteration. ,in, As constants set by experience, they can be modified to different constants in the system depending on the specifications of the cigarette paper currently being used; S3.3, Calculate the adjustment step size in the (k+1)th iteration. ; S3.4, Calculate the Nth adjustment amount in the (k+1)th iteration. ; S3.5, when When, it means that the first time is obtained. The Nth adjustment amount in the next iteration And as Otherwise, assign k+1 to Then, return to S3.2.

[0026] S4, after the controller 5 activates the binocular camera 3 to acquire an image of the cigarette paper conveying guide trough 4 after the Nth correction, the deviation of the cigarette paper after the Nth correction is calculated based on the image of the cigarette paper after the Nth correction. ,like If the threshold is exceeded, proceed to step S5; otherwise, return to S1. S5, Controller 5 initiates redundant correction mode: Calculate the adjustment amount for the Nth redundant correction of the cigarette paper guide block 7. The position of the cigarette paper guide block 7 is adjusted axially by driving the servo motor 9, thereby performing the Nth redundant correction of the cigarette paper. In this embodiment, as Figure 3 As shown, in the redundant correction mode of the dual-track cigarette paper automatic correction system control method, the adjustment step size when k=1 is... Halve the number of iterations, increase the maximum number of iterations K (generally by doubling it), and then execute the process according to S3.

[0027] S6, after the controller 5 activates the binocular camera 3 to acquire images of the cigarette paper conveying guide trough 4 after the Nth redundant correction, it calculates the deviation of the cigarette paper after the Nth redundant correction. ,like If the threshold is exceeded, proceed to step S6; otherwise, return to S1.

[0028] The controller 5 stores target values ​​for the gap between the edge of the cigarette paper and the inner wall of the cigarette paper conveying guide 4 for different specifications of cigarette paper. and deviation As required, when the cigarette paper specifications are switched, the host computer sends a specification switching command to the controller 5. After receiving the command, the controller 5 automatically calls the parameters of the corresponding specification and updates the algorithm for obtaining the cigarette paper deviation and the adaptive step size gradient descent algorithm.

[0029] S7. Assign N+1 to N and check if N=Nmax is true. If true, prompt the correction failure and alarm. At this time, controller 5 controls the cigarette rolling equipment to stop running and displays the red alarm message "Cigarette paper offset" on the operation display screen, and switches to manual correction mode. Otherwise, return to S2.

Claims

1. An automatic correction system for double-track cigarette paper, characterized in that, include: Testing mechanism, controller (5), and correction actuator; The testing mechanism includes: a frame (1), a mounting frame (2), a binocular camera (3), and a cigarette paper conveying guide trough (4); The correction mechanism includes: cigarette paper guide block (7), guide roller assembly (8), servo motor (9), and circular cutter (10); A guide roller assembly (8) is fixedly installed on one side of the bottom front of the frame (1). The guide roller assembly (8) is covered with cigarette paper and is used to guide the conveying direction of the cigarette paper. The cigarette paper conveying guide groove (4) is provided on the frame (1) and downstream of the guide roller assembly (8) for conveying the slit cigarette paper; A cigarette paper guide block (7) is provided on the frame (1) and upstream of the guide roller assembly (8); A circular cutter (10) is provided between the cigarette paper guide block (7) and the cigarette paper conveying guide groove (4); The mounting frame (2) is provided on the frame (1) and above the cigarette paper conveying guide groove (4), and the binocular camera (3) is fixedly installed in the inner cavity of the mounting frame (2); When the cigarette machine starts running, the controller (5) controls the servo motor (9) to drive the cigarette paper guide block (7) to adjust its axial position so as to adjust the axial position of the cigarette paper during the conveying process; The controller (5) sends an optocoupler signal to the binocular camera (3) to trigger the binocular camera (3) to start acquiring images of cigarette paper in the cigarette paper conveying guide groove (4); The controller (5) corrects the deviation of the cigarette paper conveying guide groove (4) according to the cigarette paper image.

2. The automatic correction system for double-track cigarette paper according to claim 1, characterized in that, The binocular camera (3) consists of two industrial cameras and is symmetrically installed on both sides of the cigarette paper conveying guide groove (4), forming a 45° angle with the surface of the cigarette paper in the cigarette paper conveying guide groove (4).

3. A control method for an automatic correction system based on the double-track cigarette paper as described in claim 1, characterized in that, The cigarette paper conveying guide groove (4) is corrected according to the following steps: S1, Define and initialize the number of corrections N=0; S2, the controller (5) calculates the Nth deviation of the cigarette paper based on the currently acquired cigarette paper image. ,like If the threshold is exceeded, proceed to step S3; otherwise, return to S2. S3, the controller (5) calculates the Nth adjustment amount of the cigarette paper guide block (7). , so as to drive the servo motor (9) to adjust the position of the cigarette paper guide block (7) axially, thereby correcting the cigarette paper for the Nth time; S4, after the controller (5) activates the binocular camera (3) to acquire an image of the cigarette paper conveying guide trough (4) after the Nth correction, the deviation of the cigarette paper after the Nth correction is calculated based on the image of the cigarette paper after the Nth correction. ,like If the threshold is exceeded, proceed to step S5; otherwise, return to S1. S5, the controller (5) starts the redundancy correction mode: calculates the adjustment amount of the Nth redundancy correction of the cigarette paper guide block (7). The position of the cigarette paper guide block (7) is adjusted axially by driving the servo motor (9) to perform the Nth redundant correction on the cigarette paper. S6, after the controller (5) activates the binocular camera (3) to acquire images of the cigarette paper conveying guide trough (4) after the Nth redundant correction, it calculates the deviation of the cigarette paper after the Nth redundant correction. ,like If the threshold is exceeded, proceed to step S6; otherwise, return to S1. S7: Assign N+1 to N, check if N=Nmax is true. If true, indicate that the correction failed and issue an alarm; otherwise, return to S2.

4. The control method for the automatic correction system of double-track cigarette paper according to claim 2, characterized in that, S2 is calculated according to the following steps. : S2.1, Denoise and radial distortion correction are performed on the currently acquired cigarette paper image, and the sub-pixel coordinates of the cigarette paper edge in the corrected left and right images are extracted using the dual-threshold adaptive Canny edge detection operator and the Sobel gradient direction interpolation algorithm. S2.2, Based on the sub-pixel coordinates of the cigarette paper edge from each viewpoint, a semi-global matching algorithm combined with edge line constraints is used to calculate the disparity of the corrected left and right images, obtaining the left and right gaps between the cigarette paper edge and the inner wall of the cigarette paper conveying guide 4, and taking the smaller value. As the Nth reference value; S2.3, will and target value By comparison, the deviation of the cigarette paper was obtained. .

5. The control method for the automatic correction system of double-track cigarette paper according to claim 2, characterized in that: In S3, the Nth adjustment amount of the cigarette paper guide block (7) is calculated according to the following steps. : S3.1, Define and initialize the current iteration number k=1; define the maximum iteration number as K and the decay coefficient as... Randomly initialize the adjustment amount for the Nth iteration in the kth iteration. Randomly initialize the adjustment step size in the k-th iteration. ; S3.2, Establish and Feedback curves between And calculate the gradient of the Nth adjustment loss function under the kth iteration. ,in, These are constants defined by experience. S3.3, Calculate the adjustment step size in the (k+1)th iteration. ; S3.4, Calculate the Nth adjustment amount in the (k+1)th iteration. ; S3.5, when When, it means that the first time is obtained. The Nth adjustment amount in the next iteration And as Otherwise, assign k+1 to Then, return to S3.

2.

6. The control method for the automatic correction system of double-track cigarette paper according to claim 4, characterized in that: In the redundant correction mode, the adjustment step size when k=1 is... After halving the number of iterations and increasing the maximum number of iterations K, the process is executed according to S3.

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