A method and system for controlling the stockpiling of tobacco materials

Abstract

This application relates to a method and system for controlling tobacco material stacking, comprising: real-time acquisition of key stacking data and control of stacking state initiation based on stacking initiation conditions; during stacking state initiation, dynamically controlling the conveyor belt speed for seven-stage stacking based on core detection data and stacking state data; real-time acquisition of stacking state data, controlling stacking state cessation based on the key stacking data and stacking cessation conditions, and initiating downstream equipment based on the initiation count accumulation sequence; and controlling conveyor belt shutdown and stacking state recovery based on real-time material accumulation, normal accumulation, and stacking warning values. Using the technical solution of this application, it is possible to accurately determine stacking initiation conditions to avoid uneven initial stacking, dynamically adjust conveyor belt speed to ensure uniform distribution of seven-stage stacking, accurately stop stacking and link downstream equipment through count accumulation, and also enable emergency shutdown and safe recovery, ensuring safe and continuous stacking.

Description

Technical Field

[0001] This application relates to the field of tobacco production technology, and in particular to a method and system for controlling the stacking of tobacco materials. Background Technology

[0002] In the tobacco processing industry, the material stacking stage of the conveyor belt at the loose and rehydrated outlet is a crucial node connecting the loose and rehydrated process with subsequent processing. This stage needs to adapt to dynamic changes in material flow, constraints on the total stacking distance of the conveyor belt, and limitations on the total stacking time to achieve uniform material stacking. It must ensure that the length of each stack is consistent and that multiple stacks are orderly distributed within the stacking range, directly determining the consistency of subsequent tobacco sheet processing and the continuity of the production process. With the tobacco industry's increasing demands for precision and intelligence in production, traditional stacking control methods are no longer sufficient to meet the management and control requirements of modern production.

[0003] In existing technologies, tobacco material stacking often employs a control mode with fixed belt speed and single-parameter triggering for start and stop. The belt conveyor speed is preset to a fixed value, and the start of stacking depends solely on a single parameter such as time or distance. The stopping of stacking is also based on a single threshold; if the time or distance threshold is met, the downstream equipment starts under independent timing control. However, a fixed speed cannot adapt to increased flow, leading to problems such as excessively sparse stacking in the early stages and excessively dense stacking in the later stages, or even material blockage. Furthermore, single-parameter triggering for start and stop can easily result in deviations in start timing or untimely stopping, causing uneven initial stacking or exceeding stacking limits. Simultaneously, the downstream equipment becomes disconnected from the stacking status, easily leading to equipment idling or material accumulation and blockage.

[0004] It should be noted that the information disclosed in the background section above is only used to enhance the understanding of the background of this disclosure, and therefore may include information that does not constitute prior art known to those skilled in the art. Summary of the Invention

[0005] To address the aforementioned issues, this application provides a method and system for controlling tobacco material stockpiling. This system can accurately determine stockpiling start-up conditions to avoid uneven initial stockpiling, dynamically adjust belt speed to ensure uniform distribution of seven-stage stockpiling, accurately stop stockpiling, and link downstream equipment through counting and accumulation. It can also perform emergency shutdown and safe recovery, ensuring safe and continuous stockpiling.

[0006] To achieve the objectives of this application, the following technical solution is provided: In a first aspect, this application provides a method for controlling the stockpiling of tobacco materials, comprising: Real-time acquisition of key data on material stockpiling, and control of stockpiling status based on stockpiling start conditions; the key data on material stockpiling includes the actual material flow rate at the conveyor inlet, the current stockpiling duration, and the actual distance between the material accumulation front and the start / stop trigger point; When the stacking state is started, the conveyor belt speed is dynamically controlled to perform seven-level stacking based on core detection data and stacking status data; the core detection data includes real-time material accumulation amount, normal accumulation amount, stacking warning value, and single stacking reference time; the stacking status data includes stable production flow rate, total stacking distance of the conveyor belt, and total stacking time. Real-time acquisition of stockpiling status data; control the stockpiling status to stop based on the key stockpiling data and stockpiling stop conditions; and start downstream equipment based on the start count accumulation sequence. Based on real-time material accumulation, normal accumulation, and material accumulation warning values, the system controls the belt conveyor to stop and restore the material accumulation status.

[0007] In one possible implementation, the step of acquiring key stockpile data in real time and controlling the stockpile status based on stockpile start-up conditions includes: The timing unit is activated to record the material stacking time in real time, starting from the appearance of a flow signal on the electronic scale. The actual distance between the material accumulation front and the start / stop trigger point is collected in real time using a displacement detection probe. The material flow rate signal at the inlet of the belt conveyor is collected in real time by an electronic scale. Combined with the production characteristics of the loose and moist outlet, the actual material flow rate at the inlet of the belt conveyor is obtained by the first formula. When the actual material flow rate at the conveyor inlet is 0, the current stacking time is 90 seconds, and the actual distance between the material stacking front and the start / stop trigger point is 0, the stacking state is started.

[0008] In one possible implementation, the first formula is:

[0009] in, This represents the actual material flow rate at the conveyor inlet. This represents the actual distance between the material accumulation front and the start / stop trigger point.

[0010] In one possible implementation, the step of dynamically controlling the conveyor belt speed for seven-stage stacking based on core detection data when the stacking state is initiated includes: When the stockpiling state is initiated, the core detection data and the stockpiling state data are acquired; Based on the core detection data and the stockpiling status data, the adjustment speed is calculated using the second formula to control the conveyor belt speed. According to the third formula, the time it takes for a single pile of material to reach the phototube detection point is calculated based on the controlled speed. Based on the controlled speed and the time it takes for a single pile of material to reach the phototube detection point, seven material stacking operations are performed sequentially according to the waiting time of each pile; the waiting times of each pile are 21 seconds, 18 seconds, 15 seconds, 12 seconds, 9 seconds, 6 seconds and 3 seconds respectively.

[0011] In one possible implementation, the second formula is:

[0012] in, To regulate speed, The rated speed of the belt, This represents the real-time material accumulation level. This is normal accumulation level. This is the early warning value for stockpiling. This represents the actual distance between the material accumulation front and the start / stop trigger point. This refers to the total distance over which the belt conveyor can stack materials. This is the current stockpiling time. This is the baseline time for a single stockpile. Total stockpiling time This represents the actual material flow rate at the conveyor inlet. To stabilize production flow, As the first weighting coefficient, This is the second weighting coefficient. This is the third weighting coefficient. It is the fourth weighting coefficient.

[0013] In one possible implementation, the third formula is:

[0014] in, This refers to the time it takes for a single stockpile of material to travel to the phototube detection point. The length of a single pile of materials. This is the delay time for phototube detection.

[0015] In one possible implementation, the steps of acquiring real-time stockpile status data, controlling the stockpile status to stop based on the key stockpile data and stockpile stop conditions, and starting downstream equipment based on the start count accumulation sequence include: When the actual material flow rate at the conveyor inlet is greater than or equal to the stable production flow rate, or the actual distance between the material accumulation front and the start / stop trigger point is greater than or equal to the total material accumulation distance of the conveyor, or the current material accumulation time is greater than or equal to the total material accumulation time, the material accumulation state is controlled to stop. Based on the time when the material is piled up, the count is accumulated once per second to obtain the count value; When the count value is greater than or equal to the preset downstream equipment material operation comparison value, the downstream equipment is started sequentially.

[0016] In one possible implementation, the step of controlling the belt conveyor shutdown and restoring the stacking state based on real-time material accumulation, normal accumulation, and stacking warning value includes: When the ratio of the real-time material accumulation amount to the material accumulation warning value is greater than or equal to 0.9, the belt conveyor is controlled to stop urgently. When the ratio of the real-time material accumulation to the normal accumulation is less than or equal to 0.5, and the actual distance between the material accumulation front and the start / stop trigger point is less than or equal to half of the total material accumulation distance of the belt conveyor, the belt conveyor is controlled to resume the material accumulation state.

[0017] In one possible implementation, the tobacco material stockpiling control method further includes: The surface of the detection components is periodically blew to remove tobacco dust; the detection components are all the detection components that acquire key data, core detection data and stack status data of the material.

[0018] Secondly, this application also provides a tobacco material stacking control system for executing the above-described tobacco material stacking control method, the system comprising: Laser level detection sensor is used to collect the real-time accumulation amount of tobacco materials. Displacement detection probe is used to collect the actual distance between the front edge of material accumulation and the start / stop trigger point in real time; Phototubes are used to detect whether a single pile of materials has reached a preset detection point and output a stable detection signal to determine the starting point of the detection delay. The control module is used to acquire key data of the stockpiling and control the stockpiling state to start based on the stockpiling start conditions; it is also used to dynamically control the conveyor belt speed for seven-level stockpiling by using core detection data and stockpiling state data when the stockpiling state is started; it is also used to acquire stockpiling state data in real time, control the stockpiling state to stop based on the key data of the stockpiling and stockpiling stop conditions, and start downstream equipment based on the start count accumulation sequence; and it is used to control the conveyor belt to stop and the stockpiling state to recover based on the real-time material accumulation amount, normal accumulation amount and stockpiling warning value.

[0019] The technical solution provided in this application may include the following beneficial effects: The tobacco material stacking control method and system provided in this application can accurately determine the stacking start conditions by collecting key stacking data in real time, ensuring that the stacking start is completely matched with the initial state of material conveying, and avoiding uneven initial stacking caused by start-up timing deviations. Furthermore, after the stacking state is started, based on core detection data such as real-time material accumulation, normal accumulation, stacking warning value, and single-stack stacking reference time, combined with stacking status data such as stable production flow, total stackable distance of the belt conveyor, and total stacking time, the system dynamically controls the belt conveyor speed to complete seven-level stacking, effectively adapting to changes in material state during the stacking process and ensuring that each stack of material is evenly distributed within the stackable range. Simultaneously, it can accurately control the stacking stop based on key stacking data and stacking stop conditions, avoiding stacking overload, and sequentially start downstream equipment through start-up count accumulation logic, improving equipment linkage reliability. It can also achieve emergency belt conveyor shutdown to prevent material blockage and stacking recovery under safe conditions by comparing real-time material accumulation, normal accumulation, and stacking warning value, ensuring the safety and continuity of the stacking process.

[0020] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and are not intended to limit this disclosure. Attached Figure Description

[0021] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used together with the embodiments of the invention to explain the invention and do not constitute a limitation thereof. Obviously, the drawings described below are merely some embodiments of this disclosure, and those skilled in the art can obtain other drawings based on these drawings without any creative effort.

[0022] Figure 1 A schematic flowchart illustrating a method for controlling the stockpiling of tobacco materials provided in an embodiment of this application; Figure 2 A flowchart illustrating step S100 of a tobacco material stockpiling control method provided in an embodiment of this application; Figure 3 A flowchart illustrating step S200 of a tobacco material stockpiling control method provided in an embodiment of this application; Figure 4 A flowchart illustrating step S300 of a tobacco material stockpiling control method provided in an embodiment of this application; Figure 5 A flowchart illustrating step S400 of a tobacco material stockpiling control method provided in an embodiment of this application; Figure 6 This is a schematic diagram of a tobacco material stacking control system provided in an embodiment of this application. Detailed Implementation

[0023] Exemplary embodiments will now be described more fully with reference to the accompanying drawings. However, these exemplary embodiments can be implemented in many forms and should not be construed as limited to the examples set forth herein; rather, they are provided so that this disclosure will be more comprehensive and complete, and will fully convey the concept of the exemplary embodiments to those skilled in the art. The described features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.

[0024] This example implementation first provides a method for dynamic disturbance power management and tobacco material stacking control under conditions of sparse feedback and missing observations. (Reference) Figure 1 As shown, the tobacco material stockpiling control method may include the following steps: Step S100: Acquire key data of the material stacking in real time, and control the start of the material stacking state based on the material stacking start conditions; the key data of the material stacking includes the actual material flow rate at the belt conveyor inlet, the current material stacking time, and the actual distance between the material stacking front and the start / stop trigger point.

[0025] Step S200: When the stacking state is started, the conveyor belt speed is dynamically controlled to perform seven-level stacking by using core detection data and stacking status data; the core detection data includes real-time material accumulation amount, normal accumulation amount, stacking warning value, and single stacking reference time; the stacking status data includes stable production flow rate, total stacking distance of the conveyor belt, and total stacking time.

[0026] Step S300: Acquire the stockpiling status data in real time, control the stockpiling status to stop based on the key stockpiling data and stockpiling stop conditions, and start the downstream equipment based on the start count accumulation sequence.

[0027] Step S400: Based on the real-time material accumulation amount, normal accumulation amount and material accumulation warning value, control the belt conveyor to stop and restore the material accumulation status.

[0028] The aforementioned tobacco material stacking control method enables precise triggering of stacking start conditions by relying on real-time acquisition and collaborative judgment of multi-dimensional key stacking data, avoiding uneven initial stacking caused by start-up timing deviations. Through dynamic linkage between core detection data and stacking status data, combined with real-time adjustment of belt speed using control algorithms, material stacking is completed in seven stages, ensuring uniform distribution of each stack within the total stackable distance, adapting to the process constraints of stable production flow and total stacking time. Simultaneously, based on multiple conditions, precise control of stacking stop prevents stacking overload, and downstream equipment is started sequentially through counting accumulation based on stacking completion, improving equipment linkage reliability. Furthermore, monitoring the ratio of real-time stacking volume to warning values ​​and normal stacking volume enables emergency shutdown to prevent material blockage and safe stacking recovery. Timely purging of detection components ensures data accuracy, ultimately achieving precise, efficient, and safe continuous operation of the tobacco material stacking process.

[0029] Below, we will refer to Figures 2 to 5 The steps of the tobacco material stacking control method described in this example embodiment will be explained in more detail.

[0030] In step S100, key data of the material stacking is acquired in real time, and the stacking status is controlled to start based on the material stacking start conditions; the key data of the material stacking includes the actual material flow rate at the belt conveyor inlet, the current stacking time, and the actual distance between the material stacking front and the start / stop trigger point.

[0031] It should be noted that by synchronously collecting and collaboratively judging multi-dimensional material stacking data, it is ensured that the material stacking start conditions are completely matched with the arrival status of the smoke sheets on the outlet conveyor belt, that is, the material stacking distance s=0, the stacking time t=90s, and the material flow rate m=0. This avoids the risk of premature or delayed material stacking due to misjudgment of a single data point, thereby preventing uneven material stacking or blockage.

[0032] In one possible implementation, such as Figure 2 As shown, step S100 may further include the following sub-steps: In step S110, the timing unit is started to record the stacking time in real time, with the appearance of a flow signal on the electronic scale as the starting point for timing.

[0033] It should be noted that the timing accuracy of the timing unit can be ≤0.1s. The recorded stacking time is not only the basis for determining the stacking start condition, but also the basis for monitoring the total stacking time.

[0034] In step S120, the actual distance between the material accumulation front and the start / stop trigger point is collected in real time by a displacement detection probe.

[0035] It should be noted that the detection stroke of the displacement detection probe can be 0-3.5m, which is consistent with the total material stacking distance of the belt conveyor, and the detection error is ≤±2mm; the actual distance data collected will be used simultaneously for determining the material stacking start condition and triggering the material stacking stop condition.

[0036] In step S130, the material flow rate signal at the inlet of the belt conveyor is collected in real time by an electronic scale, and the actual material flow rate at the inlet of the belt conveyor is obtained by combining the loose and moistened outlet production characteristics with the first formula.

[0037] It should be noted that the first formula is obtained by fitting the increasing characteristics of material flow rate in the loosening and rehydration process. When s < 90s, no smoke flakes appear on the outlet belt. At this time, the actual material flow rate m = 0 is determined to ensure that the flow rate data is consistent with the actual conveying state of the material.

[0038] The first formula is:

[0039] in, This represents the actual material flow rate at the conveyor inlet. This represents the actual distance between the material accumulation front and the start / stop trigger point.

[0040] It should be noted that this formula is obtained by fitting the linear increasing characteristics of the loose rehydrated outlet material flow rate and the stacking distance, and the unit of s is seconds; when s < 90s, no smoke flakes have appeared on the outlet conveyor belt yet, and the actual material flow rate m = 0 is determined at this time; when s ≥ 90s, the actual flow rate is calculated by this formula to ensure the matching of flow rate data with the material stacking progress.

[0041] In step S140, when the actual material flow rate at the conveyor inlet is 0, the current stacking time is 90 seconds, and the actual distance between the material stacking front and the start / stop trigger point is 0, the stacking state is started.

[0042] It should be noted that the start-up condition is set in combination with the material conveying sequence (i.e., 90 seconds corresponds to the arrival of the tobacco sheets at the outlet belt), the initial stacking state (i.e., distance 0 corresponds to no pre-stacking), and the flow rate state (i.e., flow rate 0 corresponds to the tobacco sheets not starting to stack). All three parameters must be met simultaneously to avoid premature / delayed start of stacking caused by a single condition triggering, and to ensure that the stacking rhythm is completely synchronized with the arrival rhythm of the tobacco sheets.

[0043] In step S200, when the stacking state is started, the conveyor belt speed is dynamically controlled to perform seven-level stacking by using core detection data and stacking state data; the core detection data includes real-time material accumulation amount, normal accumulation amount, stacking warning value, and single stacking reference time; the stacking state data includes stable production flow rate, total stacking distance of the conveyor belt, and total stacking time.

[0044] It should be noted that among the core detection data: real-time material accumulation, normal accumulation, and material accumulation warning value are used to calculate the proportion coefficient of belt speed control; the single pile accumulation reference time is the standard accumulation time reference under rated speed; among the material accumulation status data: stable production flow rate, total stackable distance, and total accumulation time are used to limit the accumulation boundary; seven-level accumulation refers to accumulating a total distance of 3.5m in 7 stages at a length of 0.5m / pile, and ensuring uniform material distribution on the belt conveyor by dynamically adjusting the belt speed to adapt to flow rate changes.

[0045] In one possible implementation, such as Figure 3 As shown, step S200 may further include the following sub-steps: In step S210, when the stockpiling state is started, the core detection data and the stockpiling state data are acquired.

[0046] Understandably, the core detection data can be collected in real time by components such as laser level detection sensors and displacement detection probes, while the stockpiling status data is based on pre-set benchmark parameters. The accurate acquisition of both types of data allows for dynamic calculation of the belt speed control, ensuring that the speed control can simultaneously match the real-time stockpiling status of the material with the pre-set stockpiling boundary requirements.

[0047] In step S220, based on the core detection data and the stacking status data, the adjustment speed is calculated using the second formula to control the conveyor belt speed.

[0048] Understandably, dynamically controlling the conveyor speed of the belt conveyor is the core of the seven-stage stacking process. It does not use a fixed belt speed for stacking, but rather uses multi-dimensional data to collaboratively calculate and dynamically adapt the speed to changes in material accumulation, stacking distance, stacking time, and material flow rate. This avoids problems such as excessive material thickness, uneven distribution, or blockage during the stacking process, and ensures uniform stacking of multiple material piles within a predetermined distance.

[0049] The second formula is:

[0050] in, To regulate speed, The rated speed of the belt, This represents the real-time material accumulation level. This is normal accumulation level. This is the early warning value for stockpiling. This represents the actual distance between the material accumulation front and the start / stop trigger point. This refers to the total distance over which the belt conveyor can stack materials. This is the current stockpiling time. This is the baseline time for a single stockpile. Total stockpiling time This represents the actual material flow rate at the conveyor inlet. To stabilize production flow, As the first weighting coefficient, This is the second weighting coefficient. This is the third weighting coefficient. It is the fourth weighting coefficient.

[0051] It should be noted that the weighting coefficients must satisfy 0 < , , , <1 and + + + =1, in practical applications, it is usually... , The weighting is set higher, such as , Meanwhile, the proportion of each term in the formula reflects the degree of influence of the corresponding parameter on the stockpile state; finally, the actual control speed is obtained by multiplying it with the rated speed, realizing an adaptive speed control logic where the more full the stockpile, the farther the distance, the longer the duration, and the larger the flow rate, the slower the speed, ensuring the stability of the stockpile process. Furthermore, , , , It can be determined through empirical data or through pre-production experiments, as detailed below: Step 1: Based on the core requirements of tobacco stockpiling (anti-clogging material, uniform stacking), determine the priority of the impact of four factors on stockpile stability: First priority The corresponding real-time material accumulation amount: The accumulation amount directly determines whether there is material blockage and is the core indicator for preventing material overload, with the highest priority; the second highest priority. The corresponding material flow rate is positively correlated with the accumulation velocity. Overloading the flow rate will cause a surge in the accumulation volume in a short period of time, making it the second highest priority; the third highest priority. The corresponding stacking distance: the distance determines whether the stacked material exceeds the permissible stacking range of 3.5m, with the third priority; the fourth priority... The corresponding stockpiling time: Time is a secondary reference indicator with the lowest priority. Step 2: Through orthogonal experimental design of different weight combinations, verify indicators such as stockpiling uniformity and number of blockages, and determine the preliminary weights: Set the value range of each coefficient. 0.3-0.5 0.2-0.4 0.1-0.2 0.05-0.15, select 5-8 weight combinations, test in a simulated stockpiling environment, and statistically analyze stockpiling uniformity, blockage frequency, and belt load fluctuation values. Select the combination with the optimal indicators. Step 3: Based on the actual production workshop's belt conveyor parameters and material characteristics, fine-tune the initial weights: If the on-site stockpiling volume frequently approaches the warning value: increase... If adjusted from 0.4 to 0.45, it reduces... For example, adjust from 0.1 to 0.05; if the material flow rate fluctuates greatly: increase If adjusted from 0.3 to 0.35, it reduces... For example, adjust from 0.2 to 0.15; if the stacking distance frequently approaches the conveyor belt, the total stacking distance can be increased. If adjusted from 0.2 to 0.25, it reduces... Step 4: Run the adjusted weighting coefficients in 1-2 batches of actual production for verification.

[0052] For example, the normal stacking amount can be a material height of 10cm, the stacking warning value can be a material height of 18cm, the single stacking base time can be 1.1s, the stable production flow rate can be 4800, and the total stacking time can be 120s.

[0053] In step S230, the time it takes for a single pile of material to reach the phototube detection point is calculated based on the third formula and the controlled speed.

[0054] It should be noted that the core purpose of calculating this time is to determine the timing of the material reaching the detection point after the current stacking is completed. This serves as the time benchmark for connecting the current stack detection with the start of the next stacking, thus avoiding the overlapping or excessive spacing of multiple stacks of material due to timing misalignment.

[0055] The third formula is as follows:

[0056] in, This refers to the time it takes for a single stockpile of material to travel to the phototube detection point. The length of a single pile of materials. This is the delay time for phototube detection.

[0057] It should be noted that the optional single-pile material length is a fixed value of 0.5m, which matches the single-pile length requirements of the seven-level stockpile. A fixed value of 4 seconds is used to eliminate fluctuations in the detection signal caused by material shaking and dust interference; It is a single pile of material with controlled speed The actual time taken to reach the detection point, and The result after addition It is the total time from the completion of a single stack of materials to the output of a stable detection signal from the phototube. This time will be used as the starting point for the start timing of the waiting process for the next stack of materials.

[0058] In step S240, based on the controlled speed and the time it takes for the single pile of material to reach the phototube detection point, the material is stacked seven times in sequence according to the waiting time of each pile; the waiting time of each pile is 21 seconds, 18 seconds, 15 seconds, 12 seconds, 9 seconds, 6 seconds and 3 seconds in sequence.

[0059] It should be noted that the reason for using a decreasing sequence of waiting times for each pile is to adapt to the characteristic that the flow rate of tobacco material increases proportionally with the stacking process. The later the pile, the greater the material flow rate. If the waiting time is too long, it will cause the material in the later pile to overlap with the material in the previous pile. The decreasing setting of 21s to 3s can ensure that the seven piles of material are evenly distributed within a stackable distance of 3.5m. The stacking process logic is as follows: single pile stacking completed → single pile calculation → photoelectric tube detection completed → entering the waiting time of the corresponding pile → starting the next pile stacking. Through precise matching of the timing, the orderly and uniform stacking of the seven levels of stacking is achieved.

[0060] In step S300, the stacking status data is acquired in real time, and the stacking status is stopped based on the key stacking data and the stacking stop conditions. The downstream equipment is started based on the start count accumulation sequence.

[0061] It should be noted that this step ensures that the material stacking process does not exceed the limit by triggering the material stacking stop under multiple conditions. At the same time, it achieves precise matching between the downstream equipment and the material conveying rhythm through counting accumulation linkage, avoiding downstream equipment idling or material accumulation and blockage.

[0062] In one possible implementation, such as Figure 4 As shown, step S300 may include the following sub-steps: In step S310, when the actual material flow rate at the conveyor inlet is greater than or equal to the stable production flow rate, or the actual distance between the material accumulation front and the start / stop trigger point is greater than or equal to the total material accumulation distance of the conveyor, or the current material accumulation time is greater than or equal to the total material accumulation time, the material accumulation state is controlled to stop.

[0063] It should be noted that among the conditions for stopping the material stacking status, if the actual material flow rate at the conveyor inlet is greater than or equal to the stable production flow rate, the production has entered a stable stage and no further material stacking is required; if the actual distance between the material stacking front and the start / stop trigger point is greater than or equal to the total stacking distance of the conveyor, the stacking area of ​​the conveyor is full; and if the current stacking time is greater than or equal to the total stacking time, the stacking time has reached the preset upper limit. The multi-condition design can ensure that the stacking stops in a timely manner under any over-limit scenario, avoiding equipment overload or material overflow.

[0064] In step S320, based on the time point when the material is completed, the count is accumulated once per second to obtain the count value.

[0065] It should be noted that the completion time of the material stacking usually corresponds to 210 seconds after the start of step S100, which is the total time for matching the seven-level material stacking. The essence of the count accumulation per second is to convert time into a quantifiable linkage trigger indicator. The count value directly corresponds to the time taken for the material to be transported from the stacking area to the downstream equipment, providing an accurate time reference for the start-up timing of the downstream equipment.

[0066] In step S330, when the count value is greater than or equal to the preset downstream equipment material operation comparison value, the downstream equipment is started sequentially.

[0067] It should be noted that the material operation comparison value of downstream equipment is preset based on the actual time it takes for materials to be transported from the stockpiling area to the corresponding downstream equipment. For example, if a certain equipment requires materials to arrive in 15 seconds, its comparison value is set to 15. Sequential start means that the material is transported in the order of arrival. For example, the conveying equipment adjacent to the stockpiling area is started first, and then the subsequent processing equipment is started. This avoids the surge in power load caused by starting multiple devices at the same time, and at the same time ensures that the equipment is ready when the materials arrive at the downstream equipment.

[0068] In step S400, based on the real-time material accumulation amount, normal accumulation amount and material accumulation warning value, the belt conveyor is stopped and the material accumulation status is restored.

[0069] In one possible implementation, such as Figure 5 As shown, step S400 may include the following sub-steps: In step S410, when the ratio of the real-time material accumulation amount to the material accumulation warning value is greater than or equal to 0.9, the belt conveyor is controlled to stop urgently.

[0070] It should be noted that this condition is set to trigger emergency protection in advance to prevent malfunctions such as material blockage and overflow after the accumulation reaches the warning value. At the same time, an emergency shutdown will trigger an on-site audible and visual alarm to remind operators to deal with the accumulated material in time. For example, the material accumulation warning value corresponds to a material height of 18cm. A ratio ≥0.9 means that the accumulation is ≥16.2cm, which is close to the overload threshold.

[0071] In step S420, when the ratio of the real-time material accumulation amount to the normal accumulation amount is less than or equal to 0.5, and the actual distance between the material accumulation front and the start / stop trigger point is less than or equal to half of the total material accumulation distance of the belt conveyor, the belt conveyor is controlled to resume the material accumulation state.

[0072] Understandably, this recovery condition is a dual safety constraint. For example, a stockpile volume ratio of ≤0.5 to normal stockpile volume corresponds to a stockpile volume of ≤5cm (i.e., the normal stockpile volume is 10cm), which is within the safe range; a distance ≤ half of the total distance, 1.75m (i.e., the total distance is 3.5m), indicates that there is sufficient remaining space in the stockpile area; both conditions being met simultaneously can prevent premature recovery of the stockpile from causing overload again and ensure the stability of the stockpile process after recovery.

[0073] In one possible implementation, the tobacco material stockpiling control method further includes: The surface of the detection components is periodically blew to remove tobacco dust; the detection components are all the detection components that acquire key data, core detection data and stack status data of the material.

[0074] It is understandable that dust from tobacco materials can easily adhere to the surfaces of components such as laser level sensors and displacement probes, leading to increased errors in the detection data. Timed purging is typically set to occur every 5 minutes to maintain the accuracy of the detection components and prevent problems such as misjudgment of the timing of material stacking start / stop and deviation in speed control due to data errors. This is a necessary maintenance measure to ensure the stable operation of the entire control method.

[0075] Furthermore, in this exemplary embodiment, a tobacco material stacking control system is also provided for executing the above-described tobacco material stacking control method. (See reference...) Figure 6 As shown, the system may include...

[0076] Laser level detection sensor is used to collect the real-time accumulation amount of tobacco materials. Displacement detection probe is used to collect the actual distance between the front edge of material accumulation and the start / stop trigger point in real time; Phototubes are used to detect whether a single pile of materials has reached a preset detection point and output a stable detection signal to determine the starting point of the detection delay. The control module is used to acquire key data of the stockpiling and control the stockpiling state to start based on the stockpiling start conditions; it is also used to dynamically control the conveyor belt speed for seven-level stockpiling by using core detection data and stockpiling state data when the stockpiling state is started; it is also used to acquire stockpiling state data in real time, control the stockpiling state to stop based on the key data of the stockpiling and stockpiling stop conditions, and start downstream equipment based on the start count accumulation sequence; and it is used to control the conveyor belt to stop and the stockpiling state to recover based on the real-time material accumulation amount, normal accumulation amount and stockpiling warning value.

[0077] It should be noted that the production sequence workflow adapted for loose, rehydrated export is as follows: 1. Installation and Commissioning: Fix the material detection and stacking mechanism to the frame of the loose and rehydrated outlet conveyor belt, and debug the laser level detection sensor (detection height 5cm higher than the conveyor belt) and displacement detection probe (detection stroke 0~3.5m), and set the algorithm parameters ( , , , , (weighting coefficients, etc.) preset comparison values ​​for downstream equipment. Complete the signal connection with the belt conveyor drive system and downstream equipment.

[0078] 2. Material preparation stage (0-90 seconds): The electronic scale shows flow, but no smoke appears on the outlet conveyor belt. The device is in standby mode, and the counting and accumulation linkage unit has not been started.

[0079] 3. Material stacking execution phase (90-210 seconds, total 120 seconds): (1) At 90 seconds, smoke flakes appeared on the outlet conveyor belt. The equipment triggers the material stacking start command and enters the material stacking mode; (2) Real-time data acquisition by laser level detection sensor Displacement detection probe acquisition Speed ​​acquisition encoder acquisition The algorithm's computational unit calculates according to the dynamic speed control formula. belt conveyor Run, complete the first pile of material stacking (length 0.5m, running time 1.1 seconds); (3) When the first pile of material reaches the phototube detection point, after a 4-second detection delay, a signal is triggered. After waiting for 21 seconds, the second pile of material is started. The process of "pile material → detection delay → waiting time" is followed to complete the piling of 7 piles of material. The waiting time for each pile is 21s, 18s, 15s, 12s, 9s, 6s, and 3s respectively. (4) During the stockpiling process, The algorithm grows proportionally over time. Dynamic adjustment of weighting coefficients To avoid excessive material buildup due to increased flow rate; when Approximately 3.5m or When it is close to 120 seconds, Automatic lifting speeds up the completion of material stacking.

[0080] 4. Continuous operation and equipment linkage phase (after 210 seconds): (1) At 210 seconds, The equipment triggers a stop stacking command, and the belt conveyor switches to continuous operation. (2) The counting and accumulation linkage unit starts counting based on 210 seconds. ),when Reaching the comparison value of the first downstream device When the count value is reached, the device is activated; subsequent devices are activated sequentially according to the count value, achieving sequential linkage.

[0081] 5. Exception handling: If near ( This triggers an emergency shutdown command; the dust purging port purifies the detection components every 5 minutes to ensure detection accuracy.

[0082] Furthermore, this example embodiment also provides a detailed method and system for controlling tobacco material stacking, applied to the tobacco sheet belt conveyor line at the loose and re-moistened outlet of a cigarette factory's tobacco processing workshop, with the belt's rated design speed... The belt width is 1000mm, and the material density is... Normal production material height is 10cm, corresponding to , Process setting parameters: , , , Weighting coefficient , , , Phototube detection delay No signal delay pauses for 0.01 seconds; downstream equipment includes belt conveyor #1 and drying machine #2. It takes 15 seconds for material to reach belt conveyor #1 and 30 seconds to reach drying machine #2. Preset comparison values. , .

[0083] After the equipment is installed and debugged, operate according to the following procedure: 0-90 seconds: The electronic scale shows flow, and the outlet conveyor belt shows no smoke. The device is in standby mode. At 90 seconds: Smoke appears on the outlet conveyor belt. The equipment triggers a material stacking start command, and the algorithm calculation unit calculates... The belt conveyor runs for 1.1 seconds, completing the first pile of material (0.5m in length). The first pile of material moves to the phototube detection point. After a 4-second detection delay, it waits for 21 seconds (cumulative 90 + 1.1 + 4 + 21 = 116.1 seconds) before starting the second pile. , , ,calculate Complete the second pile of materials at this speed; The above process was followed sequentially to complete the stacking of 7 piles of material. The waiting times for each pile were 21s, 18s, 15s, 12s, 9s, 6s, and 3s, respectively. The completion time for the 7th pile was 209.8 seconds. , ; At 210 seconds: the equipment triggers a stop stacking command, the belt conveyor switches to continuous operation, and the counting and accumulation linkage unit starts counting. ); At 225 seconds ( The counting and accumulating linkage unit outputs a start command to belt conveyor #1, and belt conveyor #1 starts. At 240 seconds ( The counting and accumulating linkage unit outputs a start command to the No. 2 wire drying machine, and the No. 2 wire drying machine starts; During operation, the dust blowing port is purged every 5 minutes, the laser sensor detection accuracy is stable, there is no uneven material accumulation or blockage, the downstream equipment starts accurately, and the linkage reliability is 100%.

[0084] Further, in the present exemplary embodiment, another detailed tobacco material stacking control method and system are also provided, which are applied to the tobacco sheet belt conveyor line at the outlet of the loose and moistening section in the silk reeling workshop of a cigarette factory. The belt width is 800 mm, M0 = 80 cm × 10 cm × 0.8 g / cm³ = 6.4 kg, M warning = 18 cm × 80 cm × 0.8 g / cm³ = 11.52 kg, the weight coefficient k1 = 0.35, k2 = 0.2, k3 = 0.15, k4 = 0.3, and the remaining parameters are the same as those in the previous exemplary embodiment.

[0085] After the equipment runs, at 150 seconds ( , , ), calculate , the belt conveyor stacks materials smoothly at this speed. After 7 stacks of materials are completed, there is no uneven stacking, and the downstream equipment starts according to the preset time, fully meeting the production requirements.

[0086] After considering the specification and practicing the invention disclosed herein, those skilled in the art will readily conceive of other embodiments of the present disclosure. This application aims to cover any variations, uses, or adaptations of the present disclosure, which follow the general principles of the present disclosure and include well-known knowledge or conventional technical means in the technical field not disclosed in the present disclosure. The specification and examples are only regarded as exemplary, and the true scope and spirit of the present disclosure are pointed out by the appended claims.

[0087] The above embodiments are only used to illustrate the technical solutions of the present application, rather than to limit it. The present application is not limited to the exact structures described above and illustrated in the drawings. It cannot be considered that the specific implementation of the present application is only limited to these descriptions. For those of ordinary skill in the technical field to which the present application pertains, without departing from the concept of the present application, various changes and modifications made should be regarded as belonging to the scope of protection of the present application.

Claims

1. A method for controlling the stockpiling of tobacco materials, characterized in that, include: Acquire key data on material stockpiling in real time and control the stockpiling status based on stockpiling start conditions; The key data for material stacking includes the actual material flow rate at the conveyor inlet, the current stacking duration, and the actual distance between the material stacking front and the start / stop trigger point. When the stacking state is started, the conveyor belt speed is dynamically controlled to perform seven-level stacking based on core detection data and stacking status data; the core detection data includes real-time material accumulation amount, normal accumulation amount, stacking warning value, and single stacking reference time; the stacking status data includes stable production flow rate, total stacking distance of the conveyor belt, and total stacking time. Real-time acquisition of stockpiling status data; control the stockpiling status to stop based on the key stockpiling data and stockpiling stop conditions; and start downstream equipment based on the start count accumulation sequence. Based on real-time material accumulation, normal accumulation, and material accumulation warning values, the system controls the belt conveyor to stop and restore the material accumulation status.

2. The method for controlling the stockpiling of tobacco materials according to claim 1, characterized in that, The step of acquiring key data of the stockpile in real time and controlling the start of the stockpile status based on the stockpile start conditions includes: The timing unit is activated to record the material stacking time in real time, starting from the appearance of a flow signal on the electronic scale. The actual distance between the material accumulation front and the start / stop trigger point is collected in real time using a displacement detection probe. The material flow rate signal at the inlet of the belt conveyor is collected in real time by an electronic scale. Combined with the production characteristics of the loose and moist outlet, the actual material flow rate at the inlet of the belt conveyor is obtained by the first formula. When the actual material flow rate at the conveyor inlet is 0, the current stacking time is 90 seconds, and the actual distance between the material stacking front and the start / stop trigger point is 0, the stacking state is started.

3. The method for controlling the stockpiling of tobacco materials according to claim 2, characterized in that, The first formula is: in, This represents the actual material flow rate at the conveyor inlet. This represents the actual distance between the material accumulation front and the start / stop trigger point.

4. The method for controlling the stockpiling of tobacco materials according to claim 1, characterized in that, The step of dynamically controlling the conveyor belt speed for seven-stage stacking based on core detection data when starting in the stacking state includes: When the stockpiling state is initiated, the core detection data and the stockpiling state data are acquired; Based on the core detection data and the stockpiling status data, the adjustment speed is calculated using the second formula to control the conveyor belt speed. According to the third formula, the time it takes for a single pile of material to reach the phototube detection point is calculated based on the controlled speed. Based on the controlled speed and the time it takes for a single pile of material to reach the phototube detection point, seven material stacking operations are performed sequentially according to the waiting time of each pile; the waiting times of each pile are 21 seconds, 18 seconds, 15 seconds, 12 seconds, 9 seconds, 6 seconds and 3 seconds respectively.

5. The method for controlling the stockpiling of tobacco materials according to claim 4, characterized in that, The second formula is: in, To regulate speed, The rated speed of the belt, This represents the real-time material accumulation level. This is normal accumulation level. This is the early warning value for stockpiling. This represents the actual distance between the material accumulation front and the start / stop trigger point. This refers to the total distance over which the belt conveyor can stack materials. This is the current stockpiling time. This is the baseline time for a single stockpile. Total stockpiling time This represents the actual material flow rate at the conveyor inlet. To stabilize production flow, As the first weighting coefficient, This is the second weighting coefficient. This is the third weighting coefficient. It is the fourth weighting coefficient.

6. The method for controlling the stockpiling of tobacco materials according to claim 4, characterized in that, The third formula is: in, This refers to the time it takes for a single stockpile of material to travel to the phototube detection point. The length of a single pile of materials. This is the delay time for phototube detection.

7. The method for controlling the stockpiling of tobacco materials according to claim 1, characterized in that, The steps of acquiring real-time stockpiling status data, controlling the stockpiling status to stop based on the key stockpiling data and stockpiling stop conditions, and starting downstream equipment based on the start count accumulation sequence include: When the actual material flow rate at the conveyor inlet is greater than or equal to the stable production flow rate, or the actual distance between the material accumulation front and the start / stop trigger point is greater than or equal to the total material accumulation distance of the conveyor, or the current material accumulation time is greater than or equal to the total material accumulation time, the material accumulation state is controlled to stop. Based on the time when the material is piled up, the count is accumulated once per second to obtain the count value; When the count value is greater than or equal to the preset downstream equipment material operation comparison value, the downstream equipment is started sequentially.

8. The method for controlling the stockpiling of tobacco materials according to claim 1, characterized in that, The steps for controlling the belt conveyor shutdown and restoring the stacking status based on real-time material accumulation, normal accumulation, and stacking warning values ​​include: When the ratio of the real-time material accumulation amount to the material accumulation warning value is greater than or equal to 0.9, the belt conveyor is controlled to stop urgently. When the ratio of the real-time material accumulation to the normal accumulation is less than or equal to 0.5, and the actual distance between the material accumulation front and the start / stop trigger point is less than or equal to half of the total material accumulation distance of the belt conveyor, the belt conveyor is controlled to resume the material accumulation state.

9. The method for controlling the stockpiling of tobacco materials according to claim 1, characterized in that, Also includes: The surface of the detection components is periodically blew to remove tobacco dust; the detection components are all the detection components that acquire key data, core detection data and stack status data of the material.

10. A tobacco material stacking control system, characterized in that, The system is used to execute the tobacco material stacking control method as described in any one of claims 1 to 9, the system comprising: Laser level detection sensor is used to collect the real-time accumulation amount of tobacco materials. Displacement detection probe is used to collect the actual distance between the front edge of material accumulation and the start / stop trigger point in real time; Phototubes are used to detect whether a single pile of materials has reached a preset detection point and output a stable detection signal to determine the starting point of the detection delay. The control module is used to acquire key data of the stockpiling and control the stockpiling state to start based on the stockpiling start conditions; it is also used to dynamically control the conveyor belt speed for seven-level stockpiling by using core detection data and stockpiling state data when the stockpiling state is started; it is also used to acquire stockpiling state data in real time, control the stockpiling state to stop based on the key data of the stockpiling and stockpiling stop conditions, and start downstream equipment based on the start count accumulation sequence; and it is used to control the conveyor belt to stop and the stockpiling state to recover based on the real-time material accumulation amount, normal accumulation amount and stockpiling warning value.

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