A method for determining a clogging

Abstract

The application discloses a kind of plugging determination methods, comprising: the material image information of target position on conveying mechanism is collected, material image information is analyzed by image processing algorithm, to obtain the material accumulation height of target position, when the material accumulation height of target position exceeds preset height, control system controls first alarm to issue warning;Collect the operating parameter of motor, whether the operating parameter is located outside the preset parameter interval is judged, when the operating parameter is located outside the preset parameter interval, the duration reaches preset time, control system controls second alarm to issue warning;When first alarm and second alarm issue warning simultaneously, then determine that material on conveying mechanism occurs plugging phenomenon.The application judges whether plugging by material height and motor operating parameter two aspects, to avoid the problem that tobacco shred is formed and equipment is damaged due to plugging phenomenon, and then improve production efficiency.

Description

Technical Field

[0001] This invention relates to the field of cigarette manufacturing technology, and in particular to a method for determining material blockage. Background Technology

[0002] The tobacco processing line is a crucial production link in the cigarette industry. The various stages of the line operate in series, meaning materials are transported via multiple interconnected belt conveyors. During this transport, processes such as tobacco processing, pressing, humidification, rehydration, and air separation occur. If a blockage occurs at any stage, it not only causes tobacco breakage but also affects the normal operation of subsequent stages, potentially leading to equipment shutdowns in that area and reducing the overall production line efficiency. Summary of the Invention

[0003] The purpose of this invention is to solve the technical problem of material blockage in existing tobacco processing production lines, which leads to tobacco breakage and reduced production efficiency. This invention provides a method for determining material blockage, which uses both material height and motor operating parameters to judge whether blockage has occurred, thereby avoiding tobacco breakage and equipment damage caused by material blockage and ultimately improving production efficiency.

[0004] To address the aforementioned technical problems, embodiments of the present invention disclose a blockage determination method for determining whether material being conveyed on a conveying mechanism is blocked. The conveying mechanism is driven by a motor, and the blockage determination method includes:

[0005] The system collects material image information at the target location on the conveyor mechanism, obtains the material accumulation height at the target location based on the material image information, and controls the first alarm to sound an alarm when the material accumulation height at the target location exceeds the preset height.

[0006] The system collects the motor's operating parameters and determines whether the operating parameters are outside the preset parameter range. When the operating parameters are outside the preset parameter range for a preset time, the control system controls the second alarm to sound an alarm.

[0007] When the first alarm and the second alarm sound simultaneously, it is determined that there is a blockage of material on the conveyor mechanism.

[0008] Using the above technical solution, when the material accumulation height at the target location exceeds the preset height and the motor operating parameters remain outside the preset parameter range for a preset period of time, the first alarm and the second alarm will sound simultaneously, thus automatically alerting the operator to the material blockage. This allows the operator to address the blockage problem in a timely manner, preventing tobacco breakage and equipment damage, thereby improving production efficiency.

[0009] According to another specific embodiment of the present invention, the operating parameters of the motor include the operating current of the motor. When the operating current of the motor exceeds the preset current and the duration reaches the preset time, the control system controls the second alarm to issue an alarm.

[0010] According to another specific embodiment of the present invention, the operating parameters of the motor include the motor speed. When the motor speed is lower than the preset speed and the duration reaches the preset time, the control system controls the second alarm to issue an alarm.

[0011] According to another specific embodiment of the present invention, the operating parameters of the motor include the operating current of the motor and the speed of the motor. When the operating current of the motor exceeds the preset current for a certain period of time and the speed of the motor is lower than the preset speed for a certain period of time, the control system controls the second alarm to issue an alarm.

[0012] According to another specific embodiment of the present invention, the acquisition of motor operating parameters includes: acquiring the motor operating current through a current sensor.

[0013] According to another specific embodiment of the present invention, the acquisition of motor operating parameters includes: acquiring the motor speed through a photoelectric encoder.

[0014] According to another specific embodiment of the present invention, the conveying mechanism is a belt conveyor, and the target position is the belt discharge port and / or the belt corner.

[0015] According to another specific embodiment of the present invention, acquiring material image information at a target location on the conveying mechanism includes: acquiring material images using a high-definition camera.

[0016] According to another specific embodiment of the present invention, the preset time is 100ms. Attached Figure Description

[0017] Figure 1 A flowchart of the blockage determination method in an embodiment of the present invention is shown. Detailed Implementation

[0018] The following specific embodiments illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. Although the description of the present invention is presented in conjunction with preferred embodiments, this does not mean that the features of the invention are limited to these embodiments. On the contrary, the purpose of describing the invention in conjunction with embodiments is to cover other options or modifications that may be derived based on the claims of the present invention. To provide a deep understanding of the invention, many specific details will be included in the following description. The invention may also be implemented without using these details. Furthermore, to avoid confusion or obscuring the focus of the invention, some specific details will be omitted in the description. It should be noted that, unless otherwise specified, the embodiments and features in the embodiments of the present invention can be combined with each other.

[0019] It should be noted that in this specification, similar reference numerals and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0020] In the description of this embodiment, it should be noted that the terms "upper", "lower", "inner", "bottom", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship that the product of the invention is usually placed in during use. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting the present invention.

[0021] The terms “first”, “second”, etc., are used only to distinguish descriptions and should not be interpreted as indicating or implying relative importance.

[0022] In the description of this embodiment, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set up," "connected," and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this embodiment based on the specific circumstances.

[0023] To make the objectives, technical solutions, and advantages of the present invention clearer, the embodiments of the present invention will be described in further detail below with reference to the accompanying drawings.

[0024] In tobacco processing production lines, belt conveyors are frequently used to transport tobacco shreds. Common blockage points on these lines are the discharge port or belt corners. A belt corner is where two belts intersect at an angle; at this point, the conveying direction changes, making blockages more likely. The discharge port is where one belt connects to the next; material transfers from one belt to the next, and the discharge port is prone to blockages due to the varying speeds of the upper and lower belts. For example, when discharging from the tobacco storage bin, if the supply of tobacco shreds on the discharge belt does not match the demand on the downstream belt (supply exceeds demand), and the effective discharge space at the discharge port is insufficient, the tobacco shreds will gradually accumulate and rise, causing blockages. This leads to tobacco breakage, a decrease in the whole tobacco yield, reduced tobacco quality, and even equipment damage.

[0025] To address the aforementioned problems, an embodiment of the present invention discloses a method for determining material blockage, used to determine whether material being conveyed on a conveying mechanism is blocked, wherein the conveying mechanism is driven by a motor, such as... Figure 1 As shown, the methods for determining material blockage include:

[0026] Step S1: Acquire material image information at the target location on the conveying mechanism, obtain the material accumulation height at the target location based on the material image information, and compare the material accumulation height at the target location with a preset height. For example, an image processing algorithm can be used to analyze the material image information to obtain the material accumulation height at the target location. When the material accumulation height at the target location does not exceed the preset height, it indicates that the material is being conveyed normally and there is no blockage; when the material accumulation height at the target location exceeds the preset height, it indicates that there is a possibility of material blockage, and the control system will control the first alarm to sound an alarm.

[0027] In this embodiment, the conveying mechanism is a belt conveyor, which is driven by a motor. The target location is the aforementioned belt discharge port and / or belt transfer point. Specifically, the preset height can be determined according to the actual situation. In this embodiment, the preset height is 10cm, meaning that if the material accumulation height at the target location exceeds 10cm, it indicates a possible blockage, and the first alarm will sound.

[0028] Step S2: Collect the motor's operating parameters and compare them with the preset parameter range to determine whether the operating parameters are outside the preset parameter range. When the duration of the motor's operating parameters being outside the preset parameter range reaches a preset time, the control system controls the second alarm to issue an alarm.

[0029] Specifically, the present invention does not limit the value of the preset time; the preset time can be determined based on actual conditions. In this embodiment, the preset time is 100ms; in other embodiments, the preset time can be 50ms, 150ms, or 200ms, etc.

[0030] Step S3: When the first alarm and the second alarm sound simultaneously, it is determined that a blockage has occurred in the material on the conveyor mechanism.

[0031] Using the above technical solution, when the material accumulation height at the target location exceeds the preset height, and the motor operating parameters remain outside the preset parameter range for a preset period of time, the first and second alarms will simultaneously sound an alarm. This automatically alerts the operator to the material blockage, allowing them to address the problem promptly and prevent tobacco breakage and equipment damage, thereby improving production efficiency. Furthermore, the material blockage determination method of this invention combines visual inspection (image method) with motor operating parameters for comprehensive judgment. Compared to relying solely on visual inspection, this method prevents misjudgments and improves accuracy.

[0032] This application does not limit the specific type of operating parameters for the motor; they may include one parameter or multiple parameters. The following three embodiments illustrate this application in detail.

[0033] Example 1

[0034] The motor's operating parameters include its operating current. When the motor's operating current exceeds a preset current for a preset duration, the control system activates a second alarm. The principle behind detecting material blockage by monitoring the motor's operating current is as follows: the motor operates by generating rotational torque through electromagnetic induction, thereby driving the load. When material blockage occurs, the amount of material increases per unit time, the load increases, and the motor needs to increase the strength of the electromagnetic field to obtain greater torque to overcome the load's resistance. Since the strength of the electromagnetic field is proportional to the current, the current increases during blockage. Therefore, observing the change in current can indicate whether material blockage has occurred. In this embodiment, the preset current is 10A. When the motor's operating current exceeds 10A for 100ms, the second alarm sounds.

[0035] Example 2

[0036] The motor's operating parameters include its rotational speed. When the motor speed falls below a preset speed for a preset duration, the control system activates a second alarm. The principle behind detecting motor speed as a indicator of material blockage is as follows: when blockage occurs, the weight of the material on the conveyor belt increases, causing the belt to stop or slow down, thus reducing the motor speed. Therefore, observing changes in rotational speed can indicate whether a blockage has occurred. In this embodiment, the preset speed is 1000 rpm. When the motor speed exceeds 1000 rpm for 100 ms, the second alarm sounds.

[0037] Example 3

[0038] The motor's operating parameters include its operating current and speed. When the motor's operating current exceeds a preset current for a duration longer than a preset time, and the motor's speed is below a preset speed for a duration longer than a preset time, the control system activates the second alarm. In this embodiment, the second alarm activates when the motor's operating current exceeds 10A for 100ms and the motor's speed exceeds 1000rpm for 100ms. Therefore, when both the first and second alarms sound simultaneously, a blockage can be identified.

[0039] By adopting the above technical solution, this invention achieves multi-dimensional data analysis by observing changes in two parameters, current and rotation speed, based on visual inspection. This can more accurately reflect whether there is material blockage and improve the accuracy of material blockage determination.

[0040] According to another specific embodiment of the present invention, collecting the operating parameters of the motor includes: collecting the operating current of the motor through a current sensor. The present invention does not limit the type of current sensor, as long as it can collect the operating current of the motor. In this embodiment, the current sensor is a Hall effect current sensor.

[0041] According to another specific embodiment of the present invention, acquiring the operating parameters of the motor includes acquiring the motor speed via a photoelectric encoder. In other embodiments, a Hall effect speed sensor can be used to acquire the motor speed.

[0042] According to another specific embodiment of the present invention, acquiring material image information at a target location on the conveying mechanism includes: acquiring material images using a high-definition camera.

[0043] The material blockage determination method provided by this invention judges whether material blockage has occurred based on two aspects: material height and motor operating parameters. This aims to avoid problems such as tobacco breakage and equipment damage caused by material blockage, thereby improving production efficiency. Furthermore, the material blockage determination method provided by this invention has advantages such as real-time monitoring and early warning, easy integration and expansion, and is applicable to various industrial production scenarios. Its functionality can be expanded and optimized according to actual needs. For example, in different industrial scenarios, data such as vibration, inlet and outlet pressure, differential pressure, flow rate, and flow velocity can be added for comprehensive judgment to improve the accuracy of the determination.

[0044] While the present invention has been illustrated and described with reference to certain preferred embodiments, those skilled in the art should understand that the above description is a further detailed explanation of the invention in conjunction with specific embodiments, and should not be construed as limiting the specific implementation of the invention to these descriptions. Various changes in form and detail can be made by those skilled in the art, including several simple deductions or substitutions, without departing from the spirit and scope of the invention.

Claims

1. A method for determining material blockage, used to determine whether material being conveyed on a conveying mechanism is blocked, wherein, The conveying mechanism is driven by a motor, characterized in that the blockage determination method includes: The system collects material image information at the target location on the conveying mechanism, obtains the material accumulation height at the target location based on the material image information, and controls the first alarm to sound an alarm when the material accumulation height at the target location exceeds a preset height. The system collects the operating parameters of the motor and determines whether the operating parameters are outside the preset parameter range. When the operating parameters are outside the preset parameter range for a preset time, the control system controls the second alarm to issue an alarm. When the first alarm and the second alarm sound simultaneously, it is determined that a blockage has occurred in the material on the conveying mechanism.

2. The blockage determination method as described in claim 1, characterized in that, The operating parameters of the motor include the operating current of the motor. When the operating current of the motor exceeds the preset current and the duration reaches the preset time, the control system controls the second alarm to issue an alarm.

3. The blockage determination method as described in claim 1, characterized in that, The operating parameters of the motor include the motor speed. When the motor speed is lower than the preset speed and the duration reaches the preset time, the control system controls the second alarm to issue an alarm.

4. The blockage determination method as described in claim 1, characterized in that, The operating parameters of the motor include the operating current and the speed of the motor. When the operating current of the motor exceeds the preset current for a certain period of time and the speed of the motor is lower than the preset speed for a certain period of time, the control system controls the second alarm to issue an alarm.

5. The blockage determination method as described in claim 4, characterized in that, The acquisition of the motor's operating parameters includes: acquiring the motor's operating current through a current sensor.

6. The blockage determination method as described in claim 5, characterized in that, The acquisition of the motor's operating parameters includes: acquiring the motor's rotational speed via a photoelectric encoder.

7. The blockage determination method as described in claim 6, characterized in that, The conveying mechanism is a belt conveyor, and the target location is the belt discharge port and / or the belt corner.

8. The blockage determination method as described in claim 7, characterized in that, The acquisition of material image information at the target location on the conveying mechanism includes: acquiring material images using a high-definition camera.

9. The blockage determination method as described in claim 4, characterized in that, The preset time is 100ms.

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