Carton sealing and cooling method for cigarette packaging machine

Abstract

The invention discloses a cigarette packaging machine sealing box cooling method, which comprises the following steps: arranging temperature sensors in a cigarette packaging machine sealing box at a fixed point and directionally installing cooling fans to construct a fixed-point temperature control closed loop, carrying a multi-fan collaborative scheduling algorithm to avoid airflow hedging interference, and establishing a dynamic correlation mechanism of an overtemperature trigger threshold value and a production takt; the problems that according to an existing cigarette packaging machine box sealing cooling scheme, core components are prone to being damaged, the heat dissipation efficiency is low, airflow interferes with a box sealing temperature field, and a fixed threshold value cannot adapt to the production takt, so that energy consumption is high are effectively solved, and the effects that the core components are accurately cooled, the box sealing temperature field is stable, energy consumption is greatly reduced, and the equipment operation reliability is improved are achieved.

Description

Technical Field

[0001] This invention relates to a method for cooling the sealing box of a cigarette packaging machine, belonging to the field of cooling control technology for cigarette packaging equipment. Background Technology

[0002] In the cigarette sorting and packaging process, cartons of cigarettes typically require heat shrink wrapping after sorting. This process relies on the sealing device of the packaging machine to heat and shrink the wrapping film. The internal working temperature of the sealing box usually needs to be maintained in a relatively high range (e.g., 150-160℃) to ensure the quality of heat shrinking.

[0003] However, the high-temperature environment inside the sealing box poses a severe challenge to its internal and surrounding working components, especially the motor and drive rollers. First, the motor, installed at or near the bottom of the sealing box, experiences heat transfer from the interior, raising the ambient temperature of the fan and causing the motor bearings to overheat. The internal grease may liquefy and leak out, leading to damage and ultimately motor burnout. Second, the conveyor rollers inside the sealing box are also constantly exposed to high temperatures. The lubricating oil in their bearings can easily evaporate or deteriorate due to the heat, resulting in lubrication failure, dry friction, and ultimately, roller jamming, sluggish rotation, or even damage. These malfunctions not only increase equipment maintenance costs but also severely impact the continuous operating efficiency of the packaging line.

[0004] Currently, the cooling solution for sealing cigarette packaging machines in this field is to install fans for heat dissipation, or even install multiple fans with independent temperature control. Multiple cooling fans are arranged inside the sealing box, and each fan is equipped with an independent temperature detection device. All fans use a unified fixed over-temperature trigger threshold. When the temperature at the corresponding detection point exceeds the threshold, the corresponding fan starts running independently, and the fan stops independently after the temperature drops below the threshold.

[0005] However, existing methods cannot simultaneously meet the multiple requirements of core component cooling effect, sealing temperature field stability, and system energy economy, making it difficult to continuously guarantee equipment operational reliability and packaging quality. Research has found that existing solutions do not coordinate the operation logic of multiple fans. When multiple fans start and stop independently, airflow convection easily occurs. On the one hand, this offsets some of the heat dissipation effect, reducing overall heat dissipation efficiency and increasing peak system energy consumption. On the other hand, the convection airflow disrupts the temperature field inside the sealing box, causing local temperatures to deviate from the process requirement of 150-160℃, directly affecting the forming quality of the heat-shrink film. Furthermore, existing solutions use a fixed over-temperature trigger threshold, failing to consider the significant differences in the heating rate of core moving components when the cigarette packaging machine's production cycle changes dynamically: under high-speed production conditions, components operate under high load and heat up quickly; a relatively high fixed threshold can easily lead to delayed heat dissipation and component over-temperature. Under low-speed production or standby conditions, components operate under low load and heat up slowly; a relatively low fixed threshold can lead to frequent fan starts and stops, resulting in unnecessary energy waste. Summary of the Invention

[0006] (a) Purpose of the invention

[0007] Based on the above, the present invention provides a cooling method for sealing cigarette packaging machines, so as to effectively cool the core moving parts of the sealing cigarette packaging machine, while meeting multiple requirements of cooling effect of core parts, stability of sealing temperature field and energy economy of system.

[0008] (II) Technical Solution

[0009] A method for sealing and cooling cigarette packaging machines includes:

[0010] S1. Temperature sensors are placed at fixed points next to the bearing seats of each motor and roller inside the cigarette packaging machine to collect temperature data of each core moving component in real time and transmit the temperature data to the PLC controller.

[0011] S2. The PLC controller communicates with the main PLC of the production line through the production cycle input interface, reads the real-time production cycle of the cigarette packaging machine, and matches the over-temperature trigger threshold corresponding to the current working condition according to the association rules between the pre-stored over-temperature trigger threshold and the production cycle.

[0012] S3, the PLC controller determines whether the temperature of a core moving part exceeds the current over-temperature trigger threshold. If so, it calls the multi-zone fan collaborative temperature control scheduling algorithm and outputs control commands to control the start, stop and speed of each adjustable speed cooling fan. The adjustable speed cooling fans are installed one by one at a preset distance next to each target part, and the air supply direction is towards the corresponding bearing seat.

[0013] S4. When the temperature of all core moving parts drops below the over-temperature trigger threshold, the PLC controller controls the fan to stop running and returns to step S1 to repeat the temperature control process.

[0014] In one example, in step S2, the association rule is as follows: with the rated over-temperature threshold of 160℃ as the benchmark, the over-temperature trigger threshold is 158℃ when the real-time production cycle is ≥90% of the rated cycle, the over-temperature trigger threshold is 162℃ when the real-time production cycle is ≤30% of the rated cycle, and the over-temperature trigger threshold is 165℃ under standby conditions.

[0015] In one example, in step S3, the multi-region fan collaborative temperature control scheduling algorithm is as follows: when a single component overheats, the corresponding target fan is controlled to run at full load, and the other adjacent fans are adjusted to low speed to assist in airflow; when multiple components overheat at the same time, a periodic pulse alternating air supply strategy with a period of 8~15s is adopted, and only one fan is controlled to run at full load in each cycle, and the full load running time is staggered.

[0016] In one example, in step S3, when a single component overheats, the remaining adjacent fans adjust to operate at 30% of their rated speed, guiding the airflow toward the exhaust port at the top of the enclosure.

[0017] In one example, in step S3, when multiple components simultaneously exceed the temperature, the periodic pulse alternating air supply cycle is 10 seconds.

[0018] In one example, the cigarette packaging machine is equipped with two conveyor motors, three drive rollers, five temperature sensors, and five 30W adjustable speed axial flow fans inside the sealing box.

[0019] In one example, the temperature sensor is a PT100 platinum resistance temperature sensor.

[0020] (III) Beneficial Effects

[0021] This invention solves the problems of existing cigarette packaging machine sealing and cooling solutions, such as easily damaged core components, low heat dissipation efficiency, airflow interference with the sealing temperature field, and high energy consumption due to fixed thresholds not being compatible with the production cycle, by constructing a fixed-point temperature control closed loop through fixed-point temperature sensors and directional installation of cooling fans, avoiding airflow interference, and establishing a dynamic correlation mechanism between the over-temperature trigger threshold and the production cycle. Specifically:

[0022] 1. This invention uses the technical means of arranging temperature sensors at fixed points next to the bearing housing of the core moving component and installing cooling fans in a directional manner to allow the cooling airflow to act directly on the core heat-generating parts. This can control the bearing temperature within a safe range below 120°C, fundamentally avoiding lubrication failure caused by grease liquefaction and evaporation, reducing the failure rate of core components by more than 80%, and significantly reducing unplanned downtime of equipment.

[0023] 2. This invention establishes a dynamic correlation mechanism between the over-temperature trigger threshold and the production cycle. The threshold is adjusted according to the real-time production cycle. During high-speed production, the threshold is appropriately lowered to start heat dissipation in advance to avoid sudden over-temperature. During low-speed or standby conditions, the threshold is appropriately raised to reduce unnecessary fan start-stop, thereby further reducing the average energy consumption of the cooling system and improving the system's adaptability to different production scenarios.

[0024] 3. This invention incorporates a multi-region fan collaborative temperature control scheduling algorithm. When a single component overheats, adjacent fans divert air at low speeds. When multiple components overheat, a periodic pulse alternating air supply strategy is adopted. This avoids heat dissipation efficiency loss caused by airflow collision and reduces system peak energy consumption, thereby improving heat dissipation efficiency. At the same time, it can control the temperature field fluctuation of the sealing box within ±1℃, without interfering with the heat shrink film forming process, ensuring stable packaging quality. Attached Figure Description

[0025] Figure 1 This is a flowchart of the sealing and cooling method for cigarette packaging machines. Detailed Implementation

[0026] To make the above-mentioned objects, features, and advantages of the present invention more apparent and understandable, specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a thorough understanding of the present invention. However, the present invention can be practiced in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0027] Temperature sensors are fixedly arranged 5cm away from the bearing seats of each motor and roller inside the cigarette packaging machine. In this embodiment, PT100 platinum resistance temperature sensors are used, with a temperature measurement range of -200~600℃ and a detection accuracy of ±0.1℃, which is suitable for the high-temperature environment of sealing. The signal output terminals of all temperature sensors are electrically connected to the input terminals of the PLC controller. Adjustable speed cooling fans are installed 15cm away from each core moving part. The fan airflow direction is towards the corresponding bearing seat and at a 30° downward angle with the horizontal direction. This angle setting allows the cooling airflow to act directly on the bearing surface, while avoiding the upward diffusion of airflow and interference with the temperature of the upper heat shrink process area of ​​the sealing machine. The fan control terminal is electrically connected to the output terminal of the PLC controller through a contactor. The PLC controller is equipped with a production cycle input interface, which can communicate with the main PLC of the production line through conventional industrial communication protocols such as Modbus and Profinet to read the real-time production cycle of the cigarette packaging machine.

[0028] In one example, the above hardware is configured on a YF611 cigarette packaging machine. This model is the mainstream configuration for cigarette sorting lines in China. The sealing box is equipped with two conveyor motors and three drive rollers, and is equipped with five PT100 platinum resistance temperature sensors and five 30W adjustable speed axial flow fans. The rated over-temperature trigger threshold is 160℃.

[0029] refer to Figure 1 The present invention discloses a method for sealing and cooling cigarette packaging machines, comprising the following steps:

[0030] Step S1: Fixed-point temperature acquisition

[0031] First, PT100 platinum resistance temperature sensors, which are positioned 5cm away from the bearing seats of each motor and roller inside the cigarette packaging machine, are used to collect the temperature data of each core moving component in real time and transmit the temperature data to the PLC controller.

[0032] Step S2, Dynamic Threshold Matching

[0033] The PLC controller communicates with the main PLC of the production line through the production cycle input interface, reads the real-time production cycle of the cigarette packaging machine, and matches the over-temperature trigger threshold corresponding to the current working condition according to the pre-stored association rules between the over-temperature trigger threshold and the production cycle. The specific association rules are as follows: with the rated over-temperature threshold of 160℃ as the benchmark, the over-temperature trigger threshold is 158℃ when the real-time production cycle is ≥90% of the rated cycle, the over-temperature trigger threshold is 162℃ when the real-time production cycle is ≤30% of the rated cycle, the over-temperature trigger threshold is 165℃ in standby mode, and the over-temperature trigger threshold is 160℃ when the real-time production cycle is in the range of 30%~90% of the rated cycle.

[0034] Step S3: Collaborative Temperature Control

[0035] The PLC controller determines whether the temperature of any core moving component exceeds the current over-temperature trigger threshold. If so, it invokes a multi-zone fan collaborative temperature control scheduling algorithm and outputs control commands to control the start, stop, and speed of each adjustable-speed cooling fan. When a single component over-temperatures, the corresponding target fan is controlled to run at full load, while the other adjacent fans are adjusted to low speeds for auxiliary airflow. When multiple components over-temperature simultaneously, a periodic pulse alternating airflow strategy with a cycle of 8 to 15 seconds is adopted, controlling only one fan to run at full load in each cycle and staggering the full-load operation time.

[0036] In one example, when a single component overheats, the other adjacent fans are adjusted to operate at 30% of their rated speed, guiding the airflow toward the exhaust port at the top of the enclosure. Tests have shown that this solution can prevent the accumulation of temperature caused by hot airflow stagnation inside the enclosure, while also preventing new airflow from clashing.

[0037] In one example, when multiple components overheat simultaneously, the periodic pulse airflow cycle is 10 seconds. This cycle is suitable for mainstream enclosed structures with an internal volume of 1.2~1.8m³, achieving a balance between heat dissipation and energy consumption.

[0038] In one example, when multiple components overheat simultaneously, they are sorted from highest to lowest overheating level, and the fan corresponding to the component with the most severe overheating is given full-load airflow first.

[0039] Step S4: Circulating temperature control

[0040] Once the temperature of all core moving parts drops below the over-temperature trigger threshold, the PLC controller stops the fan and returns to step S1 to repeat the temperature control process.

[0041] Tests have shown that the above solution can control the bearing temperature within a safe range below 150℃, reducing the failure rate of core moving parts by more than 80%; the temperature fluctuation inside the sealing box is controlled within ±1℃, which will not interfere with the heat shrink film forming process; the average energy consumption of the cooling system is reduced by about 8% compared with the fixed threshold solution, and there are no sudden over-temperature failures during high-speed production.

[0042] The embodiments described above are merely illustrative of several implementations of the present invention, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of the present invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these modifications and improvements all fall within the scope of protection of the present invention. Therefore, the scope of protection of this patent should be determined by the appended claims.

Claims

1. A method for sealing and cooling cigarette packaging machines, characterized in that, include: S1. Temperature sensors are placed at fixed points next to the bearing seats of each motor and roller inside the cigarette packaging machine to collect temperature data of each core moving component in real time and transmit the temperature data to the PLC controller. S2. The PLC controller communicates with the main PLC of the production line through the production cycle input interface, reads the real-time production cycle of the cigarette packaging machine, and matches the over-temperature trigger threshold corresponding to the current working condition according to the association rules between the pre-stored over-temperature trigger threshold and the production cycle. S3, the PLC controller determines whether the temperature of a core moving part exceeds the current over-temperature trigger threshold. If so, it calls the multi-zone fan collaborative temperature control scheduling algorithm and outputs control commands to control the start, stop and speed of each adjustable speed cooling fan. The adjustable speed cooling fans are installed one by one at a preset distance next to each target part, and the air supply direction is towards the corresponding bearing seat. S4. When the temperature of all core moving parts drops below the over-temperature trigger threshold, the PLC controller controls the fan to stop running and returns to step S1 to repeat the temperature control process.

2. The cigarette packaging machine sealing and cooling method according to claim 1, characterized in that, In step S2, the association rule is as follows: with the rated over-temperature threshold of 160℃ as the benchmark, the over-temperature trigger threshold is 158℃ when the real-time production cycle is ≥90% of the rated cycle, the over-temperature trigger threshold is 162℃ when the real-time production cycle is ≤30% of the rated cycle, and the over-temperature trigger threshold is 165℃ under standby conditions.

3. The cigarette packaging machine sealing and cooling method according to claim 1, characterized in that, In step S3, the multi-region fan collaborative temperature control scheduling algorithm is as follows: when a single component overheats, the corresponding target fan is controlled to run at full load, and the other adjacent fans are adjusted to low speed to assist in airflow; when multiple components overheat at the same time, a periodic pulse alternating air supply strategy with a period of 8~15s is adopted, and only one fan is controlled to run at full load in each cycle, and the full load running time is staggered.

4. The cigarette packaging machine sealing and cooling method according to claim 3, characterized in that, In step S3, when a single component overheats, the other adjacent fans are adjusted to operate at 30% of their rated speed, guiding the airflow toward the exhaust port at the top of the enclosure.

5. The cigarette packaging machine sealing and cooling method according to claim 3, characterized in that, In step S3, when multiple components overheat simultaneously, the periodic pulse alternating air supply cycle is 10s.

6. The cigarette packaging machine sealing and cooling method according to claim 1, characterized in that, The cigarette packaging machine is equipped with two conveyor motors and three drive rollers inside the sealing box, and is also equipped with five temperature sensors and five 30W adjustable speed axial flow fans.

7. The cigarette packaging machine sealing and cooling method according to claim 6, characterized in that, The temperature sensor is a PT100 platinum resistance temperature sensor.

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