Digital intelligent full-automatic tobacco stem unpacking and deploying system and method

Abstract

The invention provides a digital intelligent full-automatic tobacco stem unpacking and blending system and method, and the system comprises an automatic feeding system, a tobacco stem formula dynamic blending system, an automatic weighing system, a belt cutting and box opening system, a material pouring and feeding system, a dust removal system, a control system and an information collection and analysis system. The automatic feeding system, the tobacco stem formula dynamic blending system, the automatic weighing system, the belt shearing and box opening system, the material pouring and feeding system and the dust removal system are sequentially connected. The tobacco stem processing system solves the problems of low automation degree, high labor cost, high labor intensity, lack of real-time monitoring and intelligent allocation and the like in the tobacco stem processing process in the tobacco primary processing workshop, and realizes comprehensive upgrading of tobacco stem processing.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of tobacco processing machines, in particular to a digital intelligent full-automatic tobacco stem unpacking and blending system and method. BACKGROUND

[0002] In the existing tobacco production process, the processing of tobacco stems is an indispensable link, and its efficiency and accuracy directly affect the subsequent production process. Traditional tobacco stem processing methods often rely on a large amount of manual operation, such as manual feeding, unpacking, and material taking, etc. This method not only has high labor intensity, but also has low efficiency and is prone to human error. In addition, the information of the origin, position, and weight of the tobacco stems lacks real-time monitoring and recording, making it difficult to achieve fine management of the production process. For example: Prior Art One (Publication No. CN107963286B, Name: A feeding system and method for box-packed tobacco stems), which mainly realizes the automatic feeding of box-packed tobacco stems, but still lacks in overall automation, digitization, and intelligence. The specific defects are: 1. Limited automation: Although the feeding is automated, manual intervention may still be required in subsequent unpacking, material taking, and pouring, etc., and a complete automated processing process is not formed.

[0003] 2. Insufficient digital monitoring: The system may not be able to monitor and record key information such as the origin, position, and weight of the tobacco stems in real time, and cannot provide comprehensive data support for production management.

[0004] 3. Lack of intelligent blending: There is no function of dynamically blending materials according to the formula, making it difficult to meet the precise material supply under different production demands.

[0005] 4. Low system integration: There may be a lack of efficient communication and cooperation mechanism between devices, affecting the running efficiency and stability of the overall system.

[0006] Prior Art Two (Publication No. CN107963286B, Name: A tobacco stem intelligent feeding control system and control method), which integrates a double-axis gantry robot sub-control system, a visual system mobile sub-control system, and other subsystems, realizes the functions of automatic unloading and stacking of tobacco stem packages, breaking and unloading of packages, and dustproof feeding, etc. Specifically, the system uses a double-axis gantry robot to complete the transportation of tobacco stem packages from a transport vehicle to a designated area, and uses a visual system to position and adjust the angle of the tobacco stem packages to ensure accurate grabbing and placing. At the same time, the system is also equipped with a package breaking and unloading mechanism to break and unload the tobacco stem packages at a designated location. Although it realizes the automation of tobacco stem feeding to some extent, it still has the following defects: 1. Insufficient digitization: Existing technology two mainly focuses on the automation of physical processes, but the real-time monitoring, display, and transmission functions of key information such as the origin, location, and weight of tobacco stems are relatively weak, making it difficult to meet the needs of modern production for material tracking and data analysis.

[0007] 2. Intelligence level needs to be improved: Although existing technology two has certain automation capabilities, it still needs further development in terms of intelligent aspects such as automatic storage of materials and dynamic allocation according to the formula. For example, the system cannot automatically adjust the proportion of tobacco stems and storage strategies according to production needs, limiting the improvement of production efficiency and flexibility.

[0008] 3. Low system integration: The subsystems in existing technology two are relatively independent, lacking a unified management and control platform, which limits the overall operation efficiency and stability of the system. At the same time, the information sharing and collaborative work capabilities between subsystems need to be strengthened.

[0009] Existing technology three (publication number: CN114248954B, name: Box-packed tobacco stem feeding equipment), which aims to realize the automatic handling, positioning, and feeding process of tobacco stem boxes through specific mechanical structures. The equipment mainly includes handling mechanisms, positioning mechanisms, unpacking mechanisms, and tobacco stem output mechanisms, etc. Through the coordinated work of these mechanisms, automatic feeding of tobacco stem boxes is realized. Specifically, the box-packed tobacco stem feeding equipment transports the tobacco stem box to the designated position by the handling mechanism, and then the positioning mechanism performs precise positioning. The unpacking mechanism then unpacks the tobacco stem box, and finally the tobacco stem enters the subsequent production process through the output mechanism. During the entire process, the linkage between the mechanisms is achieved through electrical control, improving the accuracy and efficiency of feeding. Although it has achieved a certain degree of automation, it still has the following defects: Firstly, the equipment still needs to be improved in terms of intelligence, such as lacking real-time monitoring and fault warning mechanisms for the entire feeding process, and being unable to timely discover and handle potential problems. Secondly, the equipment still has limitations in terms of automation, such as the unpacking efficiency, quality, and uniform feeding of the unpacking mechanism, which still need to be further optimized. In addition, the equipment also has certain deficiencies in terms of collaborative work with other production equipment, making it difficult to achieve seamless connection of the production process.

[0010] Prior art four (publication number: CN117142167A, name: A box-packed tobacco stem automatic feeding and bag removing device and method), provides a box-packed tobacco stem automatic feeding and bag removing solution. The technical solution mainly includes an automatic feeding mechanism and a bag removing mechanism, which realizes the grabbing, transportation and automatic feeding of the tobacco stem bag to the designated position through a mechanical arm or a conveyor belt and other automatic equipment, and removes the packaging bag in the tobacco stem bag through the bag removing device for subsequent processing. Although it realizes the automatic feeding and bag removing of the tobacco stem bag to a certain extent, it still has the following defects: 1. Low system integration: Prior art four mainly focuses on the feeding and bag removing two links, and fails to include subsequent links such as unpacking and deployment into a unified system, resulting in limited overall automation.

[0011] 2. Intelligent level needs to be improved: Although visual recognition and other technologies are used, there is still much room for improvement in data collection, analysis and decision support, and it is difficult to achieve optimized scheduling based on big data and artificial intelligence.

[0012] 3. Lack of flexibility: The system has poor adaptability to different types of tobacco stem bags, making it difficult to meet diversified production needs and requiring frequent parameter adjustments or component replacements.

[0013] 4. Environmental protection and safety need to be strengthened: During unpacking and bag removing, dust and noise pollution may occur, and mechanical operation also has certain safety hazards, so more effective environmental protection and safety measures need to be taken.

[0014] Prior art five (publication number: CN215189355U, name: A tobacco stem intelligent feeding control system), the system aims to realize the automatic feeding process of tobacco stem through automatic means. The system mainly includes a double-shaft truss robot subsystem, a vision system mobile subsystem, a tobacco stem bag unloading and stacking mechanism subsystem, a tobacco stem bag unpacking and unloading mechanism subsystem, and a PLC main control system. The subsystems are connected through the PLC main control system for communication, and work together to complete the tasks of tobacco stem bag recognition, grabbing, carrying, unpacking and unloading. Although it realizes the automatic feeding of tobacco stem to a certain extent, it still has the following defects: 1. Insufficient system integration: Although prior art five includes multiple subsystems, the integration between the subsystems still needs to be improved. In actual application, the data exchange and communication between the subsystems may be delayed or incorrect, affecting the overall performance of the system.

[0015] 2. Limited intelligent level: The existing technology mainly relies on preset programs and algorithms for work, and lacks self-adaptive ability to complex working conditions and unexpected situations. In actual application, when encountering irregular bale position, large posture change or high difficulty of bale breaking, the system may not be able to accurately identify and process, resulting in reduced work efficiency or failure.

[0016] 3. Missing deployment link: The existing technology mainly focuses on the automatic feeding process of tobacco stems, but lacks consideration for the subsequent deployment of tobacco stems. In the tobacco primary processing workshop, the deployment of tobacco stems is crucial to product quality and production efficiency. Therefore, a more comprehensive and systematic solution is needed to realize the automatic opening of tobacco stem bales, deployment and subsequent processing. SUMMARY

[0017] To solve the above problems, the present application discloses a digital intelligent full-automatic tobacco stem bale opening and deployment system and method, which solves the problems of low automation, high labor cost, high labor intensity, lack of real-time monitoring and intelligent deployment in the process of processing tobacco stems in the tobacco primary processing workshop, and realizes the overall upgrade of tobacco stem processing.

[0018] The specific scheme is as follows: The application discloses a digital intelligent full-automatic tobacco stem unloading and blending system, which is characterized by comprising an automatic feeding system, a tobacco stem formula dynamic blending system, an automatic weighing system, a band cutting and box opening system, a material pouring and feeding system, a dust removal system, a control system and an information acquisition and analysis system; the automatic feeding system, the tobacco stem formula dynamic blending system, the automatic weighing system, the band cutting and box opening system, the material pouring and feeding system and the dust removal system are sequentially connected, wherein the automatic feeding system is used for automatically transporting tobacco stem loaded bales from a trailer to a designated working area and reading bale information through a code reader; the tobacco stem formula dynamic blending system is used for automatically blending positions of the bales according to a preset tobacco stem formula and the bale information read by the code reader, realizing flexible configuration to meet the needs of different production batches; the automatic weighing system is used for accurately weighing the blended bales and feeding back weighing information in real time to provide accurate data support for subsequent production; the band cutting and box opening system is used for automatically cutting a binding band on the bale and opening a bale cover to prepare for subsequent unloading of the tobacco stem; the material pouring and feeding system is used for automatically pouring the tobacco stem in the bale and feeding the tobacco stem to subsequent processing equipment through a conveying device; the dust removal system is used for collecting and processing dust generated in the process of pouring, conveying and processing the tobacco stem, ensuring the cleanliness of the production environment and the health of workers; the control system takes a PLC as a main controller, integrates a vision system, a displacement laser sensor and a weight sensor, and realizes automatic control and intelligent adjustment of the automatic bale unloading and blending of the tobacco stem; and the information acquisition and analysis system is used for overall data acquisition and real-time analysis in the process of processing the tobacco stem, providing data support for optimized operation and production management of the whole system.

[0019] Further, the automatic feeding system comprises a trailer docking device, a clamping mechanism, a lifting mechanism, a horizontal moving device, a workbench and a code reader, wherein the clamping mechanism and the lifting mechanism are feeding machines and are used for realizing automatic clamping, lifting, horizontal moving, accurate dropping and loosening of the bale, finally placing the bale on the workbench for subsequent processing; and the code reader is used for reading bar code or two-dimensional code information on the bale and recording the information in the system in real time, realizing information management and tracing of the tobacco stem.

[0020] Further, the tobacco stem formula dynamic blending system is composed of upper and lower layer roller lines, which monitor positions and quantities of the bales on the roller lines in real time and adjust running speeds, directions and positions of the roller lines according to production instructions, so as to ensure accurate blending and efficient flow of the tobacco stem.

[0021] Further, the automatic weighing system comprises a high-precision weighing sensor, a data acquisition module and a display screen; wherein the high-precision weighing sensor is installed below the bale and can acquire weight data of the bale in real time and transmit the data to the system for processing and display through the data acquisition module.

[0022] Further, the strip cutting and case opening system comprises a strip cutting machine, a case opening mechanism, a strip pulling machine and corresponding pneumatic or electric driving devices; wherein the strip cutting machine can accurately cut the bundling strip, and the case opening mechanism opens the case cover by mechanical or pneumatic means to ensure that the tobacco stems can be smoothly unloaded.

[0023] Further, the material pouring and feeding system comprises a material pouring mechanism, a conveying belt and a vibrating screening device; wherein the material pouring mechanism pours the tobacco stems in the case out by mechanical means, the conveying belt sends the tobacco stems to the designated position, and the vibrating screening device is used for removing impurities and unqualified products, and a case taking machine is arranged in front of the material pouring and feeding system.

[0024] Further, the dust removal system comprises a dust suction device, a dust collector, an air pipe and a dust discharge port; wherein the dust suction device is arranged around the material pouring, conveying and processing equipment, the dust is collected to the dust collector through the air pipe for treatment, and finally discharged through the dust discharge port.

[0025] Further, the control system comprises a PLC control cabinet, a touch screen operation terminal, a sensor and a communication module; wherein the touch screen operation terminal provides a friendly man-machine interface for the operator to facilitate monitoring the system running state and adjusting the system parameters.

[0026] Further, the information collection and analysis system integrates various automatic and digital equipment, including the bar code or RFID label installed on each processing site for reading the tobacco stem case; the label contains the unique identification, weight, quantity and key information of the tobacco stem part of the tobacco stem case, and the specific data of the tobacco stem case is obtained in real time by scanning these labels.

[0027] Further, a 90° rotating platform and a manual feeding table are sequentially arranged between the automatic weighing system and the strip cutting and case opening system, and in the material pouring and feeding system, the stem material is automatically poured out with the assistance of the dust removal system by overturning the bottom plate and the upper cover; the accurate homing of the carton is ensured by the homing device to provide convenience for subsequent automatic operation.

[0028] A digital intelligent full-automatic tobacco stem unpacking and blending method, specifically comprising the following steps: S1, stem case loading: the stem case containing tobacco stems is placed on a special trailer, and the trailer is transported to a designated station; the loading machine accurately clamps the stem case through its mechanical arm, then lifts and smoothly moves to the workbench, releases the mechanical arm after completing the loading action; in this process, the information reading system synchronously scans the bar code or two-dimensional code on the stem case, and quickly records the relevant information of the stem case; S2, dynamic blending of tobacco stem formula: the stem case enters the dynamic blending system of tobacco stem formula composed of upper and lower layer of roller lines, which intelligently adjusts the rotation of the roller according to the recorded stem case information and current production demand, to realize accurate positioning and automatic blending of the stem case; S3, weighing: the prepared bale box is automatically pushed to the weighing table for accurate weighing, the weighing sensor collects the weight data in real time and transmits it to the control system; the control system judges whether the weight of the bale box is qualified according to the preset standard range, and records the weighing data for subsequent quality traceability and production management; S4, 90° rotation: the bale box that has completed weighing is conveyed to the 90° rotation platform, which accurately rotates the bale box by 90° after receiving the instruction from the control system, so that it can smoothly enter the subsequent production line and ensure the smooth progress of the production process; S5, pulling out the tape and opening the carton: before the bale box enters the production line, the vision sensor accurately detects the position of the tape, and once the tape is detected, the tape cutter quickly clamps and cuts the tape, and then the pulling mechanism pulls out the tape and recycles it to the designated position; S6, bale box opening: the bale box is conveyed to the bale box taking machine, and the outer box is smoothly taken out; then the paperboard is taken out, and in this process, the complete taking out of the carton is ensured to avoid the scattering of tobacco stems; S7, outer box folding: the taken-out outer box is positioned and folded, and the paperboard is positioned and stacked for subsequent recycling or reuse; S8, pouring: the tobacco stems are naturally poured out through the pouring mechanism, and the dust removal device ensures the cleanliness of the production environment; S9, bale box homing: after the pouring is completed, the bale box returns to the outer box taking station, and the automatic folding and collection of the lower box are completed for subsequent storage or transportation; S10, uniform tobacco stem feeding: the poured tobacco stems are stably conveyed to the silo through the belt conveyor, and the silo is provided with a uniform material device to ensure the uniform distribution of the tobacco stems; then, the inclined conveyor or the conveying roller unit accurately conveys the tobacco stems to the next production link to provide stable tobacco stem supply for subsequent processing.

[0029] In addition, the information collection and analysis system in the application collects data of each link in real time during the entire production process, including bale box information, weighing data, equipment running state, etc. Through data analysis, the system continuously optimizes the production process and improves the production efficiency.

[0030] The electric control system as the core of the whole system is responsible for controlling the operation and coordination of each device. Through the preset program and sensor feedback, the automatic start and stop of the device, fault alarm and emergency treatment are realized. The electric control system ensures the smooth progress of each process and provides strong guarantee for the stable operation of the production line.

[0031] The beneficial effects of the application are: 1. Achieving high automation: By integrating advanced mechanical arms, conveyor belts, intelligent sensors and other hardware devices, combined with an efficient control system, the entire process of tobacco stem transportation, unpacking, transmission and blending is fully automated, significantly improving production efficiency, reducing labor costs and reducing the labor intensity of workers.

[0032] 2. Achieving full digitalization: Real-time monitoring of incoming tobacco stems, including but not limited to key information such as origin, location, weight, etc., and displaying, storing and transmitting this information through digital means. This helps to achieve traceability in the production process and provides a basis for subsequent data analysis and optimization.

[0033] 3. Intelligent management is introduced: By integrating intelligent algorithms and control systems, functions such as automatic storage of tobacco stems and dynamic blending according to the formula are achieved. According to production needs, the system automatically adjusts the proportion and timing of tobacco stem feeding to ensure the continuity and stability of production. At the same time, the intelligent system can also respond and handle abnormal situations in the production process to ensure smooth production.

[0034] 4. Improve production safety: Reduce the risk of human operation through automation, avoid safety accidents caused by human operation errors. At the same time, the system is also equipped with a perfect safety monitoring and alarm mechanism to ensure that abnormal situations can be quickly discovered and handled to ensure the safety of personnel and equipment. BRIEF DESCRIPTION OF DRAWINGS

[0035] Figure 1 is a schematic view of the present invention.

[0036] Figure 2 is a top view of the present invention.

[0037] LIST OF REFERENCE NUMBERS: 1 - automatic feeding system, 2 - dynamic blending system for tobacco stem formula, 3 - automatic weighing system, 4 - belt cutting and unpacking system, 5 - pouring and feeding system, 6 - dust removal system, 7 - 90° rotating platform, 8 - manual feeding table, 9 - belt cutting machine, 10 - belt drawing machine, 11 - box taking machine. DETAILED DESCRIPTION

[0038] The present invention will be further illustrated below in conjunction with the drawings and specific embodiments, it should be understood that the following specific embodiments are only used to illustrate the present invention and not to limit the scope of the present invention.

[0039] As shown in the figure, the present application provides a digital intelligent full-automatic tobacco stem unloading and blending system, which comprises an automatic feeding system, a tobacco stem formula dynamic blending system, an automatic weighing system, a strip cutting and box opening system, a pouring and feeding system, a dust removal system, a control system and an information acquisition and analysis system. The automatic feeding system, the tobacco stem formula dynamic blending system, the automatic weighing system, the strip cutting and box opening system, the pouring and feeding system and the dust removal system are connected in sequence. The automatic feeding system is used to automatically transport the stem box loaded with tobacco stems from the trailer to the designated working area and read the stem box information through the code reader. The tobacco stem formula dynamic blending system is used to automatically blend the position of the stem box according to the preset tobacco stem formula and the stem box information read by the code reader, to realize flexible configuration and meet the needs of different production batches. The automatic weighing system is used to accurately weigh the blended stem box and feed back the weighing information in real time, to provide accurate data support for subsequent production. The strip cutting and box opening system is used to automatically cut the bundling strip on the stem box and open the stem box cover, to prepare for the unloading of the subsequent tobacco stems. The pouring and feeding system is used to automatically pour out the tobacco stems in the stem box and send the tobacco stems to the subsequent processing equipment through the conveying device. The dust removal system is used to collect and process the dust generated during the unloading, conveying and processing of the tobacco stems, to ensure the cleanliness of the production environment and the health of the employees. The control system takes PLC as the main controller, integrates the vision system, the displacement laser sensor and the weight sensor, to realize the automatic control and intelligent adjustment of the automatic unloading and blending of the tobacco stems. The information acquisition and analysis system is used for comprehensive data acquisition and real-time analysis during the processing of the tobacco stems, to provide data support for the optimized operation and production management of the entire system.

[0040] In this embodiment, the automatic feeding system comprises a trailer docking device, a clamping mechanism, a lifting mechanism, a horizontal moving device, a workbench and a code reader. The clamping mechanism and the lifting mechanism are feeding machines, which are used to realize the automatic clamping, lifting, horizontal moving, accurate dropping and loosening actions of the stem box, to finally place the stem box stably on the workbench, preparing for subsequent processing. The code reader is used to read the bar code or two-dimensional code information on the stem box and record it into the system in real time, to realize the informatization management and traceability of the tobacco stems.

[0041] In this embodiment, the tobacco stem formula dynamic blending system is composed of upper and lower layer roller lines, which monitor the position and quantity of the stem boxes on each roller line in real time and adjust the running speed, direction and position of the roller line according to the production instructions, to ensure the accurate blending and efficient flow of the tobacco stems.

[0042] In this embodiment, the automatic weighing system comprises a high-precision weighing sensor, a data acquisition module and a display screen. The high-precision weighing sensor is installed below the stem box, which can collect the weight data of the stem box in real time and transmit it to the system for processing and display through the data acquisition module.

[0043] In the embodiment, the strip cutting and case opening system comprises a strip cutting machine, a case opening mechanism, a strip pulling machine and corresponding pneumatic or electric driving devices; wherein the strip cutting machine can accurately cut the binding strip, and the case opening mechanism opens the case cover by mechanical or pneumatic means to ensure that the tobacco stems can be smoothly unloaded.

[0044] In the embodiment, the material pouring and feeding system comprises a material pouring mechanism, a conveying belt and a vibrating screening device; wherein the material pouring mechanism pours the tobacco stems in the case out by mechanical means, the conveying belt sends the tobacco stems to a designated position, and the vibrating screening device is used for removing impurities and unqualified products; and a case taking machine is arranged in front of the material pouring and feeding system.

[0045] In the embodiment, the dust removal system comprises a dust suction device, a dust remover, an air pipe and a dust discharge port; wherein the dust suction device is arranged around the material pouring, conveying and processing equipment, the dust is collected to the dust remover through the air pipe for treatment, and finally discharged through the dust discharge port.

[0046] In the embodiment, the control system comprises a PLC control cabinet, a touch screen operation terminal, a sensor and a communication module; wherein the touch screen operation terminal provides a friendly man-machine interface for the operator to facilitate monitoring the system running state and adjusting the system parameters.

[0047] In the embodiment, the information acquisition and analysis system integrates various automatic and digital equipment, including the bar code or RFID label installed on each processing site for reading the tobacco stem case; the label contains the unique identification, weight, quantity and key information of the tobacco stem part of the tobacco stem case, and the specific data of the tobacco stem case is obtained in real time by scanning the label.

[0048] In the embodiment, a 90° rotating platform and a manual feeding table are sequentially arranged between the automatic weighing system and the strip cutting and case opening system, and in the material pouring and feeding system, the stem material is automatically poured out with the assistance of the dust removal system by overturning the bottom plate and the upper cover; the accurate homing of the carton is ensured by the homing device to provide convenience for the subsequent automatic operation.

[0049] The application also provides a digital intelligent full-automatic tobacco stem bale opening and blending method, which specifically comprises the following steps: S1, stem case feeding: the stem case containing tobacco stems is placed on a special trailer, and the trailer is transported to a designated station; the feeding machine accurately clamps the stem case through the mechanical arm, then lifts and smoothly moves to the workbench, releases the mechanical arm after completing the feeding action; in this process, the information reading code system synchronously scans the bar code or two-dimensional code on the stem case, and quickly records the related information of the stem case; S2, dynamic blending of tobacco stem formula: the stem case enters the dynamic blending system of tobacco stem formula composed of upper and lower layer of carrier roller lines, the system intelligently adjusts the rotation of the carrier roller according to the recorded stem case information and current production demand, realizes accurate positioning and automatic blending of the stem case; S3, weighing: the prepared bale box is automatically pushed to the weighing table for accurate weighing, the weighing sensor collects the weight data in real time and transmits it to the control system; the control system judges whether the weight of the bale box is qualified according to the preset standard range, and records the weighing data for subsequent quality traceability and production management; S4, 90° rotation: the bale box that has completed weighing is conveyed to the 90° rotation platform, which accurately rotates the bale box by 90° after receiving the instruction from the control system, so that it can smoothly enter the subsequent production line and ensure the smooth progress of the production process; S5, pulling out the tape and opening the carton: before the bale box enters the production line, the vision sensor accurately detects the position of the tape, and once the tape is detected, the tape cutter quickly clamps and cuts the tape, and then the pulling mechanism pulls out the tape and recycles it to the designated position; S6, bale box opening: the bale box is conveyed to the bale box taking machine, and the outer box is smoothly taken out; then the paperboard is taken out, during which the complete taking out of the carton is ensured to avoid the scattering of tobacco stems; S7, outer box folding: the taken-out outer box is positioned and folded, and the paperboard is positioned and stacked for subsequent recycling or reuse; S8, pouring: the tobacco stems are naturally poured out by the pouring mechanism, and the dust removal device ensures the cleanliness of the production environment; S9, bale box homing: after the pouring is completed, the bale box returns to the outer box taking station, and the automatic folding and collection of the lower box are completed for subsequent storage or transportation; S10, uniform tobacco stem feeding: the poured tobacco stems are smoothly conveyed to the silo by the belt conveyor, and the silo is provided with a uniform material device to ensure the uniform distribution of the tobacco stems; then, the inclined conveyor or the conveying roller unit accurately conveys the tobacco stems to the next production link to provide stable tobacco stem supply for subsequent processing.

[0050] In addition, the information collection and analysis system in the present application collects data of each link in real time during the entire production process, including bale box information, weighing data, equipment running state, etc. Through data analysis, the system continuously optimizes the production process and improves the production efficiency.

[0051] The electric control system as the core of the whole system is responsible for controlling the operation and coordination of each device. Through the preset program and sensor feedback, the automatic start and stop of the device, fault alarm and emergency treatment are realized. The electric control system ensures the smooth progress of each process and provides strong guarantee for the stable operation of the production line.

[0052] The technical means disclosed in the present application are not limited to the technical means disclosed in the above embodiments, and include technical solutions composed of any combination of the above technical features. It should be noted that, for those skilled in the art, without departing from the principles of the present application, a number of improvements and refinements can be made, and these improvements and refinements are also considered within the scope of protection of the present application.

Claims

1. A digital intelligent fully automatic tobacco stem opening and dispensing system, characterized in that: The system includes an automatic feeding system, a dynamic tobacco stem formulation adjustment system, an automatic weighing system, a tape cutting and unpacking system, a material feeding system, a dust removal system, a control system, and an information acquisition and analysis system. The automatic feeding system, the dynamic tobacco stem formulation adjustment system, the automatic weighing system, the tape cutting and unpacking system, the material feeding system, and the dust removal system are connected sequentially. The automatic feeding system is used to automatically transport the stem boxes loaded with tobacco stems from the trailer to the designated work area, and read the stem box information through a barcode reader. The dynamic tobacco stem formula allocation system is used to automatically allocate the position of the stem box according to the preset tobacco stem formula and the stem box information read by the barcode reader, so as to achieve flexible configuration and meet the needs of different production batches. The automatic weighing system is used to accurately weigh the allocated stalk boxes and provide real-time feedback of the weighing information to provide accurate data support for subsequent production. The strapping and unpacking system is used to automatically cut the strapping on the stem box and open the stem box lid to prepare for the subsequent unloading of tobacco stems. The feeding system is used to automatically empty the tobacco stems from the stem box and then transport them to the subsequent processing equipment via a conveying device. The dust removal system is used to collect and treat the dust generated during the feeding, conveying and processing of tobacco stems, ensuring a clean production environment and the health of employees; The control system uses a PLC as the main controller and integrates a vision system, a displacement laser sensor, and a weight sensor to achieve automated control and intelligent adjustment of the entire tobacco stem automatic opening and distribution. The information collection and analysis system is used for comprehensive data collection and real-time analysis during the tobacco stem processing, providing data support for the optimized operation and production management of the entire system.

2. The digital intelligent fully automatic tobacco stem opening and dispensing system and method according to claim 1, characterized in that: The automatic feeding system includes a trailer docking device, a clamping mechanism, a lifting mechanism, a horizontal moving device, a worktable, and a barcode reader. The clamping mechanism and the lifting mechanism are feeding machines used to automatically clamp, lift, move horizontally, accurately drop, and release the stem boxes, ultimately placing them stably on the worktable for subsequent processing. The barcode reader is used to read the barcode or QR code information on the stem boxes and record it into the system in real time, enabling information management and traceability of the tobacco stems.

3. The digital intelligent fully automatic tobacco stem opening and dispensing system and method according to claim 1, characterized in that: The dynamic blending system for tobacco stems consists of two layers of idler rollers. It monitors the position and quantity of stem boxes on each idler roller in real time and adjusts the running speed, direction, and position of the idler rollers according to production instructions to ensure accurate blending and efficient circulation of tobacco stems.

4. The digital intelligent fully automatic tobacco stem opening and dispensing system and method according to claim 1, characterized in that: The automatic weighing system includes a high-precision weighing sensor, a data acquisition module, and a display screen. The high-precision weighing sensor is installed below the skewer and can collect the weight data of the skewer in real time. The data acquisition module then transmits the data to the system for processing and display.

5. The digital intelligent fully automatic tobacco stem opening and dispensing system and method according to claim 1, characterized in that: The tape-cutting and box-opening system includes a tape-cutting machine, a box-opening mechanism, a tape-pulling machine, and corresponding pneumatic or electric drive devices. The tape-cutting machine can accurately cut the binding tape, while the box-opening mechanism opens the stem box cover mechanically or pneumatically to ensure that the tobacco stems can be unloaded smoothly. A 90° rotating platform and a manual feeding platform are sequentially provided between the automatic weighing system and the tape-cutting and box-opening system.

6. The digital intelligent fully automatic tobacco stem opening and dispensing system and method according to claim 1, characterized in that: The feeding system includes a feeding mechanism, a conveyor belt, and a vibrating screen. The feeding mechanism mechanically pours out the tobacco stems from the stem box, the conveyor belt transports the tobacco stems to a designated position, the vibrating screen removes impurities and defective products, and a box-retrieving machine is provided in front of the feeding system.

7. The digital intelligent fully automatic tobacco stem opening and dispensing system and method according to claim 1, characterized in that: The dust removal system includes a dust collection device, a dust collector, air ducts, and a dust discharge port; wherein, the dust collection device is arranged around the unloading, conveying, and processing equipment, and collects the dust through the air ducts to the dust collector for processing, and finally discharges it through the dust discharge port.

8. The digital intelligent fully automatic tobacco stem opening and dispensing system and method according to claim 1, characterized in that: The control system includes a PLC control cabinet, a touch screen operation terminal, sensors, and communication modules; the touch screen operation terminal provides operators with a user-friendly human-machine interface, facilitating monitoring of the system's operating status and adjustment of system parameters.

9. The digital intelligent fully automatic tobacco stem opening and dispensing system and method according to claim 1, characterized in that: The information collection and analysis system integrates various automated and digital devices, including those installed at each processing station for reading barcodes or RFID tags on tobacco stem boxes. These tags contain key information such as the unique identifier of the tobacco stem box, its weight, quantity, and the location of the tobacco stems. By scanning these tags, specific data of the tobacco stem boxes can be obtained in real time.

10. A digitally intelligent fully automatic method for opening and dispensing tobacco stems, characterized in that, Specifically, the following steps are included: S1. Stem box loading: The stem box containing tobacco stems is placed on a special trailer, which is then transported to the designated work station. The loading machine accurately clamps the stem box with its robotic arm, then lifts and moves it smoothly to the worktable. After the loading action is completed, the robotic arm is released. During this process, the information reading system simultaneously scans the barcode or QR code on the stem box and quickly records the relevant information of the stem box. S2. Dynamic adjustment of tobacco stem formula: The stem box enters the dynamic adjustment system of tobacco stem formula consisting of upper and lower roller lines. The system intelligently adjusts the rotation of the rollers according to the recorded stem box information and current production needs to achieve precise positioning and automatic adjustment of the stem box. S3. Weighing: The allocated stalk boxes are automatically pushed onto the weighing platform for precise weighing. The weighing sensor collects the weight data in real time and transmits it to the control system. The control system determines whether the weight of the stalk box is qualified according to the preset standard range and records the weighing data for subsequent quality traceability and production management. S4, 90° rotation: The weighed stalk box is transported to the 90° rotating platform. After receiving the instruction from the control system, the 90° rotating platform accurately rotates the stalk box 90° so that it can smoothly enter the subsequent production line and ensure the smooth operation of the production process. S5. Pull-out strap and carton opening: Before the carton enters the production line, the vision sensor accurately detects the position of the cable tie. Once the cable tie is detected, the cable cutter quickly clamps and cuts the cable tie. Then, the pull-out mechanism pulls out the cable tie and retracts it to the designated position. S6. Unpacking the tobacco box: The tobacco box is conveyed to the box-removing machine, and the outer box is smoothly removed; then the cardboard is removed. During this process, ensure that the cardboard box is removed intact to prevent the tobacco stems from scattering. S7. Outer box folding: The removed outer box is folded in position, and the cardboard is stacked in position to facilitate subsequent recycling or reuse; S8. Discharge: The material flows out naturally through the discharge mechanism, and the dust removal device ensures a clean production environment; S9. Sterile box return: After unloading, the sterile box returns to the outer box retrieval station to complete the automatic folding and collection of the lower box for subsequent storage or transportation. S10. Uniform feeding of tobacco stems: The poured tobacco stems are smoothly conveyed to the hopper by a belt conveyor. The hopper is equipped with a uniform feeding device to ensure the uniform distribution of tobacco stems. Subsequently, the inclined conveyor or conveyor roller unit accurately transports the tobacco stems to the next production stage, providing a stable supply of tobacco stems for subsequent processing.

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