Intelligent anti-blocking control method for a cigarette dust remover

Abstract

The application discloses an intelligent anti-blocking control method for a dust remover for tobacco, which comprises the following steps: a dust falling hopper is arranged at a dust falling outlet of the dust remover, and a dust unloading valve is arranged below the dust falling hopper; the dust unloading valve is arranged on a support; one weighing sensor is arranged at each corner of the support to monitor the total weight change of the dust unloading valve and the dust falling hopper in real time; a first weight threshold, a second weight threshold and a third weight threshold are set, and the first weight threshold is less than the second weight threshold, and the second weight threshold is less than the third weight threshold; a PLC controller collects weighing data in real time through the weighing sensor, obtains the total weight of dust accumulation according to the weighing data, and compares the total weight of dust accumulation with the first weight threshold, the second weight threshold and the third weight threshold to perform graded anti-blocking control on the dust falling hopper and the dust unloading valve according to the comparison result. The method can monitor the dust accumulation amount of the dust remover in real time, improve the working efficiency of the tobacco dust remover and reduce the production cost.

Description

Technical Field

[0001] This invention relates to the technical field of anti-clogging for flue gas dust collectors, and more specifically, to an intelligent anti-clogging control method for flue gas dust collectors. Background Technology

[0002] In tobacco production, flat bag dust collectors are the core equipment of dust collection rooms. They adsorb dust-laden gas through negative pressure and separate smoke and dust from clean air using filter bags. Existing technologies have the following prominent problems: 1. Limitations of differential pressure monitoring: Traditional dust collectors rely on mechanical differential pressure gauges to determine the filter bag blockage status, but pressure changes cannot reflect the instantaneous ash accumulation in the ash hopper. When large pieces of smoke and dust fall off or the ash discharge valve malfunctions, the differential pressure gauge cannot provide timely warnings, leading to overload tripping of the ash discharge valve and causing shutdown accidents. 2. Reliability defects of mechanical level switches: Some dust collectors are equipped with mechanical level switches to detect ash accumulation height, but smoke and dust adhesion can easily lead to false triggering or failure, requiring frequent manual cleaning. In addition, emergency ash discharge relies on manual operation, and response delays may cause production interruptions. Statistics show that the production line downtime rate due to material blockage in the tobacco industry is as high as 12%-15%. 3. System airflow fluctuations and filter bag aging: Fluctuations in compressed air pressure in the blowpipe or partial blockage of filter bags after long-term use can lead to a thickening of the dust layer on the filter bag surface. When the dust layer weight exceeds a critical value, large pieces of dust detach and instantly accumulate, exceeding the ash discharge valve's capacity. At this point, traditional dust collectors lack dynamic intervention methods and can only restore operation through post-incident maintenance, severely impacting production efficiency and product quality. 4. High cost of manual inspection: Operators need to regularly check the ash accumulation in the ash hopper, posing health risks in a dusty environment, and human judgment is subject to subjective errors. Therefore, intelligent anti-clogging control that monitors ash accumulation in real time, automatically grades and discharges ash, and reduces reliance on manual labor to lower labor costs and improve production continuity and safety is of great significance. Summary of the Invention

[0003] This invention provides an intelligent anti-clogging control method for tobacco dust collectors, which solves the problems of high cost and lack of intelligence in manual inspection of dust collector anti-clogging monitoring in existing tobacco dust collection rooms. It can monitor the amount of ash accumulated in the dust collector in real time, improve the working efficiency of the tobacco dust collector, and reduce production costs.

[0004] To achieve the above objectives, the present invention provides the following technical solution:

[0005] A smart anti-clogging control method for a flue gas dust collector includes:

[0006] An ash hopper is installed at the ash discharge outlet of the dust collector, and an ash discharge valve is installed below the ash hopper. The ash discharge valve is mounted on a support, and a weighing sensor is installed at each of the four corners of the support to monitor the total weight change of the ash discharge valve and the ash hopper in real time.

[0007] Set a first weight threshold, a second weight threshold, and a third weight threshold, wherein the first weight threshold < the second weight threshold < the third weight threshold;

[0008] The PLC controller collects weighing data in real time through weighing sensors, obtains the total weight of ash accumulation based on the weighing data, and compares the total weight of ash accumulation with the first weight threshold, the second weight threshold, and the third weight threshold to perform graded anti-clogging control on the ash hopper and ash discharge valve based on the comparison results.

[0009] Preferred options also include:

[0010] An emergency ash discharge pipe is installed in the ash hopper, and an emergency ash discharge valve is provided on the emergency ash discharge pipe. When the total weight of the accumulated ash is greater than the first weight threshold and less than the second weight threshold, the emergency ash discharge valve is opened to discharge the accumulated ash in the ash hopper to the centralized dust collection pipeline.

[0011] Preferred options also include:

[0012] The system is equipped with an audible and visual alarm and a central control display screen. When the total weight of the accumulated dust is greater than the second weight threshold and less than the third weight threshold, the system controls the audible and visual alarm to sound an alarm and controls the central control display screen to display a pop-up alarm.

[0013] Preferred options also include:

[0014] When the total weight of the accumulated ash exceeds the third weight threshold, the dust removal system is controlled to trigger an interlock shutdown, and the audible and visual alarm is controlled to issue an audible and visual alarm, and the central control display screen is controlled to issue a pop-up alarm, and the emergency ash discharge valve is opened.

[0015] Preferred options also include:

[0016] A red, yellow, and green indicator light is set up. When the total weight of the accumulated dust is less than the first weight threshold, the indicator light will turn green, and the dust removal system will operate normally.

[0017] Preferred options also include:

[0018] When the total weight of the accumulated dust is greater than the second weight threshold but less than the third weight threshold, the dust removal system is controlled to issue an alarm, notify the operator to handle the situation on-site, and control the indicator light of the dust removal system to turn yellow.

[0019] Preferred options also include:

[0020] When the total weight of the accumulated dust exceeds the third weight threshold, the dust removal system is controlled to shut down and trigger an alarm, and the indicator light of the dust removal system is turned on red.

[0021] Preferred options also include:

[0022] Determine if a production end signal has been received. If so, open the emergency ash discharge valve and close it after a 20-minute delay. If not, implement anti-blockage control based on real-time weighing data.

[0023] Preferred options also include:

[0024] When the total weight of the accumulated ash exceeds the second weight threshold, the operator confirms the ash height through the explosion-proof window of the ash hopper. If the ash height exceeds the set threshold and continues to rise, manual emergency operation is performed after shutdown. After the accumulated ash is discharged, the reset switch is pressed to restore operation and the operation log is recorded.

[0025] Preferably, the manual emergency operation includes:

[0026] Use an emergency rubber mallet to tap the side wall of the dust collector's ash hopper to assist in ash removal. If ash still cannot be removed, manually open the emergency ash removal valve and discharge the accumulated ash through the emergency ash removal pipe. Close the valve after ash removal is complete.

[0027] This invention provides an intelligent anti-clogging control method for a tobacco dust collector. Weight sensors are installed below the ash hopper and ash discharge valve to detect the weight of accumulated ash in the ash hopper. A first weight threshold, a second weight threshold, and a third weight threshold are set, and the total weight of accumulated ash is compared with these three thresholds. Based on the comparison results, graded anti-clogging control is applied to the ash hopper and ash discharge valve. This method solves the problems of high cost and lack of intelligence in manual inspection for anti-clogging monitoring in existing tobacco dust collection rooms. It enables real-time monitoring of ash accumulation in the dust collector, improving the working efficiency of the tobacco dust collector and reducing production costs. Attached Figure Description

[0028] To more clearly illustrate the specific embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly described below.

[0029] Figure 1 This is a schematic diagram of an intelligent anti-clogging control method for a flue gas dust collector provided by the present invention.

[0030] Figure 2 This is a flowchart of the hierarchical anti-blocking control provided in the embodiments of the present invention.

[0031] Figure 3 This is a logic flowchart of the ash removal control provided by the present invention.

[0032] Figure 4 This is a flowchart of a manual collaborative operation provided in an embodiment of the present invention.

[0033] Figure 5A schematic diagram of an intelligent anti-clogging control system for a flue gas dust collector provided in this embodiment of the invention.

[0034] Figure 6 This is a structural diagram of the dust removal system provided in an embodiment of the present invention.

[0035] Figure 7 This is a schematic diagram of the installation of the ash discharge valve provided in an embodiment of the present invention. Detailed Implementation

[0036] To enable those skilled in the art to better understand the embodiments of the present invention, the embodiments of the present invention will be further described in detail below with reference to the accompanying drawings and implementation methods.

[0037] To address the issues of material blockage and downtime caused by ash hopper clogging in current tobacco dust collectors, which are characterized by high costs and lack of intelligence in manual inspections, this invention provides an intelligent anti-clogging control method for tobacco dust collectors. This method solves the problems of high costs and lack of intelligence in manual inspections for anti-clogging monitoring in existing tobacco dust collectors, enabling real-time monitoring of ash accumulation in the dust collector, improving the working efficiency of the tobacco dust collector, and reducing production costs.

[0038] like Figures 1-4 As shown, an intelligent anti-clogging control method for a flue gas dust collector includes:

[0039] S1: An ash hopper is installed at the ash discharge outlet of the dust collector, and an ash discharge valve is installed below the ash hopper. The ash discharge valve is installed on a support, and a weighing sensor is installed at each of the four corners of the support to monitor the total weight change of the ash discharge valve and the ash hopper in real time.

[0040] S2: Set a first weight threshold, a second weight threshold, and a third weight threshold, wherein the first weight threshold < the second weight threshold < the third weight threshold.

[0041] S3: The PLC controller collects weighing data in real time through the weighing sensor, obtains the total weight of the ash accumulation based on the weighing data, and compares the total weight of the ash accumulation with the first weight threshold, the second weight threshold and the third weight threshold, so as to perform graded anti-clogging control on the ash hopper and the ash discharge valve according to the comparison result.

[0042] In practical applications, such as Figures 5-7As shown, the intelligent anti-clogging control system of the flue gas dust collector includes: ash hopper 1, ash discharge valve 2, bracket 4, weighing sensor 3, audible and visual alarm 5, PLC controller 6, emergency ash discharge pipe 8, centralized dust collection pipe 9, reset switch 10, explosion-proof switch box 11, and central control display screen 12. The outlet of ash hopper 1 is staggered by 20-30mm from the inlet of ash discharge valve 2. The staggered joint is wrapped with wear-resistant soft material and fixed with stainless steel hose clamps. The outlet of ash discharge valve 2 is staggered by 20-30mm from the inlet of centralized dust collection pipe 9, and the staggered joint sealing method is the same as that of ash hopper 1. The bracket 4 is welded from channel steel and located directly below ash discharge valve 2, possessing sufficient strength to support ash discharge valve 2 and its weight. A weighing sensor 3 is installed at each of the four corners of the bracket 4. These weighing sensors are used to monitor the total weight change of the ash discharge valve and ash hopper in real time. The bracket design ensures that it can stably support the entire system and is easy to maintain and inspect. The outlet of the ash hopper and the inlet of the ash discharge valve can be staggered by 20mm. The staggered joint is wrapped with rubber soft material and fixed with hose clamps. The bottom of the ash discharge valve is fixed by a channel steel bracket. The weighing sensor 3 is installed at the four corners of the bracket 4, with a range of 0-500kg and an accuracy of ±0.5%. The bottom of the ash discharge valve 2 is fixed to the weighing sensor 3 with bolts. The PLC controller 6 adopts the Siemens S7-1200 series, with built-in weight threshold judgment logic. The input port is connected to the weighing sensor 3, and the output port controls the solenoid valve and the audible and visual alarm 5. The centralized dust collection pipe 9 has a diameter of Φ300mm and a negative pressure air volume ≥2000m³ / h. It connects to the outlet of the ash discharge valve of multiple dust collectors and transmits the dust to the press machine through negative pressure, which gathers and compacts the dust into cake-like blocks. PLC control system configuration: Siemens S7-1200 PLC is used, which receives the weighing sensor signal through a shielded cable; the audible and visual alarm (ExdⅡBT4 explosion-proof level) communicates with the central control system through the Modbus TCP protocol. The PLC controller reports a blockage alarm and records the event when the dust weight exceeds a weight threshold. This method employs multi-level threshold adaptive control, dynamically adjusting the alarm delay time based on the weight change rate, reducing the false alarm rate from 12% to 0.8%. It indirectly calculates the accumulated ash by weighing the entire ash discharge valve, avoiding the maintenance difficulties of traditional contact-based detection and improving accuracy to ±0.5%. This method can monitor the ash accumulation in the dust collector in real time, improving the efficiency of the tobacco dust collector and reducing production costs.

[0043] Specifically, the threshold settings include:

[0044] First weight threshold W1: The lower limit value that triggers the opening of the emergency ash discharge valve;

[0045] Second weight threshold W2: The lower limit for triggering audible and visual alarms and central control alarms;

[0046] The third weight threshold W3: the lower limit value that triggers the production line interlock shutdown, and satisfies W1 < W2 < W3.

[0047] like Figure 2 As shown, further, based on the comparison results, graded anti-clogging control is implemented for the ash hopper and ash discharge valve, including: when the weight collected by the weighing sensor is < W1: the dust removal system indicator light is green, and the system is operating normally; when W1 ≤ weight < W2: the dust removal system indicator light is green, the emergency ash discharge valve automatically opens, and the dust is discharged to the centralized dust collection pipe through the emergency ash discharge pipe; when W2 ≤ weight < W3: the dust removal system indicator light is yellow, the audible and visual alarm is activated, the central control screen pops up an alarm, and the operator is notified to handle the situation on-site; when the weight is ≥ W3: the dust removal system indicator light is red, the system triggers interlock shutdown, the audible and visual alarm is activated, the central control screen pops up an alarm, and the operator is notified to handle the situation on-site.

[0048] The method further includes: setting an emergency ash discharge pipe in the ash hopper, the emergency ash discharge pipe being equipped with an emergency ash discharge valve, and controlling the emergency ash discharge valve to open when the total weight of the accumulated ash is greater than the first weight threshold W1 and less than the second weight threshold W2, so as to discharge the accumulated ash in the ash hopper to the centralized dust collection pipeline.

[0049] In practical applications, the emergency ash discharge pipe 8 is used for rapid ash discharge. Further, the emergency ash discharge pipe 8 is installed at a 30° angle below the side wall of the ash hopper 1, with an anti-stick coating sprayed on the inner wall, and its end is connected to the centralized dust collection pipe 9. Further, the emergency ash discharge valve is a pneumatically controlled valve, which can be a pneumatic ball valve controlled by a three-position five-way solenoid valve; the explosion-proof switch box 11 is installed on the dust collector's support leg. Further, the explosion-proof switch box 11 has an IP65 protection rating and integrates a pneumatic ball valve control air circuit assembly (compressed air filter, pressure reducing valve, three-position five-way solenoid valve) to achieve automated control of the emergency ash discharge valve.

[0050] The method further includes: setting up an audible and visual alarm and a central control display screen; when the total weight of the accumulated dust is greater than the second weight threshold W2 and less than the third weight threshold W3, controlling the audible and visual alarm to sound and light, and controlling the central control display screen to pop up an alarm.

[0051] In practical applications, the central control display screen 12 is deployed in the central control room to display the weight data of each dust collector, valve status, and alarm information in real time. The audible and visual alarm is an explosion-proof LED strobe light (brightness ≥100cd) integrated with a buzzer (volume ≥85dB), installed on the support leg of the dust collector.

[0052] The method further includes: when the total weight of the accumulated ash is greater than the third weight threshold W3, controlling the dust removal system to trigger an interlock shutdown, simultaneously controlling the audible and visual alarm to issue an audible and visual alarm, controlling the central control display screen to issue a pop-up alarm, and opening the emergency ash discharge valve.

[0053] The method also includes: setting red, yellow and green indicator lights, and when the total weight of the accumulated dust is less than the first weight threshold, controlling the indicator lights to light up green, and the dust removal system to operate normally.

[0054] The method further includes: when the total weight of the accumulated ash is greater than the second weight threshold W2 and less than the third weight threshold W3, controlling the dust removal system to issue an alarm, notifying the operator to handle the situation on-site, and controlling the indicator light of the dust removal system to turn yellow.

[0055] The method further includes: when the total weight of the accumulated ash is greater than the third weight threshold W3, controlling the dust removal system to interlock and shut down and alarm, and controlling the indicator light of the dust removal system to light up red.

[0056] like Figure 3 As shown, the method also includes: determining whether a production end signal has been received; if so, opening the emergency ash discharge valve and closing it after a 20-minute delay; if not, implementing anti-blocking control based on real-time collected weighing data.

[0057] like Figure 4 As shown, the method further includes: when the total weight of the accumulated ash is greater than the second weight threshold, the operator confirms the ash height through the explosion-proof window of the ash hopper. If the ash height is greater than the set threshold and continues to rise, then manual emergency operation is performed after shutdown, and the reset switch is pressed after the ash is discharged to restore operation and record the operation log.

[0058] Furthermore, the manual emergency operation includes: using an emergency rubber mallet to tap the side wall of the dust collector's ash hopper to assist in ash discharge; if ash still cannot be discharged, manually open the emergency ash discharge valve to discharge the accumulated ash through the emergency ash discharge pipe, and close the valve after the ash discharge is completed.

[0059] In practical applications, the explosion-proof viewing window is a double-layered tempered glass structure, with a pressure resistance of ≥1.5MPa and dimensions of 300mm×200mm. It is embedded in the side wall of the ash hopper 1, allowing operators to observe the ash accumulation inside the ash hopper 1. Furthermore, the head of the emergency rubber hammer is covered with anti-static rubber and suspended next to the explosion-proof viewing window. The reset switch 10 is an explosion-proof button, installed on the panel of the explosion-proof switch box 11. Pressing it sends a reset signal to the PLC to clear the alarm status.

[0060] In one embodiment, manual emergency procedures include:

[0061] 1. Alarm Response: When the weight is ≥ W2, the operator receives an alarm and confirms the dust accumulation height through the explosion-proof viewing window.

[0062] 2. Intervention measures:

[0063] Dust accumulation is normal: Reset directly.

[0064] Abnormal ash accumulation: Use an emergency rubber mallet to tap the side wall of the ash hopper and observe the weight change. Once normal, reset the hopper.

[0065] 3. Event tracing: The PLC records the alarm time, the employee number of the reset personnel, and the weight curve, and stores them in the database.

[0066] As can be seen, this invention provides an intelligent anti-clogging control method for a tobacco dust collector. Weight sensors are installed below the ash hopper and the ash discharge valve to detect the weight of accumulated ash in the ash hopper. A first weight threshold, a second weight threshold, and a third weight threshold are set, and the total weight of accumulated ash is compared with these three thresholds to perform graded anti-clogging control on the ash hopper and the ash discharge valve based on the comparison results. This solves the problems of high cost and lack of intelligence in manual inspection for anti-clogging monitoring in existing tobacco dust collection rooms. It enables real-time monitoring of ash accumulation in the dust collector, improves the working efficiency of the tobacco dust collector, and reduces production costs.

[0067] The structure, features, and effects of the present invention have been described in detail above with reference to the embodiments shown in the figures. The above description is only a preferred embodiment of the present invention, but the present invention is not limited to the scope of implementation shown in the figures. Any changes made in accordance with the concept of the present invention, or equivalent embodiments modified to have equivalent changes, shall be within the protection scope of the present invention as long as they do not exceed the spirit covered by the specification and figures.

Claims

1. An intelligent anti-clogging control method for a flue gas dust collector, characterized in that, include: An ash hopper is installed at the ash discharge outlet of the dust collector, and an ash discharge valve is installed below the ash hopper. The ash discharge valve is mounted on a support, and a weighing sensor is installed at each of the four corners of the support to monitor the total weight change of the ash discharge valve and the ash hopper in real time. Set a first weight threshold, a second weight threshold, and a third weight threshold, wherein the first weight threshold < the second weight threshold < the third weight threshold; The PLC controller collects weighing data in real time through weighing sensors, obtains the total weight of ash accumulation based on the weighing data, and compares the total weight of ash accumulation with the first weight threshold, the second weight threshold, and the third weight threshold to perform graded anti-clogging control on the ash hopper and ash discharge valve based on the comparison results.

2. The intelligent anti-clogging control method for a flue gas dust collector according to claim 1, characterized in that, Also includes: An emergency ash discharge pipe is installed in the ash hopper, and an emergency ash discharge valve is provided on the emergency ash discharge pipe. When the total weight of the accumulated ash is greater than the first weight threshold and less than the second weight threshold, the emergency ash discharge valve is opened to discharge the accumulated ash in the ash hopper to the centralized dust collection pipeline.

3. The intelligent anti-clogging control method for a flue gas dust collector according to claim 2, characterized in that, Also includes: The system is equipped with an audible and visual alarm and a central control display screen. When the total weight of the accumulated dust is greater than the second weight threshold and less than the third weight threshold, the system controls the audible and visual alarm to sound an alarm and controls the central control display screen to display a pop-up alarm.

4. The intelligent anti-clogging control method for a flue gas dust collector according to claim 3, characterized in that, Also includes: When the total weight of the accumulated ash exceeds the third weight threshold, the dust removal system is controlled to trigger an interlock shutdown, and the audible and visual alarm is controlled to issue an audible and visual alarm, and the central control display screen is controlled to issue a pop-up alarm, and the emergency ash discharge valve is opened.

5. The intelligent anti-clogging control method for a flue gas dust collector according to claim 4, characterized in that, Also includes: A red, yellow, and green indicator light is set up. When the total weight of the accumulated dust is less than the first weight threshold, the indicator light will turn green, and the dust removal system will operate normally.

6. The intelligent anti-clogging control method for a flue gas dust collector according to claim 5, characterized in that, Also includes: When the total weight of the accumulated dust is greater than the second weight threshold but less than the third weight threshold, the dust removal system is controlled to issue an alarm, notify the operator to handle the situation on-site, and control the indicator light of the dust removal system to turn yellow.

7. The intelligent anti-clogging control method for a flue gas dust collector according to claim 6, characterized in that, Also includes: When the total weight of the accumulated dust exceeds the third weight threshold, the dust removal system is controlled to shut down and trigger an alarm, and the indicator light of the dust removal system is turned on red.

8. The intelligent anti-clogging control method for a flue gas dust collector according to claim 7, characterized in that, Also includes: Determine if a production end signal has been received. If so, open the emergency ash discharge valve and close it after a 20-minute delay. If not, implement anti-blockage control based on real-time weighing data.

9. The intelligent anti-clogging control method for a flue gas dust collector according to claim 8, characterized in that, Also includes: When the total weight of the accumulated ash exceeds the second weight threshold, the operator confirms the ash height through the explosion-proof window of the ash hopper. If the ash height exceeds the set threshold and continues to rise, manual emergency operation is performed after shutdown. After the accumulated ash is discharged, the reset switch is pressed to restore operation and the operation log is recorded.

10. The intelligent anti-clogging control method for a flue gas dust collector according to claim 9, characterized in that, The manual emergency operations include: Use an emergency rubber mallet to tap the side wall of the dust collector's ash hopper to assist in ash removal. If ash still cannot be removed, manually open the emergency ash removal valve and discharge the accumulated ash through the emergency ash removal pipe. Close the valve after ash removal is complete.

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