Cigarette production equipment dedusting system control method, electronic device, and program product

Abstract

The application provides a cigarette production equipment dust removal system control method, an electronic device and a program product, and relates to the technical field of dust removal control. The method comprises the following steps: setting a controlled interval of a target pressure parameter, wherein the target pressure parameter comprises a vacuum negative pressure main pipeline air pressure value and a dust removal main pipeline air pressure value; obtaining production data of the cigarette production equipment, determining a started unit in the cigarette production equipment according to the production data, and determining running data of the started unit, wherein the running data at least comprises power data of a vacuum negative pressure motor, a VE fan and a dust removal motor; judging whether the current vacuum negative pressure main pipeline air pressure value and the dust removal main pipeline air pressure value deviate from the respective controlled intervals according to continuously obtained sensor data; and if there is an air pressure value exceeding the limit, adjusting the power of the corresponding motor based on the running data to make the air pressure value return to the controlled interval. In this way, the problem of unstable air pressure caused by the traditional fixed power adjustment mode can be improved.

Description

Technical Field

[0001] The present invention relates to the technical field of dust removal control, and more specifically, to a control method, an electronic device, and a program product for a dust removal system of cigarette production equipment. Background Art

[0002] Rolling and packaging are two core processes in cigarette production. Rolling is the process of using a cigarette making machine to roll tobacco shreds into cigarette sticks (single cigarettes, double the length of a cigarette stick) with cigarette paper. Packaging is the process of using a packaging machine to package the rolled cigarette sticks into small boxes and cartons according to a specified quantity (such as 20 cigarettes per pack, 10 packs per carton). Dust removal pipes and vacuum negative pressure pipes are respectively connected to the rolling and packaging equipment (i.e., cigarette production equipment). The dust removal pipe is connected to a dust removal system (including a dust removal main pipe, a dust removal motor, and a dust removal motor frequency converter), which is mainly used to remove waste such as dust, tobacco dust, and short fibers generated during production, and keep the equipment clean and the production environment safe. The vacuum negative pressure pipe is connected to a vacuum negative pressure system (including a vacuum negative pressure main pipe and a vacuum negative pressure pump), which mainly provides stable and controllable vacuum negative pressure for the production equipment, and uses air flow to complete fine operations such as material grasping, conveying, fixing, and separation. In practical applications, one dust removal system or one vacuum negative pressure system is correspondingly connected to multiple rolling units and packaging units (or rolling equipment and packaging equipment).

[0003] Currently, the dust removal system and vacuum negative pressure system supporting cigarette production equipment mostly adopt a fixed power control mode, that is, the motor power is preset according to the maximum production capacity of the equipment, and the dust removal and negative pressure suction operations are continuously performed.

[0004] However, in actual production, there are dynamic change scenarios such as start-stop switching and production capacity adjustment in cigarette units. When some units are shut down, fixed power control will cause the air pressure in the vacuum negative pressure main pipe and the dust removal main pipe to exceed the standard, resulting in energy waste; when the units are started in batches, the air pressure will be insufficient due to the sudden increase in air pressure demand, and dust cannot be cleaned in time. This leads to problems such as low dust removal efficiency, high energy consumption, and poor system operation stability, which urgently need to be solved. Summary of the Invention

[0005] In view of this, the purpose of this application is to provide a control method, a system, and a program product for a dust removal system of cigarette production equipment, which can improve the traditional fixed power control mode, thereby solving the problems of low dust removal efficiency, high energy consumption, and poor system operation stability.

[0006] To achieve the above technical objectives, the technical solutions adopted in this application are as follows:

[0007] In a first aspect, the present application provides a control method for a dust removal system of a cigarette production device, which is applied to the dust removal system supporting the cigarette production device. The tipping and packaging units in the cigarette production device are respectively connected to a vacuum negative pressure pipeline and a dust removal pipeline. All the vacuum negative pressure pipelines are connected to a vacuum negative pressure system through a vacuum negative pressure main pipeline, and all the dust removal pipelines are connected to a dust removal system through a dust removal main pipeline. The method includes:

[0008] Set a controlled range for the target pressure parameter, where the target pressure parameter includes the air pressure value of the vacuum negative pressure main pipeline and the air pressure value of the dust removal main pipeline;

[0009] Obtain the production data of the cigarette production device, and determine the started units in the cigarette production device and the operation data of the started units according to the production data. Among them, the operation data at least includes the power data of the vacuum negative pressure motor, the VE fan, and the dust removal motor;

[0010] Judge whether the current air pressure value of the vacuum negative pressure main pipeline and the air pressure value of the dust removal main pipeline deviate from their respective controlled ranges according to the continuously acquired sensor data;

[0011] If the air pressure value exceeds the limit, adjust the power of the corresponding motor based on the operation data to make the air pressure value return to the controlled range.

[0012] Combined with the first aspect, in some optional embodiments, the method further includes:

[0013] Monitor the air pressure value of the vacuum negative pressure main pipeline and the operation status of the VE fan;

[0014] When the air pressure value of the vacuum negative pressure main pipeline is greater than a preset first air pressure threshold and the VE fan is in an operating state, start the dust removal system.

[0015] Combined with the first aspect, in some optional embodiments, the method further includes:

[0016] After the dust removal system is started, if the air pressure value of the vacuum negative pressure main pipeline is less than or equal to a second air pressure threshold, or the VE fan stops running, control the dust removal system to stop running.

[0017] Combined with the first aspect, in some optional embodiments, the obtaining the production data of the cigarette production device, determining the started units in the cigarette production device and the operation data of the started units according to the production data includes:

[0018] In response to the start of the cigarette production device, retrieve the production plan of the cigarette production device to obtain the production data of the cigarette production device;

[0019] Based on the production data, determine which units in the cigarette production equipment have been started, and obtain the operating data of the started units.

[0020] In conjunction with the first aspect, in some optional implementations, determining whether the current vacuum negative pressure main duct air pressure value and the dust removal main duct air pressure value deviate from their respective controlled ranges based on continuously acquired sensor data includes:

[0021] Get the current vacuum negative pressure main pipeline air pressure value; Get the current dust removal main pipeline air pressure value;

[0022] Compare the current vacuum negative pressure main pipeline air pressure value with the set target pressure parameter to determine whether the current vacuum negative pressure main pipeline air pressure value deviates;

[0023] The current air pressure value of the main dust removal pipeline is compared with the set target pressure parameter to determine whether the current air pressure value of the main dust removal pipeline deviates.

[0024] In conjunction with the first aspect, in some optional implementations, the step of adjusting the power of the corresponding motor based on the operating data to bring the wind pressure value back to the controlled range if the wind pressure value exceeds the limit includes:

[0025] If any wind pressure value exceeds the limit, the power of the corresponding motor will be adjusted based on the operating data to bring the wind pressure value back to the controlled range.

[0026] When the air pressure values ​​of the vacuum negative pressure main pipeline and the dust removal main pipeline both exceed the limit, the power of the vacuum negative pressure motor should be adjusted first, and then the power of the dust removal motor should be adjusted.

[0027] In conjunction with the first aspect, in some alternative implementations, the method further includes:

[0028] Based on the aforementioned operational data, when a new unit starts or stops in the cigarette production equipment, a graded adjustment method is adopted to gradually adjust the power of the motors (vacuum negative pressure motors and dust removal motors).

[0029] In conjunction with the first aspect, in some alternative implementations, the method further includes:

[0030] The acquired production data and sensor data are processed to construct a sample set;

[0031] Frequent itemsets among the data in the sample set are identified, and association rules for the frequent itemsets are generated. The support and confidence of each association rule are analyzed. Based on the pre-set minimum support threshold and minimum confidence threshold, the association rules of the frequent itemsets are clustered and optimized to obtain the optimal rule set.

[0032] A correlation coefficient matrix is ​​established based on the optimal rule set to form a pre-tuned rule knowledge base;

[0033] Based on the acquired production data, rules are extracted from the pre-adjustment rule knowledge base. The corresponding motor power is then simulated and adjusted in the preset production twin model, and the simulated wind pressure value is analyzed to see if it returns to the controlled range.

[0034] By acquiring real-time sensor data, the effectiveness of the extracted rules in the simulated execution process is verified. If the effectiveness meets the standard, the verification is passed, and then the power of the corresponding motor is adjusted in the cigarette production equipment.

[0035] If the verification fails, the rules will be extracted again until the verification passes.

[0036] In conjunction with the first aspect, in some optional implementations, data processing is performed on the sensor data, including: signal preprocessing, noise filtering, signal calibration, and abnormal signal detection and processing. Similarly, data processing can also be performed on production data.

[0037] In the process of mining frequent itemsets among the data in the sample set and generating association rules for the frequent itemsets, the Apriori algorithm is used to mine association rules between production data, sensor data and motor power.

[0038] Secondly, this application provides an electronic device, which includes a memory and a processor. The memory stores a computer program, and when the computer program is executed by the processor, the processor is able to execute the dust removal system control method for the cigarette production equipment.

[0039] Thirdly, this application provides a computer program product, including a computer program that, when executed by a processor, implements the dust removal system control method for cigarette production equipment.

[0040] The invention employing the above technical solution has the following advantages:

[0041] The technical solution provided in this application enables adaptive and precise control of wind pressure, solving the problem of unstable wind pressure. By setting a controlled wind pressure range and combining real-time sensor data with unit operating data, the power of the vacuum negative pressure motor and dust removal motor is dynamically adjusted, quickly restoring the wind pressure to a reasonable range. This avoids wind pressure exceeding or falling short of standards due to unit start-up and shutdown or changes in production capacity, ensuring the efficient operation of the dust removal system and improving the cleanliness of the cigarette production environment and the accuracy of equipment operation.

[0042] It can realize intelligent start and stop of the dust removal system, reducing energy waste; based on the linkage judgment between the air pressure value of the vacuum negative pressure main pipeline and the operating status of the VE fan, it can automatically realize the start and stop of the dust removal system, avoiding problems such as untimely start and stop and ineffective operation caused by manual intervention, effectively reducing the no-load and light-load operation time of the dust removal system and reducing production energy consumption. Attached Figure Description

[0043] This application can be further illustrated by the non-limiting embodiments given in the accompanying drawings. It should be understood that the following drawings only illustrate some embodiments of this application and should not be considered as limiting the scope. For those skilled in the art, other related drawings can be obtained from these drawings without any inventive effort.

[0044] Figure 1 This is a schematic diagram of the structure of an electronic device provided in an embodiment of this application.

[0045] Figure 2 A schematic flowchart illustrating the dust removal system control method for cigarette production equipment provided in this application embodiment. Detailed Implementation

[0046] The present application will be described in detail below with reference to the accompanying drawings and specific embodiments. It should be noted that similar or identical parts are referred to by the same reference numerals in the drawings or description. Implementations not shown or described in the drawings are forms known to those skilled in the art. In the description of this application, terms such as "first" and "second" are used only to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0047] Please refer to Figure 1 This application provides an electronic device, including a processor 11 and a memory 12 coupled to the processor 11. The memory 12 stores a computer program, which, when executed by the processor 11, performs the corresponding steps in the following method for controlling a dust removal system in a cigarette production equipment.

[0048] In this embodiment, the processor 11 may be an integrated circuit chip with signal processing capabilities. The above-mentioned processor 11 may be a general-purpose processor. For example, the processor 11 may be a central processing unit (CPU), a digital signal processor 11 (DSP), an application specific integrated circuit (ASIC), a field-programmable gate array (FPGA), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, and can implement or execute the various methods, steps, and logic block diagrams disclosed in the embodiments of the present application.

[0049] The memory 12 may be, but is not limited to, a random access memory, a read-only memory, a programmable read-only memory, an erasable programmable read-only memory, an electrically erasable programmable read-only memory, etc. In this embodiment, the memory 12 may be used to store target parameters, the controlled range of the target parameters, sensor data, production data, as well as the operation data and adjustment instructions of the vacuum negative pressure motor 15, the VE fan, and the dust removal motor 14. Of course, the memory 12 may also be used to store programs, and the processor 11 executes the program after receiving the execution instruction.

[0050] It can be understood that Figure 1 the structure of the electronic device 100 shown in Figure 1 is only a schematic structural diagram, and may also include more components than Figure 1 shown.

[0051] Optionally, referring to Figure 2 , the present application also provides a method for controlling a dust removal system of a cigarette production device, which can be applied to the processor 11 in the above-mentioned electronic device 100, and the processor 11 executes or implements each step in the method. Among them, the method for controlling a dust removal system of a cigarette production device is applied to a dust removal system supporting a cigarette production device. In the cigarette production device, the cigarette making and tipping unit and the packaging unit are respectively connected to a vacuum negative pressure pipeline and a dust removal pipeline. All the vacuum negative pressure pipelines are connected to a vacuum negative pressure system through a vacuum negative pressure main pipeline, and all the dust removal pipelines are connected to a dust removal system through a dust removal main pipeline; pressure sensors are installed on the vacuum negative pressure main pipeline and the dust removal main pipeline. The method includes steps 210-240; specifically,

[0052] Step 210: Set the controlled range of the target pressure parameter, where the target pressure parameter includes the wind pressure value of the vacuum negative pressure main pipeline and the wind pressure value of the dust removal main pipeline;

[0053] Step 220: Obtain production data of cigarette production equipment, determine the units that have been started in the cigarette production equipment and the operating data of the units that have been started based on the production data, wherein the operating data includes at least the power data of vacuum negative pressure motor, VE fan and dust removal motor;

[0054] Step 230: Based on the continuously acquired sensor data, determine whether the current vacuum negative pressure main pipeline air pressure value and the dust removal main pipeline air pressure value deviate from their respective controlled ranges;

[0055] A pressure sensor 13 is installed on both the vacuum negative pressure main pipe and the dust removal main pipe to continuously acquire sensor data.

[0056] Step 240: If the wind pressure value exceeds the limit, adjust the power of the corresponding motor based on the operating data to bring the wind pressure value back to the controlled range.

[0057] In the above implementation method, firstly, based on the production process design, the controlled range of the air pressure value of the vacuum negative pressure main pipeline and the air pressure value of the dust removal main pipeline are set; then, during the control of the dust removal system, by using the set controlled range, combined with real-time sensor data and unit operation data, the power of the vacuum negative pressure motor and the dust removal motor is dynamically adjusted, which can quickly bring the air pressure back to a reasonable range, avoid air pressure exceeding or falling short due to unit start-up and shutdown, production capacity changes, etc., ensure the efficient operation of the dust removal system, and improve the cleanliness of the cigarette production environment and the accuracy of equipment operation.

[0058] In this embodiment, the method is applied to the cigarette rolling and packaging workshop of a cigarette factory. The workshop's cigarette production equipment includes 10 cigarette making and receiving units and 6 packaging units, all connected to the main vacuum negative pressure pipeline and the main dust removal pipeline via vacuum negative pressure pipelines and dust removal pipelines, respectively. Each system is equipped with a vacuum negative pressure system and a dust removal system. Pressure gearboxes (primarily pressure sensors) are installed on the main vacuum negative pressure pipeline and the main dust removal pipeline. The motors corresponding to the vacuum negative pressure system and the dust removal system are equipped with motor frequency converters. When the motor frequency converters are operating normally, they can adjust the power of the vacuum negative pressure motor 15, the dust removal motor 14, and the VE fan.

[0059] The following is a detailed explanation of each step in the control method for the dust removal system of cigarette production equipment:

[0060] In step 210, the controlled range of the target pressure parameter is set. For example, the vacuum negative pressure main pipeline air pressure value is -0.068±0.005MPa, that is, the controlled range is -0.073MPa to -0.063MPa; the dust removal main pipeline air pressure value is -0.01±0.001MPa, that is, the controlled range is -0.011MPa to -0.009MPa. The selection of the target parameter here can be flexibly set according to the dust removal pipeline connected to the dust removal system and the connection method of the dust removal main pipeline, and no specific limitation is made here.

[0061] In step 220, acquiring production data from the cigarette production equipment and determining the started units and their operating data based on the production data includes:

[0062] In response to the start-up of cigarette production equipment, the production plan of the cigarette production equipment is retrieved to obtain the production data of the cigarette production equipment;

[0063] Based on the production data, determine which units in the cigarette production equipment have been started, and obtain the operating data of the started units.

[0064] In some scenarios of this embodiment, the production data of the cigarette production equipment can be obtained by querying the factory's production database (or ERP system); specifically, the daily production plan is retrieved, and it is determined that the daily production task is to roll and form A brand cigarettes, with a capacity of 5,000 cigarettes / minute, and 8 rolling and forming units and 4 packaging units have been started.

[0065] Operating data of the started units: The current frequency of the vacuum negative pressure pump inverter is 35Hz (corresponding to a motor power of 55kW), the VE fan power is 30kW (in operation), and the current frequency of the dust collector motor inverter is 28Hz (corresponding to a motor power of 45kW); the air pressure value of the vacuum negative pressure main pipeline is -0.068MPa (within a constant range), and the air pressure value of the dust collector main pipeline is -0.010MPa (within a constant range). Record the above operating data and store it.

[0066] In some scenarios of this embodiment, the preset wind pressure threshold for starting the dust removal system is: when the pressure value in the vacuum negative pressure main pipeline is greater than the specified value of -0.03MPa (that is, the wind pressure value is higher than -0.03MPa, and the negative pressure is reduced), and the VE fan corresponding to the dust removal system is in operation, the dust removal system is started;

[0067] Preset dust removal system shutdown conditions: The dust removal system will stop operating when the main vacuum negative pressure pipeline air pressure value is ≤-0.063MPa (the main vacuum negative pressure pipeline air pressure returns to the lower limit of the controlled range), or when the VE fan stops running.

[0068] In step 230, determining whether the current vacuum negative pressure main pipeline air pressure value and the dust removal main pipeline air pressure value deviate from their respective controlled ranges based on continuously acquired sensor data includes:

[0069] Get the current vacuum negative pressure main pipeline air pressure value; Get the current dust removal main pipeline air pressure value;

[0070] Compare the current vacuum negative pressure main pipeline air pressure value with the set target pressure parameter to determine whether the current vacuum negative pressure main pipeline air pressure value deviates;

[0071] The current air pressure value of the main dust removal pipeline is compared with the set target pressure parameter to determine whether the current air pressure value of the main dust removal pipeline deviates.

[0072] That is, compare the current vacuum negative pressure main pipeline air pressure value with the controlled range (-0.073MPa to -0.063MPa), and compare the current dust removal main pipeline air pressure value with the controlled range (-0.011MPa to -0.009MPa);

[0073] Confirm that the air pressure values ​​of the two main pipelines are within the controlled range corresponding to the set values, without any deviation, and there is no need to adjust the frequency of the inverter.

[0074] In step 240, if a wind pressure value exceeds the limit, adjusting the power of the corresponding motor based on the operating data to bring the wind pressure value back to the controlled range includes:

[0075] If any wind pressure value exceeds the limit, the power of the corresponding motor will be adjusted based on the operating data to bring the wind pressure value back to the controlled range.

[0076] When the air pressure values ​​of the vacuum negative pressure main pipeline and the dust removal main pipeline both exceed the limit, the power of the vacuum negative pressure motor should be adjusted first, and then the power of the dust removal motor should be adjusted.

[0077] In some scenarios, after running for 2 hours, two previously unused coiling and splicing units are started in batches in the workshop. At this point, the number of units in operation increases to 10 coiling and splicing units and 4 packaging units. Due to the increase in the number of units in operation, the air pressure values ​​of the vacuum negative pressure main pipeline and the dust removal main pipeline fluctuate. After processing, the raw signals collected by the pressure sensors show that the air pressure value of the vacuum negative pressure main pipeline drops to -0.075MPa (deviating from the lower limit of the controlled range of -0.073MPa), and the air pressure value of the dust removal main pipeline drops to -0.012MPa (deviating from the lower limit of the controlled range of -0.011MPa).

[0078] Based on the number of units already started and their operating data, and combined with the adjustment logic that "the more units started, the higher the frequency of the frequency converter", it was determined that the frequency converters for the vacuum negative pressure pump and the dust collector motor needed to be increased. The frequency of the vacuum negative pressure pump was adjusted to 40Hz (corresponding to a motor power of 60kW) and the frequency of the dust collector motor was adjusted to 32Hz (corresponding to a motor power of 50kW) through the frequency converter.

[0079] Five seconds after adjustment, the raw signals collected by the two pressure sensors were processed, and the air pressure value of the vacuum negative pressure main pipeline rose to -0.068MPa (returning to a constant value), and the air pressure value of the dust removal main pipeline rose to -0.010MPa (returning to a constant value), both within the controlled range, and the adjustment was completed.

[0080] In this embodiment, the method further includes:

[0081] Monitor the air pressure value of the vacuum negative pressure main pipeline and the operating status of the VE fan;

[0082] When the air pressure value of the vacuum negative pressure main pipeline is greater than the preset first air pressure threshold, and the VE fan is in operation, the dust removal system is started.

[0083] In some scenarios, by the fourth hour of production, some packaging units have completed their daily production tasks and shut down, reducing the number of units in operation to 8 winding and splicing units and 2 packaging units. At this time, the negative pressure of the vacuum negative pressure main pipeline decreases, and after processing, the raw signal collected by the pressure sensor shows that the air pressure value of the vacuum negative pressure main pipeline rises to -0.028MPa (greater than the specified value of -0.03MPa), and the VE fan is still running.

[0084] If the conditions for starting the dust removal system are met, immediately start the dust removal system.

[0085] In this embodiment, the method further includes: after the dust removal system is started, if the air pressure value of the vacuum negative pressure main pipeline is less than or equal to the second air pressure threshold, or if the VE fan stops running, controlling the dust removal system to stop running.

[0086] In some scenarios, after 6 hours of production, all packaging units stop, the VE fan stops running, and the raw signal collected by the pressure sensor shows that the air pressure value of the vacuum negative pressure main pipeline drops to -0.065MPa (≤-0.063MPa, returning to the controlled range). The processor controls the dust removal system to stop running to avoid ineffective operation of the dust removal system and reduce energy consumption.

[0087] In some scenarios, the method further includes: based on the operational data, when a new unit starts or stops in the cigarette production equipment, a graded adjustment method is adopted to gradually adjust the motor power. The graded adjustment method is existing technology and will not be described in detail here.

[0088] In this embodiment, the method further includes:

[0089] The acquired production data and sensor data are processed to construct a sample set;

[0090] Frequent itemsets among the data in the sample set are mined, and association rules for the frequent itemsets are generated. At the same time, the support and confidence of each association rule are analyzed. Based on the pre-set minimum support threshold (which can be set to 0.2) and minimum confidence threshold (which can be set to 0.8), the association rules of the frequent itemsets are clustered and optimized to obtain the optimal rule set.

[0091] A correlation coefficient matrix is ​​established based on the optimal rule set to form a pre-tuned rule knowledge base;

[0092] Based on the acquired production data, rules are extracted from the pre-adjustment rule knowledge base. The corresponding motor power is then simulated and adjusted in the preset production twin model, and the simulated wind pressure value is analyzed to see if it returns to the controlled range.

[0093] By acquiring real-time sensor data, the effectiveness of the extracted rules in the simulated execution process is verified. If the effectiveness meets the standard, the verification is passed, and then the power of the corresponding motor is adjusted in the cigarette production equipment.

[0094] If the verification fails, the rules will be extracted again until the verification passes.

[0095] In some scenarios, frequent itemsets among the data in the sample set are mined, and association rules for the frequent itemsets are generated. Specifically, the Apriori algorithm is executed to mine the association rules of "number of started units - frequency converter frequency - wind pressure value", and rule clustering optimization is performed to establish a pre-adjusted rule knowledge base.

[0096] The association rule states: "When the number of coiling units started is ≥8 and the number of packaging units started is ≥4, the frequency of the vacuum negative pressure pump inverter needs to be adjusted to 38Hz~42Hz (corresponding to a stable air pressure of -0.068±0.005MPa), and the frequency of the dust removal motor inverter needs to be adjusted to 30Hz~34Hz (corresponding to a stable air pressure of -0.01±0.001MPa)". This rule has a support of 0.85 and a confidence of 0.92, which meets the minimum threshold requirement.

[0097] Clustering and optimization of association rules yields the optimal rule set. A correlation coefficient matrix of "number of starting units - frequency converter frequency - wind pressure value" is established to form a pre-adjustment rule knowledge base.

[0098] In the production twin model, the adjustment was simulated: the number of units to be started was set to 8 coiling units and 4 packaging units. The frequency of the vacuum negative pressure pump inverter was adjusted to 40Hz and the frequency of the dust removal motor inverter was adjusted to 32Hz. The simulated wind pressure value was stably maintained at -0.068MPa and -0.010MPa, which met the constant value requirement.

[0099] The effectiveness of the simulation rule was verified by processing real-time data from on-site pressure sensors. After actual adjustment, the wind pressure values ​​of the vacuum negative pressure main pipeline and the dust removal main pipeline remained stable within a constant range, and the effectiveness met the standard. The rule was then incorporated into the actual control process to achieve active pre-adjustment of wind pressure.

[0100] In some scenarios of this embodiment, the production twin model can be built in different ways, such as building a simulation model based on MATLAB / Simulink, or building a cloud twin model based on an industrial internet platform. The focus is on optimizing the simulation logic of "number of start-up units - frequency converter frequency - wind pressure value" to adapt to different workshop information architectures. At the same time, a simulation module of signal processing algorithm can be integrated to improve the simulation accuracy of the model.

[0101] The Apriori algorithm can be combined with the Spark big data framework for parallel execution, improving the efficiency of mining large-scale production data (such as long-term operating data of multiple workshops and multiple units), and is suitable for large cigarette production groups, further optimizing the accuracy of frequency adjustment of frequency converters.

[0102] In this embodiment, the sensor data is processed, including: signal preprocessing, noise filtering, signal calibration, and abnormal signal detection and processing.

[0103] In some scenarios, signal preprocessing specifically includes: format conversion: converting the analog signal (4-20mA current signal) output by the pressure sensor into a digital signal (corresponding to the wind pressure value, unit MPa). The conversion is completed through the analog input module of the PLC controller, with a conversion accuracy of ±0.00005MPa, ensuring that the converted digital signal is consistent with the original analog signal; and range filtering: based on the preset reasonable wind pressure range (vacuum negative pressure main pipeline: -0.08MPa~-0.05MPa, dust removal main pipeline: -0.015MPa~-0.005MPa), the converted digital signal is initially filtered to remove abnormal data that obviously exceeds the reasonable range.

[0104] Noise filtering can be achieved using a combination of moving average filtering and Kalman filtering algorithms; for example:

[0105] Moving average filtering: Select the most recent 5 sets of preprocessed valid data (collection period of 0.5 seconds, corresponding to data within 2.5 seconds), calculate their arithmetic mean, and use it as the initial filtered data for the current moment. The formula is:

[0106] (1),

[0107] in The data at time n is the filtered data. The effective data at time i is preprocessed; high-frequency random noise is quickly filtered out, and the signal fluctuation amplitude is reduced.

[0108] Kalman filtering: A secondary filter is applied to the preliminary data after moving average filtering to further eliminate system interference and noise caused by sensor drift. The core parameters are set as follows:

[0109] Equations of state (2),

[0110] Observation equations (3),

[0111] in, This represents the estimated true wind pressure value at time k. This represents the estimated true wind pressure value at time k-1. This indicates process noise (system interference). This represents the original sensor reading at time k, which is the wind pressure data collected by the pressure sensor after processing with a moving average filter and including noise. The sensor measurement noise represents the measurement error caused by drift, temperature changes, and electromagnetic interference inherent in the pressure sensor itself; A=1 (state transition matrix), H=1 (observation matrix), and process noise variance. Observation noise variance Initial covariance The optimal estimate is calculated using Kalman filtering and used as the final effective data for wind pressure judgment, ensuring data stability while guaranteeing a filtering delay of ≤0.1 seconds, so as not to affect the real-time performance of the control process.

[0112] Signal calibration processing: During long-term operation, pressure sensors may experience measurement deviations due to factors such as changes in ambient temperature, probe wear, and electromagnetic interference. Regular calibration using a calibration algorithm is necessary to ensure the accuracy of the collected data. The calibration cycle is set to 30 minutes before daily production. Specific steps are as follows:

[0113] Zero-point calibration: Connect the pressure sensor to a standard pressure calibrator, place it under standard atmospheric pressure (0 MPa), acquire the sensor output signal, and record the zero-point deviation value. If the deviation exceeds ±0.0001MPa (sensor accuracy range), the sensor zero point will be automatically adjusted to eliminate the deviation.

[0114] Range calibration: The ranges of the two pressure sensors were calibrated separately. The pressure sensor on the vacuum negative pressure main pipeline was calibrated to a range of -0.08MPa to -0.05MPa, and the pressure sensor on the dust removal main pipeline was calibrated to a range of -0.015MPa to -0.005MPa. Three different standard pressure values ​​were input using a standard pressure calibrator, and the deviations between the sensor measurements and the standard values ​​were recorded. A linear calibration equation y was then established.

[0115] (4),

[0116] Where y is the calibrated data, x is the filtered data, k is the calibration coefficient, and b is the calibration offset. All subsequent data are calibrated using this equation to ensure that the measurement error is ≤ ±0.0001MPa.

[0117] Real-time calibration compensation: During the production process, one set of filtered data is extracted every hour and compared with the historical calibration benchmark value. If the deviation is ≤ ±0.0001MPa, no adjustment is required; if the deviation exceeds the range, a simple calibration is automatically started to adjust the calibration offset b to ensure data accuracy.

[0118] Abnormal Signal Judgment and Handling: An abnormal signal is defined as follows: three consecutive sets of collected data (corresponding to 1.5 seconds) exceeding the reasonable range; five consecutive sets of data with fluctuations ≥0.001MPa (vacuum negative pressure main pipeline) or ≥0.0002MPa (dust removal main pipeline); or a signal transmission interruption exceeding 0.5 seconds. Upon determination of an abnormal signal, an alarm is immediately triggered (alarm information is displayed on the human-machine interface, and an audible and visual alarm is issued simultaneously). Historical best data (the average of the most recent 10 valid data sets) is then used to replace the current abnormal data to maintain normal control flow. If the abnormality persists for more than 30 seconds, it is determined to be a sensor malfunction.

[0119] In one embodiment, an electronic device includes a memory and a processor, the memory storing a computer program that, when executed by the processor, enables the processor to perform the dust removal system control method for cigarette production equipment.

[0120] In one embodiment, this embodiment provides a computer program product, including a computer program; the computer program is stored in a USB flash drive (computer-readable storage medium), and when the computer program is executed by a processor (such as a PLC processor or an industrial computer processor), it implements the control method of the dust removal system of the cigarette production equipment described above; wherein, the computer program includes the following functional modules:

[0121] Parameter preset module: Used to preset the constant wind pressure value and controlled range of the vacuum negative pressure main pipeline and the dust removal main pipeline, the start and stop threshold of the dust removal system, and the minimum support threshold and minimum confidence threshold of the Apriori algorithm. It allows users to adjust the frequency converter adjustment range according to production needs and adapt to the adjustment requirements of different numbers of start-up units. At the same time, it presets signal processing algorithm parameters (filter window, calibration cycle, anomaly judgment threshold, etc.) and supports manual adjustment.

[0122] Data acquisition module: used to retrieve the production plan of cigarette production equipment, determine the number of started units and their operating status, receive real-time raw wind pressure signals collected by two pressure sensors, and obtain the current frequency converter data of vacuum negative pressure pump and dust removal motor;

[0123] Signal processing module: Used to execute a four-level signal processing algorithm of "preprocessing-filtering-calibration-anomaly judgment", convert the raw signal collected by the pressure sensor into effective wind pressure data, process abnormal signals and trigger alarms, periodically perform sensor calibration, and output effective data that can be used for subsequent judgment;

[0124] Wind pressure judgment module: used to compare the effective wind pressure value output by the signal processing module with the controlled range corresponding to the constant value, output the wind pressure deviation judgment result, and at the same time determine whether the wind pressure value of the vacuum negative pressure main pipeline has reached the start-up and shutdown threshold of the dust removal system;

[0125] Inverter regulation module: Based on the number of started units and the deviation of air pressure, it generates inverter frequency regulation commands for vacuum negative pressure pump and dust collector motor, and clarifies the regulation logic that "the more started units, the higher the inverter frequency", to ensure that the air pressure returns to a constant value;

[0126] Start / Stop Control Module: Monitors the operating status of the VE fan and the effective air pressure value of the vacuum negative pressure main pipeline after treatment, and generates start / stop commands for the dust removal system strictly according to the condition of "air pressure value > -0.03MPa and VE fan running";

[0127] Data mining and optimization module: used to collect production data, effective data after processing from pressure sensors, and inverter operation data, build a sample set, execute the Apriori algorithm to mine the association rules of "number of started units - inverter frequency - wind pressure value", perform rule clustering optimization, and establish a pre-adjustment rule knowledge base;

[0128] Simulation verification module: used to extract rules, simulate the adjustment of inverter frequency in the production twin model, and verify the effectiveness of the rules through the effective data processed by the pressure sensor to ensure that the simulated wind pressure value is stable within a constant range;

[0129] Command execution module: Used to transmit frequency adjustment commands from the frequency converter and start / stop commands from the dust removal system to the corresponding devices, execute the actual control operations, and provide feedback on the execution results.

[0130] It should be noted that those skilled in the art will understand that, for the sake of convenience and brevity, the specific working process of the electronic device described above can be referred to the corresponding steps in the aforementioned method, and will not be elaborated further here.

[0131] Based on the above description of the embodiments, those skilled in the art can clearly understand that this application can be implemented by hardware or by using software plus necessary general-purpose hardware platforms. Based on this understanding, the technical solution of this application can be embodied in the form of a software product. The software product can be stored in a non-volatile storage medium (such as CD-ROM, USB flash drive, mobile hard drive, etc.) and includes several instructions to cause an electronic device (such as a personal computer, server, or network device, etc.) to execute the methods described in the various implementation scenarios of this application.

[0132] In summary, this application provides a control method, system, and program product for a dust removal system in cigarette production equipment. In this technical solution, a controlled range for a target pressure parameter is first set, where the target pressure parameter includes the air pressure value of the vacuum negative pressure main pipeline and the air pressure value of the dust removal main pipeline. Production data of the cigarette production equipment is acquired, and based on the production data, the units already started in the cigarette production equipment and their operating data are determined. The operating data includes at least the power data of the vacuum negative pressure motor, the VE fan, and the dust removal motor. Based on continuously acquired sensor data, it is determined whether the current air pressure value of the vacuum negative pressure main pipeline and the air pressure value of the dust removal main pipeline deviate from their respective controlled ranges. If any air pressure value exceeds the limit, the power of the corresponding motor is adjusted based on the operating data to bring the air pressure value back to the controlled range. This improves upon the traditional fixed power control mode, which leads to low dust removal efficiency, high energy consumption, and poor system stability.

[0133] In the embodiments provided in this application, it should be understood that the disclosed systems and methods can also be implemented in other ways. The system and method embodiments described above are merely illustrative. For example, the flowcharts and block diagrams in the accompanying drawings illustrate the architecture, functionality, and operation of possible implementations of systems, 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, program segment, or part of code, which includes one or more executable instructions for implementing a specified logical function. It should also be noted that each block in a block diagram and / or flowchart, and combinations of blocks in block diagrams and / or flowcharts, 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. Furthermore, the functional modules 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.

[0134] The above description is merely an embodiment of this application and is not intended to limit the scope of protection of this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the scope of protection of this application.

Claims

1. A method for controlling a dust removal system in cigarette production equipment, characterized in that, A dust removal system is applied to cigarette production equipment, wherein the cigarette making and packaging units in the cigarette production equipment are respectively connected to vacuum negative pressure pipelines and dust removal pipelines, all of the vacuum negative pressure pipelines are connected to a vacuum negative pressure system through a main vacuum negative pressure pipeline, and all of the dust removal pipelines are connected to a dust removal system through a main dust removal pipeline; the method includes: Set a controlled range for the target pressure parameters, wherein the target pressure parameters include the air pressure value of the vacuum negative pressure main pipeline and the air pressure value of the dust removal main pipeline; Obtain production data from cigarette production equipment, determine the units that have been started in the cigarette production equipment and their operating data based on the production data, wherein the operating data includes at least the power data of the vacuum negative pressure motor, VE fan and dust removal motor; Based on continuously acquired sensor data, determine whether the current air pressure value of the vacuum negative pressure main pipeline and the air pressure value of the dust removal main pipeline deviate from their respective controlled ranges; If the wind pressure value exceeds the limit, the power of the corresponding motor will be adjusted based on the operating data to bring the wind pressure value back to the controlled range.

2. The method according to claim 1, characterized in that, The method further includes: Monitor the air pressure value of the vacuum negative pressure main pipeline and the operating status of the VE fan; When the air pressure value of the vacuum negative pressure main pipeline is greater than the preset first air pressure threshold, and the VE fan is in operation, the dust removal system is started; After the dust removal system is started, if the air pressure value of the vacuum negative pressure main pipeline is less than or equal to the second air pressure threshold, or if the VE fan stops running, the dust removal system is controlled to stop running.

3. The method according to claim 1, characterized in that, The process of acquiring production data from cigarette production equipment, determining which units in the cigarette production equipment have been started based on the production data, and the operating data of the started units includes: In response to the start-up of cigarette production equipment, the production plan of the cigarette production equipment is retrieved to obtain the production data of the cigarette production equipment; Based on the production data, determine which units in the cigarette production equipment have been started, and obtain the operating data of the started units.

4. The method according to claim 1, characterized in that, The step of determining whether the current vacuum negative pressure main pipeline air pressure value and the dust removal main pipeline air pressure value deviate from their respective controlled ranges based on continuously acquired sensor data includes: Get the current vacuum negative pressure main pipeline air pressure value; Get the current dust removal main pipeline air pressure value; Compare the current vacuum negative pressure main pipeline air pressure value with the set target pressure parameter to determine whether the current vacuum negative pressure main pipeline air pressure value deviates; The current air pressure value of the main dust removal pipeline is compared with the set target pressure parameter to determine whether the current air pressure value of the main dust removal pipeline deviates.

5. The method according to claim 1, characterized in that, If the wind pressure value exceeds the limit, the power of the corresponding motor will be adjusted based on the operating data to bring the wind pressure value back to the controlled range, including: If any wind pressure value exceeds the limit, the power of the corresponding motor will be adjusted based on the operating data to bring the wind pressure value back to the controlled range. When the air pressure values ​​of the vacuum negative pressure main pipeline and the dust removal main pipeline both exceed the limit, the power of the vacuum negative pressure motor should be adjusted first, and then the power of the dust removal motor should be adjusted.

6. The method according to claim 1, characterized in that, The method further includes: Based on the aforementioned operational data, when a new unit starts or stops in the cigarette production equipment, a graded adjustment method is adopted to gradually adjust the motor power.

7. The method according to claim 1, characterized in that, The method further includes: The acquired production data and sensor data are processed to construct a sample set; Frequent itemsets among the data in the sample set are identified, and association rules for the frequent itemsets are generated. The support and confidence of each association rule are analyzed. Based on the pre-set minimum support threshold and minimum confidence threshold, the association rules of the frequent itemsets are clustered and optimized to obtain the optimal rule set. A correlation coefficient matrix is ​​established based on the optimal rule set to form a pre-tuned rule knowledge base; Based on the acquired production data, rules are extracted from the pre-adjustment rule knowledge base. The corresponding motor power is then simulated and adjusted in the preset production twin model, and the simulated wind pressure value is analyzed to see if it returns to the controlled range. By acquiring real-time sensor data, the effectiveness of the extracted rules in the simulated execution process is verified. If the effectiveness meets the standard, the verification is passed, and then the power of the corresponding motor is adjusted in the cigarette production equipment. If the verification fails, the rules will be extracted again until the verification passes.

8. The method according to claim 7, characterized in that, Data processing of sensor data includes: signal preprocessing, noise filtering, signal calibration, and abnormal signal detection and processing.

9. An electronic device, characterized in that, The electronic device includes a memory and a processor, wherein the memory stores a computer program that, when executed by the processor, enables the processor to perform the method as described in any one of claims 1-8.

10. A computer program product, characterized in that, It includes a computer program that, when executed by a processor, implements the method as described in any one of claims 1-8.

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