A tea production process line and an intelligent control system thereof

Abstract

This application discloses a tea production line, including several process execution devices. These devices are arranged sequentially along the tea processing direction, including at least one withering device, at least one fixation device, a primary air-sorting device, a primary rehumidification device, a shaping device, a hot air drying device, a secondary rehumidification device, an electric drying device, a secondary air-sorting device, and a color sorting device. The tea production line also includes several conveyor units, connecting the various devices. This invention combines sensor technology, distributed control, and centralized coordination to quantify, control, and optimize key process parameters during production. It solves the quality fluctuation problem caused by differences in manual operation in traditional production, ensuring highly consistent appearance, color, moisture content, and aroma across different batches of products, thus improving the standardization and intelligence of green tea production.

Description

Technical Field

[0001] This invention relates to a production process line, specifically a tea production process line and its intelligent control system, belonging to the field of tea processing technology. Background Technology

[0002] Green tea (such as Anji White Tea, West Lake Longjing, and Huangshan Maofeng) has high economic value due to its unique quality characteristics and flavor. The processing techniques for this type of tea, especially key processes like shaping, forming, and drying to achieve its specific "straight strip" shape, largely depend on meticulous control during processing. Traditionally, this type of processing relies heavily on the personal experience and sensory judgment of tea masters. This predominantly manual production model has significant drawbacks: First, process parameters (such as the temperature and humidity during withering, the temperature and time for fixing, the temperature curve and frequency of shaping, and the temperature gradient for drying) are difficult to quantify and reproducibly maintain, leading to large fluctuations in product quality between batches, poor uniformity in color, aroma, moisture content, and appearance, and difficulty in achieving stable, high-standard industrial production. Second, production efficiency is low, labor costs are high, and production scale is limited by the number of skilled workers.

[0003] To improve production efficiency and reduce labor intensity, various types of stand-alone automated equipment have been introduced in the tea processing industry, such as automatic withering machines, continuous withering machines, leaf shaping machines, and chain-plate dryers. These devices have achieved mechanization or automation of single processes, increasing production capacity to some extent. However, most existing solutions are simply linear connections of these stand-alone machines, forming an "automation island" production line. Each piece of equipment typically operates independently, with operators setting and monitoring parameters separately, lacking a central intelligent system for collaborative optimization and closed-loop control of the entire process. Material flow between devices is not smooth, and key process parameters cannot be dynamically and adaptively adjusted based on the real-time output of the previous process (such as the moisture content of withered leaves and the leaf temperature of withered leaves) or the current state of the raw materials. For example, the withering endpoint is still determined by manual experience, the withering temperature cannot be automatically compensated based on the amount of leaves fed, and the air-separation accuracy cannot be adjusted in real time based on the output quality. Therefore, existing automated production lines have failed to fundamentally solve the core problems of poor product quality stability and excessive reliance on manual intervention, while also exhibiting insufficient overall energy consumption optimization and limited intelligence. Summary of the Invention

[0004] Based on the above background, the purpose of this invention is to provide a tea production line and its intelligent control system that can realize continuous, standardized, and intelligent production and adaptively adjust key process parameters, thereby solving the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: A tea production line includes at least one withering device, at least one fixation device, a primary air separation device, a primary rehumidification device, a tea leaf shaping device, a hot air drying device, a secondary rehumidification device, an electric drying device, a secondary air separation device, and a color sorting device arranged sequentially along the tea processing direction. The tea production line also includes several conveyor units, which are connected to each other. The conveyor units include at least one or more of the following: Z-type elevator, reciprocating horizontal conveyor, vibrating conveyor, and cooling elevator.

[0006] By adopting the above technical solution, the originally segmented key processing steps are physically connected and integrated through conveyor units, constructing a complete and continuous production line. Based on the spatial location and material transfer requirements between each step, the conveyor units are configured with Z-type elevators, reciprocating horizontal conveyors, vibrating conveyors, and cooling elevators. This not only enables automatic, stable, and efficient material flow between steps, effectively improving production efficiency, but more importantly, it lays the necessary physical foundation for unified, precise, and intelligent collaborative control across the entire production line.

[0007] The conveyor unit upstream of the spreading device includes several Z-shaped elevators, the number of which is equal to the number of spreading devices. Each Z-shaped elevator corresponds to and is connected to a spreading device. The conveyor unit between the spreading device and the fixing device includes several Z-shaped elevators and several reciprocating horizontal conveyors, the number of which is equal to the number of fixing devices. The conveyor unit from the fixing device to the primary air classifier includes a vibrating conveyor and a cooling elevator arranged in sequence.

[0008] The conveyor unit from the primary air classifier to the primary rehumidification unit includes a vibrating conveyor and a Z-type elevator arranged in sequence; the conveyor unit between the primary rehumidification unit and the sizing unit includes a Z-type elevator.

[0009] The conveyor unit from the sorting device to the secondary rehumidification device includes a vibrating conveyor and an elevator arranged in sequence, and the hot air drying device is located on one side of this vibrating conveyor; the conveyor unit between the secondary rehumidification device and the electric drying device includes a Z-type elevator; the conveyor unit from the electric drying device to the secondary air classifier includes a vibrating device and a Z-type elevator; the conveyor unit from the secondary air classifier to the color sorter includes a vibrating device and a Z-type elevator.

[0010] By adopting the above technical solutions, the specific configuration and connection of the conveyor units were refined to address the specific spatial layout relationships and process connection requirements between key process devices. For example, a Z-type elevator is used to achieve vertical conveying and precise docking of materials between working planes at different heights; a reciprocating horizontal conveyor is used to achieve long-distance, adjustable-path, horizontal and uniform material distribution between the spreading and fixing devices; a vibrating conveyor and a cooling elevator are set up after fixing to take into account the material conveying, spreading, and preliminary cooling; and a hot air drying device is integrated on one side of the conveying path between the shaping and secondary rehydration processes, achieving a compact layout and efficient connection of processes. This constitutes a flexible material flow network that is efficient, stable, and adaptable to the process flow, ensuring that materials run continuously along the predetermined process route without stagnation or cross-contamination, and providing a reliable physical basis for accurately controlling the material supply, residence time, and process rhythm of each process. It is a key support for achieving full-process stabilization and automation.

[0011] An intelligent control system for a tea production line includes: Several sensor groups: Several sensor groups are respectively installed on the spreading device, the fixing device, the primary air separation device, the primary rehumidification device, the strip shaping device, the hot air drying device, the secondary rehumidification device, the electric drying device, the secondary air separation device, and the color sorting device; Several intelligent control cabinets: Each of the aforementioned intelligent control cabinets corresponds one-to-one with the spreading device, the fixing device, the primary air separation device, the primary rehumidification device, the strip shaping device, the hot air drying device, the secondary rehumidification device, the electric drying device, the secondary air separation device, and the color sorting device. Each of the aforementioned intelligent control cabinets is electrically connected to the actuator and its sensor group of the corresponding device. Main control center: The main control center is connected to several intelligent control cabinets.

[0012] By adopting the above technical solutions, a distributed collaborative control architecture was constructed to solve the "automation island" problem in traditional production lines where each piece of equipment is controlled independently and cannot form a system synergy. In terms of monitoring, this architecture deploys dedicated sensor groups on each core process unit, enabling comprehensive, real-time online acquisition of key process parameters. In terms of control, each process unit is equipped with a dedicated intelligent control cabinet, which not only independently completes the basic logic control of its own unit, but more importantly, acts as an edge computing node, processing local sensor data in real time and quickly and accurately driving actuators (such as heaters, fans, motors, etc.) to make adjustments based on preset algorithms or instructions from the upper layer, forming a regional rapid response closed loop. Furthermore, a main control center is set up as the system's "brain," interconnected with all intelligent control cabinets through a high-speed communication network, realizing the convergence of data across the entire production line, unified management of process models, and centralized issuance and scheduling of production instructions. The advanced nature of this architecture lies in the fact that it not only ensures the real-time and reliability of the control of each process unit (distributed control), but also realizes the fusion analysis of cross-process data, global optimization and collaborative linkage of the production process through the main control center (centralized management), laying the core hardware and system framework foundation for the ultimate realization of adaptive and intelligent production based on real-time feedback and process models.

[0013] The sensor group of the spreading device includes a temperature sensor, a humidity sensor, and a weight sensor; the intelligent control cabinet connected to it is configured to: control the ambient temperature inside the spreading device at 20-25℃ and the relative humidity at 65%-75% according to the signals from the temperature sensor and the humidity sensor; monitor the weight loss rate of the tea leaves according to the signal from the weight sensor, and automatically terminate the spreading process when the weight loss rate is 10%-15%. The sensor group of the blanching device includes a temperature sensor; the intelligent control cabinet connected to it is configured to: control the empty pot temperature of the blanching device at 180-220℃ according to the signal of the temperature sensor, control the leaf temperature after adding the leaves at 120-150℃, and control the reciprocating frequency of the pot at 100-170 times / min. The sensor group of the primary air separation device includes an image sensor; the intelligent control cabinet connected to it is configured to monitor the state of the tea leaves at the outlet of the primary air separation device according to the signal from the image sensor, and dynamically adjust the motor speed of the primary air separation device to separate impurities from the tea leaves.

[0014] The sensor group of the primary rehumidification device includes a temperature sensor, a humidity sensor, and a thickness sensor; the intelligent control cabinet connected to it is configured to: control the ambient temperature of the primary rehumidification device at 20-28℃ and the ambient humidity at 70%-85% based on the signals from the temperature sensor and the humidity sensor; control the thickness of the tea pile at 5-10cm and the rehumidification time at 0.5-4 hours based on the signal from the thickness sensor. The sensor group of the shaping device includes a temperature sensor; the intelligent control cabinet connected to it is configured to control the temperature of the pot of the shaping device in stages according to the signal of the temperature sensor: 60-70℃ in the initial stage, 80-85℃ in the middle stage, and 75-80℃ in the final stage; and control the reciprocating frequency of the pot to 120-150 times / min. The sensor group of the hot air drying device includes a temperature sensor; the intelligent control cabinet connected to it is configured to control the temperature of the hot air drying device in stages according to the signal from the temperature sensor: 60-65℃ for the preheating stage, 75-85℃ for the main drying stage, and 70-75℃ for the shaping stage; and control the thickness of the spread leaves to be 1.5-2 cm.

[0015] The sensor group of the secondary rehumidification device includes a temperature sensor, a humidity sensor, and a thickness sensor; the intelligent control cabinet connected to it is configured to: control the ambient temperature of the secondary rehumidification device at 22-25℃ and the ambient humidity at 65%-70% according to the signals from the temperature sensor and the humidity sensor; and control the thickness of the tea pile at 5-8cm and the rehumidification time at 20-30 minutes according to the signal from the thickness sensor. The sensor group of the electric drying device includes a temperature sensor; the intelligent control cabinet connected to it is configured to: control the drying temperature of the electric drying device at 80-90℃, control the re-drying time at 40-50 minutes, and control the leaf thickness at 1.5-2.5 cm according to the signal of the temperature sensor. The sensor group of the secondary air separation device includes an image sensor; the intelligent control cabinet connected to it is configured to monitor the state of the tea leaves at the outlet of the secondary air separation device based on the signal from the image sensor, and dynamically adjust the motor speed of the secondary air separation device.

[0016] By adopting the above technical solution, precise, automated, and intelligent control of key processes throughout the entire production process of green tea, especially straight-leaf teas such as Anji white tea, has been achieved. This solution configures specialized sensor groups and matching control logic for the core process influencing factors of each process, transforming the traditional fuzzy operation relying on "experience" and "sensory perception" into precise control based on "physical quantities" and "models."

[0017] Specifically, in the withering process, integrating weight sensors and using weight loss rate as the endpoint criterion for withering replaces traditional manual touch and experience-based judgment, thus solving the biggest source of quality control fluctuations in this stage. In the fixation and shaping processes, real-time feedback from temperature sensors and staged program control enable precise management of the intensity and rhythm of heat action, ensuring accurate enzyme inactivation and effective shaping of the leaf strands. In the air-classification process, image sensors are introduced for online visual detection, allowing the air-classification intensity to be adaptively adjusted in real time according to the purity of the output material, improving the accuracy and efficiency of impurity removal. In the rehumidification process, comprehensive control of temperature and humidity, along with precise control of the material layer accumulation via thickness sensors, achieves controllable and uniform moisture balance. In the drying process, coordinated control of staged temperature curves and leaf thickness ensures stable achievement of drying efficiency, aroma development, and final moisture content standards.

[0018] The main control center includes: The data storage and analysis module is used to receive and store process parameter data uploaded by each intelligent control cabinet in real time, and to perform trend analysis and fault warning on historical data. The process model management module is used to store and maintain the optimal process parameter models for each process, and can call up the corresponding model parameters according to different tea varieties or grades. The production scheduling and collaborative control module is used to issue process parameter settings to each intelligent control cabinet according to production instructions, and when an abnormality in a certain process parameter or equipment failure is detected, it sends linkage adjustment instructions to the intelligent control cabinet of the related process to maintain the stable operation of the production line.

[0019] By adopting the above technical solutions, the data storage and analysis module not only achieves real-time aggregation and long-term archiving of process data throughout the entire process, providing a complete "data chain" for product quality traceability, but more importantly, through in-depth mining and trend analysis of massive historical data, it can identify potential risks such as equipment performance degradation and process parameter drift in advance, realizing predictive maintenance from post-processing to pre-event warning, and ensuring the long-term reliability of production operations. The process model management module digitizes and models the validated optimal process parameters, process logic, and even expert experience in green tea processing. This enables the production line to quickly and accurately call and execute the corresponding "digital process formula" for different tea varieties (such as Anji white tea and West Lake Longjing) or grade requirements, realizing flexible switching of production modes and precise inheritance of standardized knowledge. The production scheduling and collaborative control module can not only automatically schedule all equipment on the line to start sequentially and run according to the model according to the production plan, but also, more importantly, has the ability to intelligently link across processes. When the real-time data from any sensor exceeds the normal threshold set by the model (e.g., abnormally high moisture content in tea leaves after a single re-moistening), or when the operating status of a certain piece of equipment is abnormal (e.g., insufficient heating power of the fixing machine), this module can, based on its understanding of the process logic, calculate in real time and immediately send compensatory or protective adjustment commands (e.g., appropriately increasing the temperature of the tea leaves or extending the drying time) to the control cabinets of related downstream processes (e.g., shaping and initial drying). This allows the production line to dynamically adapt to fluctuations in raw materials and compensate for changes in equipment status, thereby automatically maintaining the stability of the overall process route and the consistency of product quality when interference occurs, truly realizing the leap from "single-machine automation" to "system intelligence."

[0020] The intelligent control system for this tea production line includes the following steps: S1: Fresh leaves are fed into the withering device by the conveyor unit. Under intelligent control, they are withered in an environment of 20-25℃ and 65%-75% humidity until the water loss reaches the endpoint of 10%-15% as determined by the weight loss rate. S2: The withered leaves are fed into the blanching device by the conveyor unit, and blanching is completed at a pan temperature of 180-220℃ when empty, 120-150℃ after the leaves are added, and a reciprocating frequency of 100-170 times / min. S3: After the blanched leaves are cooled, they enter the primary air classifier. The rotation speed of the primary air classifier is controlled by feedback from the image sensor to complete the initial impurity removal. S4: After winnowing, the tea leaves enter a rehumidification device and are rehumidified for 0.5 to 4 hours at 20 to 28°C and 70% to 85% humidity to soften the leaf texture. S5: The rehydrated leaves enter the shaping device and pass through three stages in sequence: 60-70℃, 80-85℃, and 75-80℃, and are shaped at a reciprocating frequency of 120-150 times / min. S6: The strips of leaf pass through a hot air dryer and undergo three stages in sequence: preheating at 60-65℃, main drying at 75-85℃, and shaping at 70-75℃ to complete the initial drying. S7: The initially dried leaves enter the secondary rehumidification device and are rehumidified for 20 to 30 minutes at 22-25℃ and 65%-70% humidity to balance the moisture content; S8: The rehydrated leaves are put into an electric dryer and slowly dried at a low temperature of 80-90℃ for 40-50 minutes to complete the re-drying and aroma enhancement; S9: The re-dried leaves undergo a second air separation and color sorting device for final impurity removal and grading to obtain straight-shaped finished tea.

[0021] Compared with the prior art, the beneficial effects of the present invention are: This invention combines sensor technology, distributed edge control, and central collaborative decision-making to quantify, control, and optimize key process parameters in the production process. It solves the quality fluctuation problem caused by differences in manual operation in traditional production, ensuring that different batches of products achieve highly consistent appearance, color, moisture content, and aroma quality, thus improving the standardization and intelligence level of green tea production.

[0022] Other features and advantages of the present invention will be disclosed in detail in the following detailed description and accompanying drawings. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the process line of the present invention, from the spreading process to the shaping process; Figure 2 This is a schematic diagram of the process line from the strip forming process to the coloring process of the present invention; Figure 3 This is a schematic diagram of the full-process intelligent control system for a single process execution device of the present invention.

[0024] The attached diagrams are labeled as follows: 1. Process execution device; 101. Spreading device; 102. Fixing device; 103. Primary air separation device; 104. Primary rehumidification device; 105. Shaping device; 106. Hot air drying device; 107. Secondary rehumidification device; 108. Electric drying device; 109. Secondary air separation device; 1010. Color sorting device; 2. Conveyor unit; 201. Z-type elevator; 202. Reciprocating horizontal conveyor; 203. Vibrating conveyor; 204. Cooling elevator; 3. Sensor group; 4. Intelligent control cabinet; 5. Main control center; 501. Data storage and analysis module; 502. Process model management module; 503. Production scheduling and collaborative control module. Detailed Implementation

[0025] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0026] In this embodiment of the invention, a tea production line is described, see [link to relevant documentation]. Figure 1 and Figure 2 As shown, the tea production line includes at least one withering device 101, at least one fixation device 102, a primary air separation device 103, a primary rehumidification device 104, a leaf shaping device 105, a hot air drying device 106, a secondary rehumidification device 107, an electric drying device 108, a secondary air separation device 109, and a color sorting device 1010 arranged sequentially along the tea processing direction.

[0027] The tea production line also includes several conveyor units 2, which are connected to each other. The conveyor units 2 include at least one or more of the following: Z-type elevator 201, reciprocating horizontal conveyor 202, vibrating conveyor 203, and cooling elevator 204.

[0028] The process line is arranged linearly along the tea processing direction, from the fresh leaf inlet to the finished product outlet. Its core components include: a withering device 101 for tea leaf withering, a fixation device 102 for inactivating enzyme activity, a wind-sorting device for initial impurity removal, a rehumidification device for moisture balancing, a shaping device 105 for leaf shaping, a hot air drying device 106 for initial dehydration, a rehumidification device for further moisture balancing, an electric drying device 108 for aroma enhancement and final drying, a wind-sorting device for fine impurity removal, and a color sorting device 1010 for grading.

[0029] To achieve automatic and continuous material flow between functional units, the process line is equipped with a complete conveyor unit 2. These conveying devices are selected and connected based on the spatial relationship between adjacent processes and material transfer requirements. They mainly include a Z-type elevator 201 for vertical material lifting, a reciprocating conveyor 202 for horizontal uniform material distribution and conveying, a vibrating conveyor 203 that combines conveying and cooling functions, and a cooling elevator 204 installed after the tea leaves are withered to rapidly cool them down. The conveyor unit 2 organically connects the aforementioned independent devices in series, forming a complete, closed, and continuous material processing channel from fresh leaf input to finished product sorting and output.

[0030] The conveyor unit 2 upstream of the spreading device 101 includes several Z-shaped elevators 201, the number of which is equal to the number of spreading devices 101. Each Z-shaped elevator 201 corresponds to and is connected to one spreading device 101. The conveyor unit 2 between the spreading device 101 and the fixing device 102 includes several Z-shaped elevators 201 and several reciprocating horizontal conveyors 202, the number of which is equal to the number of fixing devices 102. The conveyor unit 2 from the fixing device 102 to the primary air classifier 103 includes a vibrating conveyor 203 and a cooling elevator 204 arranged in sequence. The conveyor unit 2 from the primary air classifier 103 to the primary rehumidification device 104 includes a vibrating conveyor 203 and a Z-shaped elevator 201 arranged in sequence. The conveyor unit 2 between the primary rehumidification device 104 and the shaping device 105 includes a Z-shaped elevator 201. The conveyor unit 2 from the sorting device 105 to the secondary rehumidification device 107 includes a vibrating conveyor 203 and an elevator arranged in sequence, with the hot air drying device 106 located on one side of this vibrating conveyor 203. The conveyor unit 2 between the secondary rehumidification device 107 and the electric drying device 108 includes a Z-shaped elevator 201. The conveyor unit 2 from the electric drying device 108 to the secondary air classifier 109 includes a vibrating device and a Z-shaped elevator 201. The conveyor unit 2 from the secondary air classifier 109 to the color sorter 1010 includes a vibrating device and a Z-shaped elevator 201.

[0031] In this embodiment, an equal number of Z-shaped elevators 201 are installed upstream of the spreading device 101. The discharge port of each Z-shaped elevator 201 is directly connected to the inlet of the corresponding spreading device 101, responsible for vertically lifting the fresh leaves and evenly feeding them into each spreading process. Between the spreading device 101 and the fixing device 102, several Z-shaped elevators 201 and a reciprocating horizontal conveyor 202 of the same number as the fixing devices 102 are installed. This combination lifts the withered tea leaves from the output end of the spreading device 101 and distributes them horizontally and evenly to the inlet of each fixing device 102 via the reciprocating horizontal conveyor 202. From the fixing device 102 to the primary air separation device 103, a vibrating conveyor 203 and a cooling elevator 204 are arranged in sequence. The vibrating conveyor 203 receives the fixing tea leaves and transports and initially cools them, and then the cooling elevator 204 further cools the tea leaves during the lifting process. Between the primary air-separation device 103 and the primary rehumidification device 104, the conveying path consists of a vibrating conveyor 203 and a Z-shaped elevator 201 arranged sequentially. The vibrating conveyor 203 receives the air-separated tea leaves, while the Z-shaped elevator 201 lifts them to the inlet height of the primary rehumidification device 104. The primary rehumidification device 104 and the shaping device 105 are directly connected by the Z-shaped elevator 201, enabling vertical conveying of the rehumidified tea leaves. Downstream of the shaping device 105, the tea leaves are output via the vibrating conveyor 203. A hot air drying device 106 is arranged on one side of the vibrating conveyor 203, allowing the tea leaves to be dried while being conveyed by the vibrating conveyor 203 to the shaping device 105. The conveying from the shaping device 105 to the secondary rehumidification device 107 is mainly completed by the vibrating conveyor 203 and its end elevator. The secondary rehumidification device 107 and the electric drying device 108 are connected by a Z-shaped elevator 201. A vibrating device and a Z-shaped elevator 201 are sequentially installed between the electric drying device 108 and the secondary air separation device 109. Similarly, a vibrating device and a Z-shaped elevator 201 are sequentially installed between the secondary air separation device 109 and the color sorting device 1010 to complete the final conveying.

[0032] An intelligent control system for a tea production line, such as Figure 3 As shown, it includes: Several sensor groups 3: Several sensor groups 3 are respectively installed on the spreading device 101, the fixing device 102, the primary air separation device 103, the primary rehumidification device 104, the strip straightening device 105, the hot air drying device 106, the secondary rehumidification device 107, the electric drying device 108, the secondary air separation device 109, and the color sorting device 1010.

[0033] Several intelligent control cabinets 4: Several intelligent control cabinets 4 correspond one-to-one with the spreading device 101, the fixing device 102, the primary air separation device 103, the primary rehumidification device 104, the strip shaping device 105, the hot air drying device 106, the secondary rehumidification device 107, the electric drying device 108, the secondary air separation device 109, and the color sorting device 1010. Each intelligent control cabinet 4 is electrically connected to the actuator and its sensor group 3 of the corresponding device.

[0034] Main control center 5: Main control center 5 is connected to several intelligent control cabinets 4.

[0035] In this embodiment, a set of dedicated sensor groups 3 are installed on each process execution device 1 of the production line, namely the spreading device 101, the fixing device 102, the primary air separation device 103, the primary rehumidification device 104, the strip straightening device 105, the hot air drying device 106, the secondary rehumidification device 107, the electric drying device 108, the secondary air separation device 109, and the color sorting device 1010, to collect the key process parameters of the device in real time.

[0036] Each of the aforementioned process execution devices 1 is equipped with an independent intelligent control cabinet 4. These intelligent control cabinets 4 are installed one-to-one with the process devices. Each intelligent control cabinet 4 is electrically connected to the execution mechanism on the process device it is responsible for and the sensor group 3 deployed on that device through electrical circuits, thereby forming a local monitoring and control closed loop for a single device.

[0037] Simultaneously, a central control center 5 is established. This control center 5 establishes a two-way communication connection with all the intelligent control cabinets 4 deployed next to each process unit through an industrial communication network, thereby forming an overall intelligent control network architecture of centralized management and decentralized control.

[0038] The sensor group 3 of the tea spreading device 101 includes a temperature sensor, a humidity sensor, and a weight sensor. The intelligent control cabinet 4 connected to it is configured to: control the ambient temperature inside the tea spreading device 101 at 20-25°C and the relative humidity at 65%-75% based on the signals from the temperature and humidity sensors; and monitor the weight loss rate of the tea leaves based on the signal from the weight sensor, automatically terminating the tea spreading process when the weight loss rate is between 10% and 15%.

[0039] The sensor group 3 of the blanching device 102 includes a temperature sensor. The intelligent control cabinet 4 connected to it is configured to: control the empty pot temperature of the blanching device 102 at 180-220℃, control the leaf temperature after leaf addition at 120-150℃, and control the reciprocating frequency of the pot at 100-170 times / min, based on the signal from the temperature sensor.

[0040] The sensor group 3 of the primary air separation device 103 includes an image sensor. The intelligent control cabinet 4 connected to it is configured to monitor the state of the tea leaves at the outlet of the primary air separation device 103 based on the signal from the image sensor, and dynamically adjust the motor speed of the primary air separation device 103 to separate impurities from the tea leaves.

[0041] The sensor group 3 of the primary rehumidification device 104 includes a temperature sensor, a humidity sensor, and a thickness sensor. The connected intelligent control cabinet 4 is configured to: control the ambient temperature of the primary rehumidification device 104 at 20–28°C and the ambient humidity at 70%–85% based on signals from the temperature and humidity sensors; and control the tea leaf accumulation thickness at 5–10 cm and the rehumidification time at 0.5–4 hours based on signals from the thickness sensor.

[0042] The sensor group 3 of the forming device 105 includes a temperature sensor. The intelligent control cabinet 4 connected to it is configured to control the temperature of the pot in the forming device 105 in stages according to the signal from the temperature sensor: 60-70℃ in the initial stage, 80-85℃ in the middle stage, and 75-80℃ in the final stage. The reciprocating frequency of the pot is controlled at 120-150 times / min.

[0043] The sensor group 3 of the hot air drying device 106 includes a temperature sensor. The intelligent control cabinet 4 connected to it is configured to control the temperature of the hot air drying device 106 in stages according to the signal from the temperature sensor: 60-65℃ for the preheating stage, 75-85℃ for the main drying stage, and 70-75℃ for the shaping stage. It also controls the thickness of the spread leaves to be 1.5-2 cm.

[0044] The sensor group 3 of the secondary rehumidification device 107 includes a temperature sensor, a humidity sensor, and a thickness sensor. The intelligent control cabinet 4 connected to it is configured to: control the ambient temperature of the secondary rehumidification device 107 at 22–25°C and the ambient humidity at 65%–70% based on the signals from the temperature and humidity sensors; and control the tea leaf stack thickness at 5–8 cm and the rehumidification time at 20–30 minutes based on the signal from the thickness sensor.

[0045] The sensor group 3 of the electric drying device 108 includes a temperature sensor. The intelligent control cabinet 4 connected to it is configured to control the drying temperature of the electric drying device 108 at 80-90°C, the re-drying time at 40-50 minutes, and the leaf thickness at 1.5-2.5 cm based on the signal from the temperature sensor.

[0046] The sensor group 3 of the secondary air separation device 109 includes an image sensor. The intelligent control cabinet 4 connected to it is configured to monitor the state of the tea leaves at the outlet of the secondary air separation device 109 based on the signal from the image sensor, and dynamically adjust the motor speed of the secondary air separation device 109.

[0047] In this embodiment, the tea-spreading device 101 is equipped with temperature and humidity sensors for monitoring environmental parameters, as well as a weight sensor for real-time weighing of the tea leaves. The intelligent control cabinet 4, corresponding to the tea-spreading device 101, receives real-time signals from these sensors. The control program inside the cabinet is configured to maintain the ambient temperature inside the tea-spreading device 101 within the range of 20 to 25 degrees Celsius and control the relative humidity within the range of 65% to 75% based on feedback data from the temperature and humidity sensors. Simultaneously, the control cabinet continuously processes data from the weight sensor to calculate the real-time weight loss rate of the tea leaves during the spreading process. When the control system determines that the weight loss rate reaches a preset range of 10% to 15%, the control cabinet automatically issues a command to terminate the spreading process and initiate the discharge procedure.

[0048] A temperature sensor is installed on the blanching device 102 to monitor the temperature of the blanching vat. The corresponding intelligent control cabinet 4, based on the feedback signal from this temperature sensor, precisely regulates the heating unit of the blanching device 102, maintaining the vat temperature between 180 and 220 degrees Celsius when empty, and stabilizing the leaf temperature between 120 and 150 degrees Celsius after fresh leaves are added. Furthermore, the control cabinet also controls the reciprocating motion frequency of the blanching vat within a preset program, ranging from 100 to 170 times per minute.

[0049] An image sensor is installed at the outlet of the primary air classifier 103. The corresponding intelligent control cabinet 4 of the primary air classifier 103 is configured to receive and analyze the images of the tea leaves flowing out of the tea leaves in real time, and determine the separation of impurities in the tea leaves through image recognition algorithms. Based on the analysis results, the control cabinet dynamically adjusts the speed of the drive motor of the primary air classifier 103 fan, thereby optimizing the impurity removal effect in real time according to the actual state of the tea leaves.

[0050] Inside the primary rehumidification device 104, temperature sensors, humidity sensors, and thickness sensors for monitoring the thickness of the tea layer are installed. The corresponding intelligent control cabinet 4 adjusts the temperature and humidity control equipment within the rehumidification chamber based on signals from the temperature and humidity sensors, ensuring the ambient temperature is maintained between 20 and 28 degrees Celsius and the ambient humidity between 70% and 85%. Simultaneously, based on the tea accumulation information fed back by the thickness sensor, the control cabinet adjusts the conveyor belt's running speed to control the tea accumulation thickness on the mesh belt to a loose and uniform state of 5 to 10 centimeters, indirectly regulating the total rehumidification time to between 0.5 and 4 hours.

[0051] A temperature sensor is installed on the skewer device 105 to monitor the temperature of the trough. The corresponding intelligent control cabinet 4, based on the temperature signal, performs phased program control of the heating source: in the initial stage of skewer preparation, the trough temperature is controlled at 60 to 70 degrees Celsius. In the middle stage, the temperature is increased to 80 to 85 degrees Celsius. In the final stage, the temperature is maintained at 75 to 80 degrees Celsius. Simultaneously, the control cabinet also stably controls the reciprocating frequency of the skewer at 120 to 150 times per minute.

[0052] A temperature sensor is installed in the hot air drying device 106 to monitor the drying temperature. Based on feedback from this sensor, its intelligent control cabinet 4 implements phased regulation of the hot air temperature: during the preheating stage, the temperature is controlled at 60 to 65 degrees Celsius. During the main drying stage, the temperature is raised to 75 to 85 degrees Celsius. During the shaping stage, the temperature is stabilized at 70 to 75 degrees Celsius. The control cabinet also controls the thickness of the tea leaves spread on the drying mesh belt to 1.5 to 2 centimeters by adjusting the feeding or conveying speed.

[0053] Inside the secondary rehumidification device 107, temperature, humidity, and thickness sensors are also installed. The corresponding intelligent control cabinet 4, based on signals from the temperature and humidity sensors, controls the rehumidification environment temperature at 22 to 25 degrees Celsius and the humidity at 65% to 70%. Simultaneously, based on signals from the thickness sensor, it adjusts the conveyor belt speed to control the tea leaf accumulation thickness at 5 to 8 centimeters, ensuring a rehumidification time of 20 to 30 minutes.

[0054] A temperature sensor is installed on the electric drying unit 108 to monitor the temperature of the drying chamber. The intelligent control cabinet 4, connected to this sensor, adjusts the power of the heating elements based on the feedback from the sensor to maintain the temperature inside the drying chamber at 80 to 90 degrees Celsius. The control cabinet also controls the total re-drying time to 40 to 50 minutes and the leaf thickness to 1.5 to 2.5 centimeters by controlling the speed of the tea leaves on the drying conveyor belt.

[0055] An image sensor is also installed at the outlet of the secondary air separation device 109. The corresponding intelligent control cabinet 4 is configured to continuously receive signals from the image sensor, monitor the purity of the tea leaves after secondary air separation, and dynamically adjust the motor speed of the air separation device based on the image analysis results to achieve refined impurity removal control.

[0056] Main control center 5 includes: The data storage and analysis module 501 is used to receive and store the process parameter data uploaded by each intelligent control cabinet 4 in real time, and to perform trend analysis and fault early warning on historical data.

[0057] The process model management module 502 is used to store and maintain the optimal process parameter models for each process, and can call up the corresponding model parameters according to different tea varieties or grades.

[0058] The production scheduling and collaborative control module 503 is used to issue process parameter setting values ​​to each intelligent control cabinet 4 according to the production instructions, and when an abnormality in a certain process parameter or equipment failure is detected, it sends a linkage adjustment command to the intelligent control cabinet 4 of the related process to maintain the stable operation of the production line.

[0059] In this embodiment, the main control center 5 includes a data storage and analysis module 501. This module continuously and in real-time receives and aggregates all process parameter data uploaded periodically by each intelligent control cabinet 4 through the industrial communication network within the production line. This data includes, but is not limited to, temperature, humidity, weight, and image analysis results. All received data is categorized and stored in a related database, forming a complete production history. The data analysis engine embedded in this module can perform multi-dimensional statistical and trend analysis on the stored historical process parameter data. For example, it can analyze the temperature control deviation trend of specific equipment over a period of time, or the correlation of key parameters when production volume changes. Based on preset analysis models and thresholds, this module can automatically identify potential performance degradation or process drift and promptly generate fault warning reports, sending them to operators to achieve predictive maintenance and preventative process adjustments.

[0060] The main control center 5 also includes a process model management module 502. This module constructs a digital process knowledge base at the software level, storing and maintaining verified and optimized standard process parameter models for each process step, tailored to different tea varieties (such as Anji White Tea and West Lake Longjing) and product grades. These models exist in the form of data files or configuration files, defining details such as the target weight loss rate during withering, temperature curves at each stage, and air separation sensitivity parameters. When switching production varieties or grades, operators can select the corresponding model through the human-machine interface, and the process model management module 502 will automatically call up all preset parameter sets within that model.

[0061] The core coordination function of the main control center 5 is implemented by a production scheduling and collaborative control module 503. This module receives production instructions (such as product type, batch, and output) from the production management system. Based on the instructions, the module first retrieves the corresponding process parameter model from the process model management module 502, and then sends the parameter settings (such as target temperature and target time) for each process in the model to the corresponding intelligent control cabinets 4 via the communication network, directing all equipment on the production line to start and operate according to preset parameters. During production, this module continuously monitors the real-time data stream from the data storage and analysis module 501. When it detects that the process parameters reported by any intelligent control cabinet 4 continuously deviate from the set range (for example, the humidity of a certain rehumidification device is abnormally low), or when it receives an equipment fault alarm signal, the collaborative logic algorithm within this module is triggered. The algorithm immediately sends specific linkage adjustment instructions to one or more related subsequent intelligent control cabinets 4 based on the preset process flow relationships. For example, if insufficient rehumidification is detected (tea leaves are too dry), the module can send a command to the control cabinet of the subsequent tea-rolling device 105 to temporarily lower its initial set temperature to prevent the tea leaves from cracking due to excessive dryness. This real-time command linkage across processes aims to proactively compensate for anomalies in the preceding processes, thereby maintaining the stability and continuity of the entire production line's process route and ensuring the consistency of the final product quality.

[0062] In this embodiment, the intelligent control system for the tea production line includes the following steps: S1: Fresh leaves are fed into the withering device 101 via conveyor unit 2. Under intelligent control, they are withered in an environment of 20-25℃ and 65%-75% humidity until the water loss reaches the endpoint of 10%-15% as determined by the weight loss rate.

[0063] S2: The withered leaves are fed into the blanching device 102 via the conveyor unit 2, and blanching is completed at a pan temperature of 180-220℃ when empty, a pan temperature of 120-150℃ after adding the leaves, and a reciprocating frequency of 100-170 times / min.

[0064] S3: After being cooled, the blanched leaves enter the primary air classifier 103. The rotation speed of the air classifier is controlled by feedback from the image sensor to complete the initial impurity removal.

[0065] S4: After winnowing, the tea leaves enter the rehumidification device 104 and are rehumidified for 0.5 to 4 hours at 20 to 28°C and 70% to 85% humidity to soften the leaf texture.

[0066] S5: The rehydrated leaf enters the shaping device 105 and passes through three stages in sequence: 60-70℃, 80-85℃, and 75-80℃, and is shaped at a reciprocating frequency of 120-150 times / min.

[0067] S6: The strips are dried in a hot air dryer, and the initial drying is completed in three stages: preheating at 60-65℃, main drying at 75-85℃, and shaping at 70-75℃.

[0068] S7: The initially dried leaves enter the secondary rehumidification device 107 and are rehumidified for 20 to 30 minutes at 22 to 25°C and 65% to 70% humidity to balance the moisture content.

[0069] S8: The rehydrated leaves are put into an electric dryer and dried slowly at a low temperature of 80-90℃ for 40-50 minutes to complete the re-drying and aroma enhancement.

[0070] S9: The re-dried leaves are subjected to a second air separation and color sorting device 1010 for final impurity removal and grading to obtain straight-shaped finished tea.

[0071] This invention provides a tea production line and its intelligent control system, which can realize continuous, standardized and intelligent production, and can adaptively adjust key process parameters.

[0072] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0073] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A tea production line, characterized in that, The tea production line includes several process execution devices (1), which are respectively arranged in sequence along the tea processing direction: at least one withering device (101), at least one fixation device (102), a primary air separation device (103), a primary rehumidification device (104), a leaf shaping device (105), a hot air drying device (106), a secondary rehumidification device (107), an electric drying device (108), a secondary air separation device (109), and a color sorting device (1010). The tea production line also includes several conveyor units (2), and the various devices are connected by the conveyor units (2); the conveyor units (2) include at least one or more of the following: Z-type elevator (201), reciprocating flat conveyor (202), vibrating conveyor (203) and cooling elevator (204).

2. The tea production line according to claim 1, characterized in that, The conveyor unit (2) upstream of the spreading device (101) includes several Z-type elevators (201), the number of which is equal to the number of spreading devices (101), and the Z-type elevators (201) correspond one-to-one with the spreading devices (101) and are connected; the conveyor unit (2) between the spreading device (101) and the fixing device (102) includes several Z-type elevators (201) and several reciprocating flat conveyors (202), the number of which is equal to the number of fixing devices (102); the conveyor unit (2) from the fixing device (102) to the primary air classifier (103) includes a vibrating conveyor (203) and a cooling elevator (204) arranged in sequence.

3. The tea production line according to claim 1, characterized in that, The conveyor unit (2) from the primary air separation device (103) to the primary rehumidification device (104) includes a vibrating conveyor (203) and a Z-type elevator (201) arranged in sequence; the conveyor unit (2) between the primary rehumidification device (104) and the strip forming device (105) includes a Z-type elevator (201).

4. The tea production line according to claim 1, characterized in that, The conveyor unit (2) from the sorting device (105) to the secondary rehumidification device (107) includes a vibrating conveyor (203) and an elevator arranged in sequence, and the hot air drying device (106) is located on one side of the vibrating conveyor (203); the conveyor unit (2) between the secondary rehumidification device (107) and the electric drying device (108) includes a Z-type elevator (201); the conveyor unit (2) from the electric drying device (108) to the secondary air separation device (109) includes a vibrating device and a Z-type elevator (201); the conveyor unit (2) from the secondary air separation device (109) to the color sorting device (1010) includes a vibrating device and a Z-type elevator (201).

5. An intelligent control system for a tea production line, characterized in that, The intelligent control system for this tea production line includes: Several sensor groups (3): Several sensor groups (3) are respectively disposed on the spreading device (101), the fixing device (102), the primary air separation device (103), the primary re-moistening device (104), the strip straightening device (105), the hot air drying device (106), the secondary re-moistening device (107), the electric drying device (108), the secondary air separation device (109), and the color sorting device (1010); Several intelligent control cabinets (4): Several intelligent control cabinets (4) correspond one-to-one with the spreading device (101), the fixing device (102), the primary air separation device (103), the primary re-moistening device (104), the strip-forming device (105), the hot air drying device (106), the secondary re-moistening device (107), the electric drying device (108), the secondary air separation device (109), and the color sorting device (1010). Each intelligent control cabinet (4) is electrically connected to the actuator and its sensor group (3) of the corresponding device. Main control center (5): The main control center (5) is connected to several intelligent control cabinets (4) respectively.

6. The intelligent control system for tea production line according to claim 5, characterized in that, The sensor group (3) of the spreading device (101) includes a temperature sensor, a humidity sensor and a weight sensor; the intelligent control cabinet (4) connected thereto is configured to: control the ambient temperature inside the spreading device (101) at 20-25°C and the relative humidity at 65%-75% according to the signals from the temperature sensor and the humidity sensor; monitor the weight loss rate of the tea leaves according to the signal from the weight sensor, and automatically terminate the spreading process when the weight loss rate is 10%-15%; The sensor group (3) of the blanching device (102) includes a temperature sensor; the intelligent control cabinet (4) connected thereto is configured to: control the empty pot temperature of the blanching device (102) at 180-220°C according to the signal of the temperature sensor, control the leaf temperature after adding the leaves at 120-150°C, and control the reciprocating frequency of the pot at 100-170 times / min. The sensor group (3) of the primary air separation device (103) includes an image sensor; the intelligent control cabinet (4) connected thereto is configured to monitor the tea state at the outlet of the primary air separation device (103) according to the signal of the image sensor, and dynamically adjust the motor speed of the primary air separation device (103) to separate impurities in the tea.

7. The intelligent control system for tea production line according to claim 6, characterized in that, The sensor group (3) of the primary rehumidification device (104) includes a temperature sensor, a humidity sensor and a thickness sensor; the intelligent control cabinet (4) connected thereto is configured to: control the ambient temperature of the primary rehumidification device (104) at 20-28°C and the ambient humidity at 70%-85% according to the signals of the temperature sensor and the humidity sensor; control the thickness of the tea pile at 5-10cm and the rehumidification time at 0.5-4 hours according to the signal of the thickness sensor; The sensor group (3) of the strip-arranging device (105) includes a temperature sensor; the intelligent control cabinet (4) connected thereto is configured to: control the temperature of the trough of the strip-arranging device (105) in stages according to the signal of the temperature sensor: 60-70℃ in the initial stage, 80-85℃ in the middle stage, and 75-80℃ in the final stage; and control the reciprocating frequency of the trough at 120-150 times / min; The sensor group (3) of the hot air drying device (106) includes a temperature sensor; the intelligent control cabinet (4) connected thereto is configured to control the temperature of the hot air drying device (106) in stages according to the signal of the temperature sensor: 60-65°C in the preheating stage, 75-85°C in the main drying stage, and 70-75°C in the shaping stage; and control the thickness of the spread leaves to be 1.5-2 cm.

8. The intelligent control system for tea production line according to claim 7, characterized in that, The sensor group (3) of the secondary rehumidification device (107) includes a temperature sensor, a humidity sensor and a thickness sensor; the intelligent control cabinet (4) connected thereto is configured to: control the ambient temperature of the secondary rehumidification device (107) at 22-25℃ and the ambient humidity at 65%-70% according to the signals of the temperature sensor and the humidity sensor; control the thickness of the tea pile at 5-8cm and the rehumidification time at 20-30 minutes according to the signal of the thickness sensor; The sensor group (3) of the electric drying device (108) includes a temperature sensor; the intelligent control cabinet (4) connected thereto is configured to: control the drying temperature of the electric drying device (108) at 80-90°C, control the re-drying time at 40-50 minutes, and control the leaf thickness at 1.5-2.5 cm according to the signal of the temperature sensor. The sensor group (3) of the secondary air separation device (109) includes an image sensor; the intelligent control cabinet (4) connected thereto is configured to monitor the tea state at the outlet of the secondary air separation device (109) according to the signal of the image sensor, and dynamically adjust the motor speed of the secondary air separation device (109).

9. The intelligent control system for tea production line according to claim 8, characterized in that, The main control center (5) includes: The data storage and analysis module (501) is used to receive and store the process parameter data uploaded by each intelligent control cabinet (4) in real time, and to perform trend analysis and fault warning on historical data. The process model management module (502) is used to store and maintain the optimal process parameter model for each process, and can call the corresponding model parameters according to the different tea varieties or grades. The production scheduling and collaborative control module (503) is used to issue process parameter setting values ​​to each intelligent control cabinet (4) according to the production instructions, and when an abnormal parameter of a certain process or equipment failure is detected, it sends a linkage adjustment instruction to the intelligent control cabinet (4) of the related process to maintain the stable operation of the production line.

10. The intelligent control system for tea production line according to claim 9, characterized in that, Includes the following steps: S1: Fresh leaves are fed into the spreading device (101) via the conveyor unit (2). Under intelligent control, they are withered in an environment of 20-25℃ and 65%-75% humidity until the water loss endpoint of 10%-15% is reached by the weight loss rate determination. S2: The withered leaves are fed into the blanching device (102) via the conveyor unit (2), and blanching is completed at a pot temperature of 180-220℃ when empty, a pot temperature of 120-150℃ after adding the leaves, and a reciprocating frequency of 100-170 times / min. S3: After the blanched leaves are cooled, they enter the primary air classifier (103). The rotation speed of the primary air classifier (103) is controlled by the feedback of the image sensor to complete the initial impurity removal. S4: After winnowing, the tea leaves enter a rehumidification device (104) and are rehumidified for 0.5 to 4 hours at 20 to 28°C and 70% to 85% humidity to soften the leaf texture; S5: The rehydrated leaf enters the shaping device (105) and passes through three stages in sequence: 60-70℃, 80-85℃, and 75-80℃. The leaf is shaped at a reciprocating frequency of 120-150 times / min. S6: The strips of leaf pass through a hot air dryer and undergo three stages in sequence: preheating at 60-65℃, main drying at 75-85℃, and shaping at 70-75℃ to complete the initial drying. S7: The initially dried leaves enter the secondary rehumidification device (107) and are rehumidified for 20 to 30 minutes at 22 to 25°C and 65% to 70% humidity to balance the moisture content; S8: The rehydrated leaves are put into an electric dryer and slowly dried at a low temperature of 80-90℃ for 40-50 minutes to complete the re-drying and aroma enhancement; S9: The re-dried leaves are subjected to a second air separation and color sorting device (1010) for final impurity removal and grading to obtain straight strip-shaped finished tea.

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