Method for accurately regulating and controlling environment temperature and humidity in tobacco shred cutting process
By combining data binding and seasonal regulation with steam film control, the problem of low precision in environmental temperature and humidity control in tobacco processing has been solved, achieving stability of tobacco leaf moisture content and optimization of energy consumption, thus improving the level of tobacco processing technology.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2026-01-13
- Publication Date
- 2026-04-14
AI Technical Summary
In current tobacco processing, environmental temperature and humidity control parameters are fixed or rely on manual experience, resulting in low control precision, large fluctuations in tobacco leaf moisture content, which affects product quality, wastes energy, and lacks adaptability to seasonal differences.
By linking production batches with environmental temperature and humidity through a data acquisition system, and adopting a seasonal control scheme, combined with steam and film control methods, the air conditioning humidity of the leaf storage room and leaf cutting process is dynamically adjusted according to the difference in tobacco leaf moisture content, so as to ensure the consistency of leaf cutting moisture content and energy consumption optimization.
It achieves dynamic correlation control between ambient temperature and humidity and tobacco leaf moisture content, improves the stability and consistency of cut leaf moisture content, balances control speed and energy saving, and enhances the system's adaptability and intelligence level.
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Abstract
Description
Technical Field
[0001] This invention belongs to the field of tobacco processing technology, specifically relating to a method for precisely controlling the temperature and humidity of the environment during the leaf cutting process. Background Technology
[0002] In tobacco processing, maintaining a stable moisture balance in the tobacco leaves during storage and ensuring uniform moisture loss during the cutting process are crucial for maintaining consistent moisture content in the cut tobacco shreds. Both of these rely on precise control of ambient temperature and humidity. Currently, tobacco processing workshops commonly use air conditioning systems to regulate temperature and humidity. The control methods are mainly divided into steam control and membrane control: steam control has a fast reaction speed but higher energy consumption; membrane control has a slower reaction speed but lower energy consumption.
[0003] In the process of developing this application, the applicant discovered four major problems with existing control technologies: First, the control parameters are fixed or rely on human experience, failing to establish a dynamic correlation with the actual moisture content changes of tobacco leaves, resulting in low control precision; second, when external environmental fluctuations (such as seasonal changes or sudden weather changes) or production anomalies occur, the moisture content of tobacco leaves fluctuates greatly, and the consistency of the moisture content of cut leaves is poor, affecting product quality; third, the control methods are singular, either pursuing speed at high energy consumption or pursuing energy conservation at slow response, failing to achieve a balance between the two; fourth, there is a lack of control strategies targeting seasonal differences, as the environmental conditions during non-heating and heating seasons are different, but the control logic is the same, resulting in insufficient adaptability.
[0004] To address the above problems, this invention is proposed. Summary of the Invention
[0005] In the process of developing this application, the applicant discovered that the changes in the moisture content of tobacco leaves at the entrance of the storage room (A), the moisture content at the exit (B), and the moisture content of the shredded tobacco leaves at the exit of the cutting process (C) directly reflect the moisture loss status of each process. Existing technologies do not fully utilize the differences in these three parameters for targeted control, resulting in poor air conditioning coordination between the storage room and the cutting process. This not only fails to guarantee the stability of tobacco quality but also causes unnecessary energy waste.
[0006] The purpose of this invention is to overcome the shortcomings of the prior art and provide a method for precisely controlling the environmental temperature and humidity in the tobacco cutting process, so as to achieve dynamic binding of environmental temperature and humidity with changes in tobacco leaf moisture content, seasonal differentiation adaptation, and optimized balance between control speed and energy consumption.
[0007] To achieve the above objectives, the present invention adopts the following technical solution:
[0008] This application provides a method for precisely controlling the temperature and humidity of the environment during the leaf cutting process, the method comprising:
[0009] 1) Parameter acquisition: Establish the binding relationship between production batch and ambient temperature and humidity through the data acquisition system, test and record the batch average moisture content of tobacco leaves at the entrance of the storage room (A), the batch average moisture content of tobacco leaves at the exit of the storage room (B), and the batch average moisture content of leaf shreds at the exit of the leaf cutting process (C).
[0010] 2) Scheme selection: The control scheme is divided according to the season. Scheme 1 is adopted during the non-heating period (April 16 to October 14 of the current year), and Scheme 2 is adopted during the heating period (October 15 of the current year to April 15 of the following year).
[0011] The basis for dividing the control scheme into seasons in this application is: during the heating season, the basic humidity of the workshop environment is lower, and the rate of moisture loss from tobacco leaves is faster, so the control threshold for moisture content difference needs to be increased; during the non-heating season, the environmental humidity is relatively stable, the rate of moisture loss is slow, and the control threshold can be appropriately reduced.
[0012] 3) Precise control: Based on the moisture content difference range of AB and BC, select steam control or film control mode to adjust the air conditioning humidity of the leaf storage room and the leaf cutting process (the initial setting is a fluctuation range of ±2%, i.e., 70±2% for the leaf storage room and 56±2% for the leaf cutting process). Finally, make the process capability index of leaf filament moisture content at the outlet of the leaf cutting process greater than 1.67 to ensure that the process capability is at a high quality level and to ensure the stability and consistency of leaf filament moisture content.
[0013] Preferably, the temperature of the leaf storage room and the leaf cutting process is maintained at (28±3)℃, which is the optimal temperature range for tobacco leaf moisture stability.
[0014] Option 1 (non-heating season) includes the following steps:
[0015] When A-B > 0.3% and B-C > 0.2%, it indicates that the moisture loss in both the leaf storage room and the leaf cutting process exceeds the normal range and requires rapid adjustment. Therefore, steam control is adopted for both processes, and the humidity in the leaf storage room and the leaf cutting process is adjusted to 70-72% and 56-58%, respectively.
[0016] When A - B > 0.3% and 0.1% ≤ B - C ≤ 0.2%: the moisture loss in the leaf storage room is abnormal and needs to be corrected quickly by using steam control; the moisture loss in the leaf cutting process is normal, and film control is used for energy saving; the humidity in the leaf storage room and the leaf cutting process should be adjusted to 70-72% and 56-58% respectively.
[0017] When 0.2%≤A-B≤0.3% and B-C>0.2%: the moisture loss in the leaf cutting process is abnormal, so steam control is adopted; the moisture loss in the leaf storage room is normal, so film control is adopted for energy saving; the humidity in the leaf storage room and the leaf cutting process are adjusted to 70~72% and 56~58%, respectively.
[0018] Option 2 (heating season) includes the following steps:
[0019] When A-B > 0.4% and B-C > 0.3%: the moisture loss of both exceeds the normal range for the heating season. A dual steam control system is used for rapid regulation, and the humidity of the leaf storage room and the leaf cutting process is adjusted to 70-72% and 56-58%, respectively.
[0020] When A-B > 0.4% and 0.1% ≤ B-C ≤ 0.3%: abnormal moisture loss in the leaf storage room, steam control; normal leaf cutting process, film control; humidity in the leaf storage room and leaf cutting process adjusted to 70-72% and 56-58% respectively.
[0021] When 0.2% ≤ A - B ≤ 0.4% and B - C > 0.3%: Abnormal moisture loss in the leaf cutting process, steam control; normal operation in the leaf storage room, film control. Adjust the humidity in the leaf storage room and the leaf cutting process to 70-72% and 56-58%, respectively.
[0022] Preferably, the method for calculating CPK in this invention is as follows:
[0023] Collect 25-30 groups of leaf fiber moisture content samples (3-5 samples per group) to ensure no abnormal fluctuations in the production process;
[0024] Set upper and lower limits (USL, LSL) for moisture content in the shredding process, calculate the sample mean (x) and standard deviation (s), and obtain CPU and CPL using the formulas CPU=(USL-x) / (3s) and CPL=(x-LSL) / 3s. The minimum of the two is CPK. CPK>1.67 indicates sufficient process capacity and high product quality consistency.
[0025] Preferably, the USL is set to 18% and the LSL is set to 16%.
[0026] Compared with the prior art, the beneficial effects of this application are as follows:
[0027] (1) This application realizes the dynamic correlation control between environmental temperature and humidity and tobacco leaf moisture content changes, and makes targeted adjustments based on the actual moisture loss state, thereby improving the stability and consistency of the moisture content of the cut leaf shreds (CPK>1.67); CPK is the process capability index.
[0028] (2) This application achieves both speed control and energy saving through the intelligent combination of steam control and membrane control.
[0029] (3) This application sets different moisture content control ranges for different seasons (non-heating season and heating season), which enhances the adaptability and robustness of the system.
[0030] (4) This application provides clear abnormal control logic, which facilitates the implementation of automated systems and improves the level of intelligence in the production process.
[0031] (5) This application reduces product quality problems caused by moisture content fluctuations and improves the overall process level of tobacco processing. Detailed Implementation
[0032] The present invention will be described below with reference to specific embodiments, but the implementation of the present invention is not limited thereto. Experimental methods not specifically described in the embodiments generally use conventional conditions and conditions described in the manual, or conditions recommended by the manufacturer. The general equipment, materials, reagents, etc., used are all commercially available unless otherwise specified. The raw materials used in the following embodiments and comparative examples are all commercially available.
[0033] In the data acquisition system, a binding relationship is established between production batch data and ambient temperature and humidity. For example, when the production batch is 1, the batch average moisture content of tobacco leaves at the entrance of the storage room is A1. Searching for the start and end times of batch production, the batch average temperature and humidity control air conditioning value of the storage room during this time period is X1, and the batch average moisture content of tobacco leaves at the exit is B1.
[0034] Similarly, when material 1 of this batch is fed into the leaf cutting process, the start and end times of batch production are searched. At this time, the average value of the ambient temperature and humidity control air conditioner of the leaf cutting process is Y1, and the average value of the leaf cutting moisture content of the batch is C1.
[0035] The following are methods for precisely controlling the temperature and humidity of the leaf cutting process during the non-heating season (April 16 to October 14 of the same year):
[0036] (1) During normal material feeding, the experiment found that:
[0037] 1) When the temperature of the tobacco storage room is controlled at (28±3)℃ and the humidity is controlled within the range of (70±2)%, the average moisture loss of A-B ("average batch moisture content of tobacco leaves at the entrance of the tobacco storage room A" minus "average batch moisture content of tobacco leaves at the exit of the tobacco storage room B") is between 0.2% and 0.3%. At this time, the moisture content of the batch of material in the storage section of the tobacco storage room is optimal, which also indicates that the temperature and humidity control of the tobacco storage room environment is optimal.
[0038] 2) When the temperature of the leaf cutting process is controlled at (28±3)℃ and the humidity is controlled within the range of (56±2)%, the average moisture loss of B-C ("average batch moisture content of tobacco leaves at the exit of the leaf storage room B" minus "average batch moisture content of leaf shreds at the exit of the leaf cutting process C") is between 0.1% and 0.2%. At this time, the moisture content of the material in the leaf cutting process of this batch is optimal, which also indicates that the temperature and humidity control of the leaf cutting process is optimal.
[0039] When 1) and 2) are satisfied at the same time, the final moisture content of the leaf filaments of this batch of material is optimal (the moisture content of the leaf filaments CPK reaches greater than 1.67), and the temperature and humidity control of the storage room and the leaf filament process environment of this batch is optimal.
[0040] (2) When the temperature and humidity of the external environment change significantly or other special reasons affect the moisture content of the materials in the production workshop, the following situations may occur:
[0041] 1) When A-B>0.3% and B-C>0.2%, quickly adjust the air conditioning of the leaf storage room using steam control to adjust the humidity control from (70±2)% to between 70~72%; at the same time, quickly adjust the air conditioning of the leaf cutting process using steam control to adjust the humidity control from (56±2)% to between 56~58%, so that the final moisture content of the leaf cuttings of the batch material is optimal (the moisture content of the leaf cuttings CPK reaches greater than 1.67).
[0042] 2) When A-B > 0.3% and B-C is between 0.1% and 0.2%, quickly adjust the air conditioning of the leaf storage room using steam control to adjust the humidity control from (70±2)% to between 70% and 72%; at the same time, adjust the air conditioning of the leaf cutting process using film control to gradually adjust the humidity control from (56±2)% to between 56% and 58%, so that the final leaf cutting moisture content of the batch material is optimal (the leaf cutting moisture content CPK reaches greater than 1.67).
[0043] 3) When A-B is between 0.2% and 0.3%, and B-C > 0.2%, quickly adjust the air conditioning of the leaf cutting process using steam control to adjust the humidity control from (56±2)% to between 56% and 58%; at the same time, adjust the air conditioning of the leaf storage room process using film control to gradually adjust the humidity control from (70±2)% to between 70% and 72%, so that the final leaf cutting moisture content of the batch material is optimal (leaf cutting moisture content CPK reaches greater than 1.67).
[0044] The above control methods are simplified as shown in Table 1.
[0045] Table 1
[0046]
[0047] The following are methods for precisely controlling the temperature and humidity of the leaf-cutting process during the heating season (October 15th of the current year to April 15th of the following year):
[0048] (1) During normal material handling, the experiment found that: 1) When the temperature of the leaf storage room is controlled at (28±3)℃ and the humidity is controlled within the range of (70±2)%, the average moisture loss of A-B ("average moisture content of the leaf storage room at the inlet of batch A" minus "average moisture content of the leaf storage room at the outlet of batch B") is between 0.2% and 0.4%. At this time, the moisture content of the batch of material in the leaf storage room is optimal, which also indicates that the temperature and humidity control of the leaf storage room environment is optimal; 2) When the temperature of the leaf cutting process is controlled at (28±3)℃ and the humidity is controlled within the range of (56±2)%, the average moisture loss of B-C ("average moisture content of the leaf storage room at the outlet of batch B" minus "average moisture content of the leaf cutting process at the outlet of batch C") is between 0.1% and 0.3%. At this time, the moisture content of the batch of material in the leaf cutting process is optimal, which also indicates that the temperature and humidity control of the leaf cutting process environment is optimal. When 1) and 2) are satisfied at the same time, the final moisture content of the leaf filaments of this batch of material is optimal (the moisture content of the leaf filaments CPK reaches greater than 1.67), and the temperature and humidity control of the storage room and the leaf filament process environment of this batch is optimal.
[0049] (2) When the temperature and humidity of the external environment change significantly or other special reasons affect the moisture content of the materials in the production workshop, the following situations may occur:
[0050] 1) When A-B>0.4% and B-C>0.3%, quickly adjust the air conditioning of the leaf storage room using steam control to adjust the humidity control from (70±2)% to between 70~72%; at the same time, quickly adjust the air conditioning of the leaf cutting process using steam control to adjust the humidity control from (56±2)% to between 56~58%, so that the final moisture content of the leaf cuttings of the batch material is optimal (the moisture content of the leaf cuttings CPK reaches greater than 1.67).
[0051] 2) When A-B > 0.4% and B-C is between 0.1% and 0.3%, quickly adjust the air conditioning of the leaf storage room using steam control to adjust the humidity control from (70±2)% to between 70% and 72%; at the same time, adjust the air conditioning of the leaf cutting process using film control to gradually adjust the humidity control from (56±2)% to between 56% and 58%, so that the final leaf cutting moisture content of the batch material is optimal (the leaf cutting moisture content CPK reaches greater than 1.67).
[0052] 3) When A-B is between 0.2% and 0.4%, and B-C > 0.3%, quickly adjust the air conditioning of the leaf cutting process using steam control to adjust the humidity control from (56±2)% to between 56% and 58%; at the same time, adjust the air conditioning of the leaf storage room process using film control to gradually adjust the humidity control from (70±2)% to between 70% and 72%, so that the final leaf cutting moisture content of the batch material is optimal (leaf cutting moisture content CPK reaches greater than 1.67).
[0053] The above control methods are simplified as shown in Table 2.
[0054] Table 2
[0055]
[0056] The following examples further illustrate the solution of this application.
[0057] Example 1
[0058] Non-heating season regulation (May 20, no heating in the workshop)
[0059] 1. The moisture content at the inlet of the leaf storage room for production batch 1 is A=22.5%, and the moisture content at the outlet is B=22.1%. The moisture content at the outlet of the leaf cutting process is C=21.8%. The temperature of both the leaf storage room and the leaf cutting process is controlled at 29℃.
[0060] 2. AB = 0.4% > 0.3%, BC = 0.3% > 0.2%, which meets condition 1) of Scheme 1;
[0061] 3. The air conditioning in the leaf storage room is controlled by steam, and the humidity is adjusted from (70±2)% to 71%; the air conditioning in the leaf cutting process is controlled by steam, and the humidity is adjusted from (56±2)% to 57%.
[0062] 4. After adjustment, 30 leaf filament samples were collected, and the calculated CPK was 1.72 > 1.67. Therefore, the leaf filament moisture content meets the quality requirements.
[0063] Example 2
[0064] Energy-saving regulation during the non-heating season (September 5th, no heating in the workshop)
[0065] 1. The moisture content at the inlet of the leaf storage room for production batch 3 is A=22.3%, the moisture content at the outlet is B=22.1%, and the moisture content at the outlet of the leaf cutting process is C=21.8%; the temperature is controlled at 28℃.
[0066] 2. AB = 0.2% (0.2% ≤ AB ≤ 0.3%), BC = 0.3% > 0.2%, which meets condition 3) of Scheme 1;
[0067] 3. The air conditioning in the leaf storage room uses thin-film control, gradually adjusting the humidity to 70%; the air conditioning in the leaf cutting process uses steam control, rapidly adjusting the humidity to 56%.
[0068] 4. After adjustment, 25 groups of leaf filament samples were collected, and the calculated CPK was 1.75 > 1.67, therefore the leaf filament moisture content met the quality requirements. Furthermore, compared to the dual steam control of the leaf storage room air conditioning and the leaf cutting process air conditioning, the control method of this application reduces energy consumption.
[0069] Example 3
[0070] Heating season regulation (Heating is available in the workshop on January 10th).
[0071] 1. The moisture content at the inlet of the leaf storage room for production batch 2 is A=23.0%, and the moisture content at the outlet is B=22.5%. The moisture content at the outlet of the leaf cutting process is C=22.1%. The temperature of both the leaf storage room and the leaf cutting process is controlled at 27℃.
[0072] 2. AB = 0.5% > 0.4%, BC = 0.4% > 0.3%, which meets the conditions of clause 1) of Scheme 2;
[0073] 3. The air conditioning in the leaf storage room is steam-controlled, with the humidity adjusted to 72%; the air conditioning in the leaf cutting process is steam-controlled, with the humidity adjusted to 58%.
[0074] 4. After adjustment, 28 leaf filament samples were collected, and the calculated CPK was 1.69 > 1.67. Therefore, the leaf filament moisture content meets the quality requirements.
Claims
1. A method for precisely controlling the temperature and humidity of the environment during the leaf cutting process, characterized in that, The method includes the following steps: 1) The average batch moisture content of tobacco leaves at the entrance of the tobacco storage room is recorded as A; the average batch moisture content of tobacco leaves at the exit of the tobacco storage room is recorded as B; the average batch moisture content of tobacco shreds at the exit of the leaf cutting process is recorded as C. 2) Use Option 1 during the non-heating season and Option 2 during the heating season; 3) Based on the moisture content difference conditions corresponding to the scheme, adjust the air conditioning humidity of the leaf storage room and the leaf cutting process by combining steam control and film control methods, so that the final leaf cutting process outlet moisture content process capacity index is greater than 1.67; The initial humidity of the air conditioner in the leaf storage room is set to 70±2%, and the initial humidity of the air conditioner in the leaf cutting process is set to 56±2%.
2. The method for precisely controlling the temperature and humidity of the leaf-cutting process according to claim 1, characterized in that, The first scheme includes the following steps: 1) When A - B > 0.3% and B - C > 0.2%: The air conditioning in the leaf storage room is steam-controlled, adjusting the humidity to 70-72%; simultaneously, the air conditioning in the leaf cutting process is steam-controlled, adjusting the humidity to 56-58%. 2) When A - B > 0.3% and B - C is 0.1~0.2%: The air conditioning in the leaf storage room is steam-controlled, adjusting the humidity to 70-72%; the air conditioning in the leaf cutting process is film-controlled, adjusting the humidity to 56-58%. 3) When A - B is between 0.2% and 0.3%, and B - C > 0.2%: The air conditioning in the leaf storage room process uses thin-film control to adjust the humidity to 70-72%; the air conditioning in the leaf cutting process uses steam control to adjust the humidity to 56-58%.
3. The method for precisely controlling the temperature and humidity of the leaf-cutting process according to claim 1, characterized in that, The second scheme includes the following steps: 1) When A-B > 0.4% and B-C > 0.3%: the air conditioning in the leaf storage room is controlled by steam, and the humidity is adjusted to 70-72%; the air conditioning in the leaf cutting process is controlled by steam, and the humidity is adjusted to 56-58%. 2) When A-B > 0.4% and 0.1% ≤ B-C ≤ 0.3%: the air conditioning in the leaf storage room uses steam control, with the humidity adjusted to 70-72%; the air conditioning in the leaf cutting process uses thin-film control, with the humidity adjusted to 56-58%. 3) When 0.2%≤A-B≤0.4% and B-C>0.3%: the air conditioning in the leaf storage room adopts film control and the humidity is adjusted to 70~72%; the air conditioning in the leaf cutting process adopts steam control and the humidity is adjusted to 56~58%.
4. The method for precisely controlling the temperature and humidity of the leaf-cutting process according to claim 1, characterized in that, The calculation of the leaf filament moisture content process capacity index is based on 25-30 sets of leaf filament moisture content sample data, and the calculation method is as follows: CPK = min(CPU, CPL); CPU = (USL - x) / 3s; CPL=(x-LSL) / 3s; Wherein, USL is the upper limit of the leaf fiber moisture content, LSL is the lower limit of the leaf fiber moisture content, x is the sample mean of leaf fiber moisture content, s is the sample standard deviation of leaf fiber moisture content, and CPK is the process capability index of leaf fiber moisture content.
5. The method for precisely controlling the temperature and humidity of the leaf-cutting process according to claim 4, characterized in that, Set USL to 18% and LSL to 16%.