A feed control method, device, equipment and readable storage medium

Abstract

This application relates to the field of industrial automation control technology, and discloses a feeding control method, device, equipment, and readable storage medium, including: collecting multi-source status data of a target feeding container; fusing the multi-source status data to generate real-time material level parameters characterizing the current material inventory; comparing the real-time material level parameters with one or more preset threshold conditions to determine the current feeding control mode; generating corresponding feeding control instructions according to the feeding control mode, and driving the feeding actuator to perform corresponding feeding control operations based on the feeding control instructions. This application effectively improves the accuracy and stability of material control in the feeding silo, significantly reduces tobacco breakage and flavoring fluctuations, ensures production continuity, has strong adaptability and traceability, improves the intelligence level of the tobacco processing process, and reduces operating costs.

Description

Technical Field

[0001] This application relates to the field of industrial automation control technology, and in particular to a material feeding control method, apparatus, equipment and readable storage medium. Background Technology

[0002] In the cigarette manufacturing process, the precision of flavoring and the flow rate of the drying process are key parameters that determine the quality of the tobacco. Currently, the flavoring feed hoppers in cigarette manufacturing workshops generally use single-level detection technology (such as radar or ultrasonic sensors) for material monitoring and trigger the tobacco feeding operation based on a fixed threshold. When the feed hopper reaches full, the system automatically stops the drying machine within 5 seconds to prevent overflow. Emergency handling relies on manual intervention, and there is no standardized recording mechanism. The overall control method is relatively rudimentary and cannot meet the needs of high-quality, continuous production.

[0003] The existing control mode relies on a single sensor signal, resulting in a measurement error of up to 15% under conditions such as loose tobacco and changes in humidity. This leads to a 32% misjudgment rate of tobacco feeding timing, frequently causing material level loss and resulting in 1-3 unplanned shutdowns of the drying machine per month. The fixed threshold cannot adapt to the density differences (180-320 kg / m³) of different tobacco brands and fluctuations in production cycle, restricting the system's flexibility and stability. At the same time, the emergency handling is crude, lacking effective process intervention methods and abnormal event traceability functions, resulting in frequent equipment start-ups and shutdowns, increased tobacco breakage, and difficulty in tracing the source of quality problems, seriously hindering the intelligent and lean development of the tobacco processing process. Summary of the Invention

[0004] In view of this, the present application provides a feeding control method, device, equipment and readable storage medium, which can effectively solve the problems in the prior art caused by large detection error of a single sensor, poor adaptability of fixed threshold control and lack of traceability in emergency handling, such as misjudgment of the timing of tobacco feeding, frequent start-up and shutdown of equipment, high tobacco breakage rate and difficulty in tracing the source of quality problems.

[0005] In a first aspect, embodiments of this application provide a material supply control method, including: Collect multi-source status data of the target feeding container; The multi-source status data are fused to generate real-time material level parameters that characterize the current material inventory. The current material supply control mode is determined by comparing the real-time material level parameters with one or more preset threshold conditions. Based on the feeding control mode, a corresponding feeding control command is generated, and based on the feeding control command, the feeding actuator is driven to perform the corresponding feeding control operation.

[0006] In some embodiments, the acquisition of multi-source status data of the target feeding container includes: Spatial ranging information is collected by a radar level sensor installed on the top of the target feeding container, and first data characterizing the height of the material inside the target feeding container is generated. Pressure signals are collected by weighing sensors installed on the support structure of the target feeding container to generate second data characterizing the mass of the material inside the target feeding container. Ambient temperature and humidity data are collected by temperature and humidity sensors arranged on the side wall of the target feeding container, and parameters for correcting changes in material bulk density are generated. The first data, the second data, and the changing parameters constitute multi-source state data.

[0007] In some embodiments, the step of fusing the multi-source state data to generate real-time material level parameters characterizing the current material inventory includes: The first and second data in the multi-source state data are weighted and fused according to preset weights to obtain a preliminary fused material level value; The initial fused material level value is compensated and corrected using the changing parameters in the multi-source state data to generate real-time material level parameters.

[0008] In some embodiments, determining the current material supply control mode based on comparing the real-time material level parameter with one or more preset threshold conditions includes: Set a first threshold and a second threshold, wherein the first threshold corresponds to the upper limit of the normal feeding range, the second threshold corresponds to the upper limit of the safety tolerance, and the first threshold is less than the second threshold; When the real-time material level parameter is lower than the first threshold, the material supply control mode is determined to be the first mode; When the real-time material level parameter is greater than or equal to the first threshold and less than the second threshold, the material supply control mode is determined to be the second mode; When the real-time material level parameter is greater than or equal to the second threshold, the material supply control mode is determined to be the third mode.

[0009] In some embodiments, generating a corresponding feeding control command according to the feeding control mode, and driving the feeding actuator to perform a corresponding feeding regulation operation based on the feeding control command, includes: In the first feeding mode, a first control command is generated to adjust the conveyor belt speed; In the second feeding mode, a second control command containing an adaptive lead time parameter is generated; In the third feeding mode, a third control command is generated to activate the forced feeding process; Based on any one of the first control command, the second control command, and the third control command, the material feeding execution mechanism is sent to drive the material feeding execution mechanism to perform the corresponding material feeding control operation.

[0010] In some embodiments, after the drive feeding actuator performs the corresponding feeding control operation, it includes: Detect and record any abnormal events that occur during the execution of material supply control operations; The information of the abnormal event is encrypted, packaged, and uploaded to the production management system for visual prompts on the human-computer interaction interface. Simultaneously, the abnormal events are generated into structured record entries and stored in a local or cloud database.

[0011] In some embodiments, the execution of the third control instruction includes: In response to the third control command, based on the start time of forced feeding, a status confirmation prompt message is sent to the human-machine interface of the actuator at preset intervals; Real-time material level parameters are collected synchronously, and the trend of material level changes is analyzed by combining the effective response results to the status confirmation prompt information. If no valid response is received within the specified response time limit after any prompt, and the material level shows a downward trend, it is determined that the abnormal continuous working condition has been entered. When the abnormal operating condition continues for a preset maximum allowable duration, the forced feeding operation is terminated and a high-level alarm signal is triggered.

[0012] Secondly, embodiments of this application provide a material feeding control device, comprising: The data acquisition module is used to collect multi-source status data of the target feeding container; The fusion processing module is used to fuse the multi-source state data to generate real-time material level parameters that characterize the current material inventory. The mode determination module is used to determine the current material supply control mode by comparing the real-time material level parameters with one or more preset threshold conditions. The instruction generation module is used to generate corresponding material supply control instructions according to the material supply control mode, and drive the material supply actuator to perform corresponding material supply control operations based on the material supply control instructions.

[0013] Thirdly, embodiments of this application provide a terminal device, the terminal device including a processor and a memory, the memory storing a computer program, and the processor executing the computer program to implement the feeding control method of the first aspect described above.

[0014] Fourthly, embodiments of this application provide a computer-readable storage medium, wherein when the computer program is executed on a processor, it implements the feeding control method of the first aspect described above.

[0015] The embodiments of this application have the following beneficial effects: by collecting multi-source state data of the target feeding container, the above data is weighted and fused and density compensated to generate high-precision real-time material level parameters; combined with preset threshold comparison, the current feeding control mode is dynamically determined; and corresponding control commands are generated accordingly to drive the conveyor belt speed adjustment, flexible smoke feeding or forced feeding and other control operations.

[0016] This application significantly improves the stability and intelligence of the feeding process, effectively reduces the risk of control inaccuracy caused by single sensor errors, and improves the accuracy of material inventory control; it avoids frequent equipment start-ups and shutdowns caused by full or empty feeding bins, reduces tobacco breakage and flavoring fluctuations; it realizes safe emergency response and operation traceability under abnormal operating conditions, enhances the continuous operation capability of the system, improves production efficiency and process consistency, and has good economic value and industrial application prospects. Attached Figure Description

[0017] To more clearly illustrate the technical solutions of the embodiments of this application, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this application and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 A flowchart of a material supply control method according to an embodiment of this application is shown; Figure 2 Another flowchart of the material supply control method according to an embodiment of this application is shown; Figure 3 This illustrates yet another flowchart of the material supply control method according to an embodiment of this application; Figure 4 A schematic diagram of a material supply control method according to an embodiment of this application is shown. Detailed Implementation

[0019] The technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments.

[0020] The components of the embodiments of this application described and illustrated in the accompanying drawings can be arranged and designed in a variety of different configurations. Therefore, the following detailed description of the embodiments of this application provided in the drawings is not intended to limit the scope of the claimed application, but merely to illustrate selected embodiments of the application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.

[0021] In the following text, the terms "comprising," "having," and their cognates, which may be used in various embodiments of this application, are intended only to indicate a particular feature, number, step, operation, element, component, or combination thereof, and should not be construed as primarily excluding the presence of one or more other features, numbers, steps, operations, elements, components, or combinations thereof, or adding the possibility of one or more combinations thereof. Furthermore, the terms "first," "second," "third," etc., are used only for distinguishing descriptions and should not be construed as indicating or implying relative importance.

[0022] Unless otherwise specified, all terms used herein (including technical and scientific terms) shall have the same meaning as commonly understood by one of ordinary skill in the art to which the various embodiments of this application pertain. Terms (such as those defined in commonly used dictionaries) shall be interpreted as having the same meaning as in their contextual meaning in the relevant technical field and shall not be construed as having an idealized or overly formal meaning, unless clearly defined in the various embodiments of this application.

[0023] The following detailed description of some embodiments of this application is provided in conjunction with the accompanying drawings. Unless otherwise specified, the following embodiments and features can be combined with each other.

[0024] Considering the shortcomings of existing flavoring feed silos in terms of material level detection accuracy, control adaptability, and emergency response mechanisms, a feeding control method is proposed. This method collects multi-source status data from the target feeding container, fuses the multi-source status data to generate a real-time material level parameter representing the current material inventory, determines the current feeding control mode based on the comparison result of this parameter with a preset threshold, and generates corresponding feeding control commands according to the mode to drive the feeding actuator to perform corresponding control operations, thereby achieving accurate, adaptive, and safe intelligent management of the material inventory in the feeding silo.

[0025] The feeding control method will be explained below with reference to some specific embodiments.

[0026] Figure 1 A flowchart of a material supply control method according to an embodiment of this application is shown. Exemplarily, the material supply control method includes the following steps: Step S100: Collect multi-source status data of the target feeding container.

[0027] Among them, multi-source state data refers to various types of signals collected from sensors based on different physical principles that reflect the state of material inventory in the feeding container, including spatial ranging information representing material height, pressure signals representing material quality, and environmental temperature and humidity parameters that affect material accumulation characteristics; by synchronously acquiring multi-dimensional sensing data, comprehensive monitoring of the material state in the feeding bin can be achieved.

[0028] In an optional embodiment, step S100 includes the following sub-steps: S101: Spatial ranging information is collected by a radar level sensor installed on the top of the target feeding container, and first data characterizing the height of the material inside the target feeding container is generated.

[0029] The radar level sensor is a 24GHz high-frequency radar level gauge, installed at the center of the top of the feeding hopper. It emits electromagnetic waves downwards and receives echo signals reflected from the material surface. Exemplarily, this sensor continuously measures the spatial distance between the material surface and the sensor within the hopper, calculates the current material accumulation height based on echo time or phase changes, and outputs it as the primary data in digital signal form. This data reflects the real-time trend of material height changes and maintains strong stability even in dusty environments. However, it may be subject to deviations due to factors such as loose tobacco leaves and hanging material, requiring correction in conjunction with other data. For example, when the moisture content of the tobacco leaves is high and the accumulation is loose, radar waves may partially penetrate or scatter, resulting in a measured height slightly lower than the actual accumulation surface. In this case, weighing data is needed for auxiliary correction.

[0030] S102, pressure signals are collected by weighing sensors installed on the support structure of the target feeding container to generate second data characterizing the mass of the material in the target feeding container.

[0031] The weighing sensors are strain gauge load cells with a resolution of 0.1 kg and a temperature drift of ≤0.005%FS / ℃. They are symmetrically arranged at four support points at the bottom of the feeding hopper to sense the load borne by the support structure. Demonstratively, each sensor converts the collected pressure signal into an electrical signal, which is then aggregated by a signal conditioning circuit to calculate the total weight. The net material mass is obtained by subtracting the hopper's own weight, serving as the second data point. This data directly reflects the total material volume and is unaffected by local changes in shape and density, exhibiting high long-term stability. For example, in a certain production run, although the radar showed a rapid rise in the material level, the weighing data indicated a slow increase in mass. Based on this, the system judged that the tobacco shreds had high bulkiness and the actual filling amount was insufficient, thus avoiding accidental triggering of the tobacco feeding operation.

[0032] S103: Collect ambient temperature and humidity data by temperature and humidity sensors arranged on the side wall of the target feeding container, and generate parameters for correcting changes in material bulk density.

[0033] The temperature and humidity sensor is an environmental sensing device installed on the side wall of the feeding hopper to monitor the temperature and humidity conditions inside the hopper. Exemplarily, this sensor outputs the current environmental parameters in real time. The control unit, based on empirical relationships established from historical data, identifies the degree of influence of temperature and humidity changes on the bulk density of the tobacco shreds and generates a corresponding compensation coefficient. This compensation coefficient is used to calibrate the error when converting volume height from weighing data, improving the fusion accuracy. For example, when an increase in humidity is detected inside the hopper, the system determines that the tobacco shreds absorb moisture and expand, resulting in a decrease in bulk density. The system then lowers the density reference value accordingly to avoid overestimating the volume due to calculations based on nominal density.

[0034] S104, the first data, the second data, and the changing parameters are combined to form multi-source state data.

[0035] The integration of multi-source state data involves organizing the three types of independently collected information into a dataset that can be processed later. For example, the three types of data are received and packaged according to a preset data format to form complete data containing height, quality and environmental compensation factors.

[0036] Step S200: The multi-source status data is fused to generate real-time material level parameters that characterize the current material inventory.

[0037] Among them, fusion processing refers to the comprehensive calculation of first data (material height), second data (material mass), and environmental impact factors from different sensors with complementary characteristics. By integrating the advantages of each data source through algorithms, the error amplification problem of a single measurement method under specific working conditions is suppressed, thereby obtaining a more accurate and stable material level estimation result than any single signal.

[0038] In an optional embodiment, step S200 includes the following sub-steps: S201, the first and second data in the multi-source state data are weighted and fused according to preset weights to obtain the preliminary fused material level value.

[0039] The first data point is the material surface height output by the radar level sensor. The first data point is in meters; the second data point is the net material mass output by the weighing sensor. It needs to be converted to an equivalent height before it can participate in fusion; as an example, the standard reference density is first used. and the cross-sectional area of ​​the feed bin Convert the weighing data into the theoretical equivalent height Then, the preliminary fusion level value is calculated using a weighted average formula:

[0040] in, And satisfy This weighting configuration is based on historical operational data calibration, prioritizing the trust of radar measurement results under normal conditions, while retaining the auxiliary correction capability of weighing data.

[0041] S202 uses the changing parameters in the multi-source state data to compensate and correct the preliminary fused material level value, and generates real-time material level parameters.

[0042] The changing parameter is the ambient temperature difference obtained by collecting and processing data from a temperature and humidity sensor. This is used to correct for drift in tobacco bulk density caused by temperature changes; exemplarily, based on empirical formulas... Dynamically calculate the current actual packing density, where The density temperature coefficient was measured and calibrated; then the equivalent height corresponding to the weighing data was recalculated:

[0043] Then, substitute the corrected height into the weighted fusion formula and recalculate the final material level value:

[0044] This completes the closed-loop correction of the initial fusion value. For example: when a rise in the internal temperature is detected, leading to... The system determined that the tobacco shreds had expanded and the density had decreased by about 18%. If the standard density conversion was still used, the equivalent height would be underestimated. After this step, the weight contribution was reasonably increased, and the final fusion material level value was closer to the actual filling state. The overall measurement error was reduced from 15% in the traditional method to 3.5%.

[0045] In other embodiments, the weighting coefficient and The Kalman filter can be dynamically adjusted based on the real-time residuals to further improve the fusion accuracy under complex working conditions.

[0046] Step S300: Based on the comparison between real-time material level parameters and one or more preset threshold conditions, determine the current material supply control mode.

[0047] Among them, the material supply control mode refers to the different operating status categories divided according to the material inventory level in the feeding hopper. By logically judging the integrated real-time material level parameters and the thresholds corresponding to key capacity nodes, the system operation stage can be accurately identified, thereby triggering differentiated control strategies to ensure that the material supply process can remain stable, safe and efficient under different working conditions.

[0048] In one alternative embodiment, such as Figure 2 As shown, step S300 includes the following sub-steps: S301, set a first threshold and a second threshold, wherein the first threshold corresponds to the upper limit of the normal feeding range, the second threshold corresponds to the upper limit of the safety tolerance, and the first threshold is less than the second threshold.

[0049] The first threshold is set at 85% of the feed bin's capacity, indicating a critical point where the material is nearing a high level but still within a controllable range. The second threshold is set at 95% capacity, serving as a warning line for entering a high-risk area, where the bin is near full but has not yet triggered a physical overflow. Exemplarily, this two-tiered threshold structure is based on the effective volume calibration of the feed bin and optimized in conjunction with equipment response delays (e.g., 2-3 seconds for conveyor belt shutdown) and the dynamic characteristics of tobacco accumulation, avoiding frequent false alarms while reserving sufficient adjustment time windows. For example, when the total effective height of the feed bin is 3.0m, the first threshold corresponds to 2.55m (85%), and the second threshold corresponds to 2.85m (95%).

[0050] S302, when the real-time material level parameter is lower than the first threshold, the material supply control mode is determined to be the first mode.

[0051] The first mode is the normal feeding mode, indicating that the current material inventory is sufficient or low, within the normal replenishment control range. Demonstrating this, the system continuously monitors the real-time material level parameter trend. If it falls below 85% of capacity, it determines that no early warning or emergency mechanism needs to be activated, maintaining the basic PID control logic to maintain the speed of the smoke-feeding conveyor belt and achieve stable feeding. At this time, the system's main task is to replenish materials according to the planned rhythm, ensuring continuous and stable flow in subsequent flavoring processes. For example, in a certain production run, the real-time material level parameter slowly rises from 72% to 83%. The system consistently determines it to be in the first mode, automatically starting the conveyor belt according to the preset smoke-feeding time node model, without triggering any alarms or mode switching.

[0052] S303, when the real-time material level parameter is greater than or equal to the first threshold and less than the second threshold, the material supply control mode is determined to be the second mode.

[0053] The second mode is an early warning mode, indicating that the material has entered the high-level operating zone, posing a risk of full storage, requiring early intervention. For example, once the material level crosses the 85% threshold, the system activates the flexible tobacco feeding algorithm, suspending the timed tobacco feeding command. Instead, it predicts the future filling curve based on historical material arrival cycles and the current consumption rate, dynamically adjusting the lead time for the next tobacco feeding operation (adaptive ±2 minutes) to delay the feeding timing and avoid rapid full storage. Simultaneously, an audible and visual alarm is triggered on the human-machine interface to alert the operator to the operating status. For instance, if the system detects that the density of the tobacco shreds is low and they are loose and prone to accumulation, it automatically adjusts the original 5-minute advance tobacco feeding to only 3 minutes, reducing instantaneous feeding pressure.

[0054] S304, when the real-time material level parameter is greater than or equal to the second threshold, the material supply control mode is determined to be the third mode.

[0055] The third mode is an emergency mode, indicating that the feed hopper is nearing full capacity, posing a risk of overflow or abnormal shutdown of downstream equipment. Demonstrating this, when the material level reaches or exceeds 95% of capacity, the system immediately enters the third mode, activating the forced feeding process: it blocks the high-level alarm signal to prevent the drying machine from automatically shutting down within 5 seconds; it locks the drying machine speed within 90%–110% of its rated value to maintain the stability of the hot air system; it simultaneously closes the upstream feed inlet pneumatic valve (response time 0.5s) to stop new material input; and it sends an encrypted alarm code ALM-002 to the MES system, recording the event start time and material level value. For example, in the event of a brief sensor malfunction causing uncontrolled material level, the real-time material level parameter rises to 96%, and the system automatically enters the third mode, successfully preventing an emergency shutdown of the drying machine and ensuring continuous production for the shift.

[0056] Step S400: Generate corresponding material supply control instructions according to the material supply control mode, and drive the material supply actuator to perform corresponding material supply control operations based on the material supply control instructions.

[0057] Among them, the material supply control command is an operation command generated after determining the current operating mode to guide the action of the field equipment. By mapping different modes to specific control strategies, control from state recognition to execution response is realized to ensure that the material inventory in the feeding silo is always in a safe, stable and efficient operating range.

[0058] In an optional embodiment, step S400 includes the following sub-steps: S401, in the first feeding mode, generates a first control command for adjusting the conveyor belt speed.

[0059] The first control command refers to the dynamic speed regulation signal output by the control unit under normal material feeding conditions, used to control the start-up, stop, and running speed of the upstream tobacco conveyor belt. Demonstratively, based on the real-time material level change rate and the preset target filling curve, a PID algorithm calculates the optimal conveyor belt speed, generating an analog or digital communication command to be sent to the frequency converter, achieving continuous and smooth adjustment of the feed flow rate. This command prioritizes ensuring the continuity of material feeding at the front end of the flavoring process, avoiding material interruptions or impactful replenishment. For example, when the real-time material level parameter is 78% and shows a slow downward trend, the system automatically increases the conveyor belt speed to 95% of the rated value to replenish material reserves in advance.

[0060] S402, in the second feeding mode, generates a second control command containing adaptive lead time parameters.

[0061] The second control command is a scheduling optimization command triggered in the early warning mode. Its core is the "flexible smoke feeding" mechanism, which means that instead of starting the conveyor belt at a fixed cycle, the optimal smoke feeding time is predicted based on the production cycle, historical material arrival intervals, and current consumption rate. As an example, the system has a built-in smoke feeding time node model, which dynamically adjusts the lead time parameter (±2min) by combining grade information (such as density and throughput) and real-time operating conditions, and embeds this parameter into the control logic to delay or advance the smoke feeding operation. At the same time, a yellow warning prompt is issued on the human-machine interface to remind the operator to pay attention to high-level risks.

[0062] For example, when the system detects that a certain brand of tobacco with a high expansion rate is accumulating faster than usual, it automatically adjusts the tobacco loading time from 5 minutes in advance to only 3 minutes in advance, effectively avoiding the risk of full storage.

[0063] For example, the threshold for triggering smoking. Generated using the following dynamic model:

[0064] in: Trigger charge amount; 0.8: empirical proportionality coefficient, a correction constant calibrated based on actual operating conditions; The system's operating voltage; Parameters related to component materials and dielectric properties; Exponential transient term; Minor fluctuation correction item; S403, in the third feeding mode, generates a third control command to activate the forced feeding process.

[0065] The third control command is a safety production maintenance command in emergency situations, designed to prevent unplanned shutdowns of the drying machine due to a full feed hopper. For example, when the system determines it has entered the third mode, it immediately generates this command and executes the following actions: silencing the high-level alarm signal and releasing the shutdown interlock for the drying machine; locking the drying machine speed at 90%–110% of its rated value to maintain stable operation of the hot air system; closing the upstream feed inlet pneumatic valve (response time 0.5s) to stop new material input; activating the backup vibrating trough and increasing the amplitude by 30% to accelerate the discharge speed. This command ensures that critical processes can continue operating under abnormal conditions, avoiding a complete line shutdown. For instance, in a case where a radar false alarm caused the material level to falsely rise to 96%, the system, despite the misjudgment, successfully maintained the drying machine's operation for 5 minutes, buying valuable time for manual troubleshooting.

[0066] S404: Based on any one of the first control command, the second control command, and the third control command, the material feeding actuator is sent to drive the material feeding actuator to perform the corresponding material feeding control operation.

[0067] The feeding actuators include field equipment such as the tobacco conveyor belt, the speed control device for the drying machine, pneumatic valves, and spare vibrating troughs. They receive command signals from the control unit and complete the action response via the PROFINET protocol (communication delay ≤1s). Demonstratively, the generated commands are encapsulated into standard industrial communication frames and transmitted to each execution node via the PLC output module, achieving multi-device collaborative operation. The entire process has a strict timing control and status feedback mechanism to ensure accurate command execution. For example, when the third control command is issued, the system completes the entire set of operations—"alarm shielding + pneumatic valve closure + vibrating trough speed increase"—within 1.2 seconds, ensuring process continuity.

[0068] In other embodiments, the third control instruction may also include a sub-instruction to limit the maximum feed rate to 120% of the rated value, in order to prevent instantaneous feeding overload during the recovery process and further improve system safety.

[0069] In one alternative implementation, S404 includes: In response to the third control command, based on the start time of forced feeding, a status confirmation prompt message is sent to the human-machine interface of the actuator at preset intervals.

[0070] The status confirmation prompt is an operation confirmation request proactively pushed by the system after activating the forced feeding mode to ensure human supervision. For example, starting from the trigger time of the third mode, the control system will pop up a prompt box and trigger an audio-visual reminder every 3 minutes through the human-machine interface, with the message "Forced feeding has been ongoing for X minutes. Please confirm the current working status." Operators are required to confirm by fingerprint recognition or button press to indicate that they are aware of the status. This mechanism prevents the emergency mode from being unsupervised for a long time and improves the safety of human-machine collaboration.

[0071] Real-time material level parameters are collected synchronously, and the trend of material level changes is analyzed by combining the effective response results to status confirmation prompts.

[0072] The trend refers to the dynamic evolution of the material inventory in the feed hopper during forced feeding, which is obtained by the control unit through first-order differential calculation based on continuously collected real-time material level parameters. For example, the system acquires the fused material level value every 50ms and determines whether it shows a downward, stable, or upward trend within each prompting cycle. If the operator completes a valid response within the specified time limit (e.g., 60 seconds), it is considered to be in a controlled state, and the system continues to maintain forced feeding. If no response is received, the system enters the abnormal judgment process.

[0073] If no valid response is received within the specified response time limit after any prompt, and the material level shows a downward trend, the abnormal continuous operating condition is determined to have been entered.

[0074] Among them, the abnormal continuous operating condition refers to the state in which the system is unconfirmed and although there are signs of recovery, there is still a risk of loss of control. For example, if there is no operator response for more than 60 seconds after a certain prompt is issued, and the system detects that the material level is still slowly decreasing (such as a decrease of 0.8% capacity per minute), it indicates that the material discharge mechanism is in effect but lacks human intervention to close the loop. At this time, it is determined to be a continuous abnormal state that needs to be alerted, and a timer is started to record the duration of the operating condition.

[0075] When the abnormal operating condition continues for the preset maximum allowable duration, the forced feeding operation will be terminated and a high-level alarm signal will be triggered.

[0076] The maximum allowed duration is set at 10 minutes, serving as the absolute upper limit for the forced feeding mode. For example, once the aforementioned "no response + decline" state accumulates to 10 minutes, regardless of whether the current material level has returned to normal, the system automatically exits the forced feeding mode, reactivates the high-level alarm interlock, and issues a red flashing alarm via an audible and visual device. Simultaneously, it sends an encrypted alarm code ALM-003 (including a timestamp and operation log snapshot) to the MES system, indicating that a reset and restart can only be performed after on-site troubleshooting by maintenance personnel. For instance, in the event of a communication interruption causing the HMI to fail to display, although the material level gradually declines, because three consecutive prompts are not acknowledged, the system terminates the emergency mode and reports an alarm precisely at the 10-minute mark, avoiding potential overflow risks.

[0077] In other implementations, the status confirmation prompt can terminate early when a rapid drop in material level is detected or when the level recovers to below 90%, thus achieving intelligent exit and improving operational efficiency.

[0078] In one alternative embodiment, such as Figure 3 As shown, step S400 includes the following sub-steps: S501 detects and records abnormal events that occur during the execution of material supply control operations.

[0079] Abnormal events refer to non-normal operating conditions caused by sudden changes in equipment status, exceeding parameter limits, or human intervention during the material supply control process. These include, but are not limited to, situations where the material level in the feeding hopper reaches 95% or higher, forced feeding mode is activated, sensor signal loss, or control command timeout failure to respond. For example, during operation, the status flags of each stage are continuously monitored. Once the system determines that a third feeding mode has been entered or a critical command (such as alarm blocking or speed locking) has been executed, an event recording mechanism is triggered, automatically generating an event identifier code and collecting contextual information such as real-time material level parameters, control mode, operation source (automatic / manual), and relevant equipment operating status at the time of occurrence as raw data. For instance, when the system detects that the radar level gauge has not updated its signal for 5 consecutive seconds and the weighing data shows a rapid increase, it is automatically marked as a "sensor abnormality + high-level risk" composite event, initiating an emergency recording process.

[0080] S502 encrypts and packages the information of abnormal events and uploads it to the production management system for visual prompts on the human-machine interface.

[0081] The encrypted packetization process involves encapsulating the collected abnormal event data using a preset encryption algorithm (such as AES-128) to generate a unique message packet, preventing data tampering or leakage during transmission. As an example, a secure communication channel is established with the MES system via the PROFINET protocol, sending the encrypted event packet to the management platform within one second of the event occurring. The MES system decrypts and parses the content, displaying a scrolling notification in the alarm information area of ​​the workshop HMI terminal, such as "ALM-002: Material level 95%, forced feeding activated (Time: 14:32:15, Operator: Zhang_S)", while highlighting the warning level with a flashing red icon to ensure timely awareness by on-site personnel. This mechanism enables real-time reporting and remote monitoring of abnormal events, supporting rapid response in production scheduling.

[0082] S503 also generates structured record entries for abnormal events and stores them in a local or cloud database.

[0083] Structured record entries refer to organizing event data into searchable log records according to a unified field format (such as event type, timestamp, triggering condition, handling action, operator ID, and associated equipment number). For example, a complete snapshot of the same event is written to a historical database table on a local industrial solid-state drive and retained for at least 6 months. Simultaneously, it is synchronized to the enterprise's private cloud platform based on network conditions for quality traceability, fault analysis, and process optimization. Each record has a unique serial number, supporting subsequent audit tracing. For instance, during a monthly process review, technicians discovered, by querying "forced feeding" events, that a certain brand of tobacco frequently triggered warnings when switching batches, leading to optimization of its tobacco feeding time node model and improved overall stability.

[0084] Figure 4 A schematic diagram of a feeding control device according to an embodiment of this application is shown. Exemplarily, the device 100 includes: Data acquisition module 110 is used to acquire multi-source status data of the target feeding container; The fusion processing module 120 is used to fuse the multi-source state data to generate real-time material level parameters that characterize the current material inventory. The mode determination module 130 is used to determine the current material supply control mode by comparing the real-time material level parameters with one or more preset threshold conditions. The instruction generation module 140 is used to generate corresponding material supply control instructions according to the material supply control mode, and drive the material supply actuator to perform corresponding material supply control operations based on the material supply control instructions.

[0085] It is understood that the apparatus of this embodiment corresponds to the method of the above embodiments, and the options in the above embodiments are also applicable to this embodiment, so they will not be described again here.

[0086] This application also provides a terminal device, exemplary of which includes a processor and a memory, wherein the memory stores a computer program, and the processor executes the computer program to enable the terminal device to perform the functions of the various modules in the above-described method or apparatus.

[0087] The processor can be an integrated circuit chip with signal processing capabilities. The processor can be a general-purpose processor, including at least one of a Central Processing Unit (CPU), Graphics Processing Unit (GPU), Network Processor (NP), Digital Signal Processor (DSP), Application-Specific Integrated Circuit (ASIC), Field-Programmable Gate Array (FPGA), or other programmable logic devices, discrete gate or transistor logic devices, or discrete hardware components. The general-purpose processor can be a microprocessor or any conventional processor, capable of implementing or executing the methods, steps, and logic block diagrams disclosed in the embodiments of this application.

[0088] The memory can be, but is not limited to, Random Access Memory (RAM), Read Only Memory (ROM), Programmable Read-Only Memory (PROM), Erasable Programmable Read-Only Memory (EPROM), Electrically Erasable Programmable Read-Only Memory (EEPROM), etc. The memory is used to store computer programs, and the processor can execute the computer programs accordingly after receiving execution instructions.

[0089] This application also provides a computer-readable storage medium for storing the computer program used in the aforementioned terminal device. For example, the computer-readable storage medium may include, but is not limited to, various media capable of storing program code, such as a USB flash drive, a portable hard drive, a read-only memory (ROM), a random access memory (RAM), a magnetic disk, or an optical disk.

[0090] In the several embodiments provided in this application, it should be understood that the disclosed apparatus and methods can also be implemented in other ways. The apparatus embodiments described above are merely illustrative. For example, the flowcharts and block diagrams in the accompanying drawings show the architecture, functionality, and operation of possible implementations of apparatus, methods, and computer program products according to various embodiments of this application. In this regard, each block in a flowchart or block diagram may represent a module, segment, or portion of code containing one or more executable instructions for implementing a specified logical function. It should also be noted that, in alternative implementations, the functions marked in the blocks may occur in a different order than those marked in the drawings. For example, two consecutive blocks may actually be executed substantially in parallel, and they may sometimes be executed in reverse order, depending on the functions involved. It should also be noted that each block in the block diagram and / or flowchart, and combinations of blocks in the block diagram and / or flowchart, can be implemented using a dedicated hardware-based system that performs the specified function or action, or using a combination of dedicated hardware and computer instructions.

[0091] In addition, the functional modules or units in the various embodiments of this application can be integrated together to form an independent part, or each module can exist independently, or two or more modules can be integrated to form an independent part.

[0092] If the aforementioned functions are implemented as software functional modules and sold or used as independent products, they can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of this application, in essence, or the part that contributes to the prior art, or a part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a smartphone, personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of this application.

[0093] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any changes or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application.

Claims

1. A material feeding control method, characterized in that, The method includes: Collect multi-source status data of the target feeding container; The multi-source status data are fused to generate real-time material level parameters that characterize the current material inventory. The current material supply control mode is determined by comparing the real-time material level parameters with one or more preset threshold conditions. Based on the feeding control mode, a corresponding feeding control command is generated, and based on the feeding control command, the feeding actuator is driven to perform the corresponding feeding control operation.

2. The material feeding control method according to claim 1, characterized in that, The multi-source status data of the target feeding container collected includes: Spatial ranging information is collected by a radar level sensor installed on the top of the target feeding container, and first data characterizing the height of the material inside the target feeding container is generated. Pressure signals are collected by weighing sensors installed on the support structure of the target feeding container to generate second data characterizing the mass of the material inside the target feeding container. Ambient temperature and humidity data are collected by temperature and humidity sensors arranged on the side wall of the target feeding container, and parameters for correcting changes in material bulk density are generated. The first data, the second data, and the changing parameters constitute multi-source state data.

3. The material feeding control method according to claim 1, characterized in that, The process of fusing the multi-source state data to generate real-time material level parameters characterizing the current material inventory includes: The first and second data in the multi-source state data are weighted and fused according to preset weights to obtain a preliminary fused material level value; The initial fused material level value is compensated and corrected using the changing parameters in the multi-source state data to generate real-time material level parameters.

4. The material feeding control method according to claim 1, characterized in that, The step of determining the current material supply control mode by comparing the real-time material level parameters with one or more preset threshold conditions includes: Set a first threshold and a second threshold, wherein the first threshold corresponds to the upper limit of the normal feeding range, the second threshold corresponds to the upper limit of the safety tolerance, and the first threshold is less than the second threshold; When the real-time material level parameter is lower than the first threshold, the material supply control mode is determined to be the first mode; When the real-time material level parameter is greater than or equal to the first threshold and less than the second threshold, the material supply control mode is determined to be the second mode; When the real-time material level parameter is greater than or equal to the second threshold, the material supply control mode is determined to be the third mode.

5. The material feeding control method according to claim 1, characterized in that, The step of generating a corresponding supply control command based on the supply control mode, and driving the supply actuator to perform a corresponding supply regulation operation based on the supply control command, includes: In the first feeding mode, a first control command is generated to adjust the conveyor belt speed; In the second feeding mode, a second control command containing an adaptive lead time parameter is generated; In the third feeding mode, a third control command is generated to activate the forced feeding process; Based on any one of the first control command, the second control command, and the third control command, the material feeding execution mechanism is sent to drive the material feeding execution mechanism to perform the corresponding material feeding control operation.

6. The material feeding control method according to claim 1, characterized in that, After the drive feeding actuator performs the corresponding feeding control operation, it includes: Detect and record any abnormal events that occur during the execution of material supply control operations; The information of the abnormal event is encrypted, packaged, and uploaded to the production management system for visual prompts on the human-computer interaction interface. Simultaneously, the abnormal events are generated into structured record entries and stored in a local or cloud database.

7. The material feeding control method according to claim 5, characterized in that, The process of executing the third control command includes: In response to the third control command, based on the start time of forced feeding, a status confirmation prompt message is sent to the human-machine interface of the actuator at preset intervals; Real-time material level parameters are collected synchronously, and the trend of material level changes is analyzed by combining the effective response results to the status confirmation prompt information. If no valid response is received within the specified response time limit after any prompt, and the material level shows a downward trend, it is determined that the abnormal continuous working condition has been entered. When the abnormal operating condition continues for a preset maximum allowable duration, the forced feeding operation is terminated and a high-level alarm signal is triggered.

8. A feeding control device, characterized in that, include: The data acquisition module is used to collect multi-source status data of the target feeding container; The fusion processing module is used to fuse the multi-source state data to generate real-time material level parameters that characterize the current material inventory. The mode determination module is used to determine the current material supply control mode by comparing the real-time material level parameters with one or more preset threshold conditions. The instruction generation module is used to generate corresponding material supply control instructions according to the material supply control mode, and drive the material supply actuator to perform corresponding material supply control operations based on the material supply control instructions.

9. A terminal device, characterized in that, The terminal device includes a processor and a memory, the memory storing a computer program, and the processor executing the computer program to implement the feeding control method according to any one of claims 1-7.

10. A computer-readable storage medium, characterized in that, It stores a computer program, which, when executed on a processor, implements the feeding control method according to any one of claims 1-7.

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