A tobacco quality upgrading processing classification method with dynamic screening and multi-stage winnowing regulation

Abstract

This invention provides a method for classifying and improving tobacco shreds through dynamic screening and multi-stage air separation, including vibrating screening, path control, multi-stage air separation, combing and fixed-length broken shred treatment, air separation rejection, and subsequent processing. First, a multi-channel louvered screening device controlled by frequency conversion performs preliminary classification of the tobacco shreds, achieving efficient and low-error sorting control. A three-stage vertical air separation system progressively separates and recovers the mixture of short shreds and small stems, maximizing tobacco shred recovery and minimizing mismixing. Next, long shreds and clumps are combed and cut to a fixed length using combing rollers and a fixed-blade device to comb the clumps, control shred length, and adjust the shred shape ratio, ensuring the finished product meets the requirements for subsequent cigarette rolling. Large stems are rejected by air separation and discharged from the production line or enter a reprocessing system. This invention possesses a highly intelligent level of tobacco shred processing and is suitable for process optimization and automation upgrades of modern tobacco processing production lines.

Description

Technical Field

[0001] This invention belongs to the technical fields of tobacco processing, material sorting, automated control and resource recycling, and specifically relates to a method for classifying and improving tobacco shreds with dynamic screening and multi-stage air separation control. Background Technology

[0002] There are currently two major problems in the production of tobacco shreds, especially in the production of slim cigarettes: the handling of long shreds and clumps, and the removal of stems. The current industry practice for handling long shreds and clumps involves first screening them, then beating or combing them, or beating all the tobacco shreds.

[0003] Currently, the screening of long filaments in the industry is all random and ineffective. Both methods of long filament screening have their advantages and disadvantages, and neither can completely process the filaments or clumps into a satisfactory state. The current method for handling stems in tobacco involves all material being fed into an air classifier. However, due to the large flow rate and significant snagging and entanglement of the filaments with the stems, the processing effect is poor. Either the removed stems contain a high filament content, or the stems are not completely removed, especially small stems. During the production of slim cigarettes, it is often the smaller stems that are punctured.

[0004] The screening-carding-shortening (unbundling) technology for long filaments or clumps mainly focuses on the preliminary screening of tobacco shreds, carding and shortening of long filaments, equipment linkage optimization, and precise measurement and control of particle size distribution. These technologies work together to improve the structural quality and rollability of tobacco shreds, while also providing a relatively universal solution for the transformation of tobacco processing production lines. Although existing technologies have made some progress in tobacco processing, some shortcomings and problems remain: Firstly, existing screening methods often rely on traditional shaking and grading screening, which cannot accurately control the particle size distribution of long and short filaments, resulting in significant randomness and inhomogeneity in the screening process. Although new seven-layer screen equipment can provide quantitative assessment of particle size distribution, achieving closed-loop control and maintaining high efficiency and accuracy in actual operation remains a challenge. Secondly, the processing of filaments and clumps is not precise enough: Although the "filament comber" and "straight-line filament breaking device" can shorten filaments and clumps, in practical applications, the shortening effect of filaments and the degree of clump unpacking are still incomplete or uneven, affecting the structure and rollability of tobacco. Thirdly, the new "screening + shortening" equipment breaks up clumps and shortens filaments through a loosening device and a reverse cutting roller, which can improve the separation effect, but there is still room for improvement in equipment linkage. In particular, how to accurately control the air volume and pressure to further improve the separation efficiency in linkage with the downstream air classification and impurity removal system is a problem that needs to be solved. Fourthly, although new equipment on the market has the potential for online modification, the adaptability of the equipment and the modification cost remain bottlenecks restricting its widespread application; how to achieve efficient integration and seamless docking of new equipment without changing the existing production line structure requires further technological breakthroughs.

[0005] In the process control of stem removal (including small stems), existing technologies mainly focus on solving the problems of efficient separation of stems from tobacco shreds, separation of stems from tobacco shreds in wet tobacco shreds, high-precision positioning and removal of stems, real-time monitoring and feedback of stem content, and improving the quality of stem recycling.

[0006] For efficient separation of stems and tobacco shreds, a multi-stage air separation system is employed. Through step-by-step gas-solid separation technology, stems with higher suspension critical velocities are gradually separated from the tobacco shreds, significantly improving separation efficiency. Addressing the issue of stem separation in wet tobacco conditions, especially under conditions of high moisture content after drying or flavoring, an online separation device and method were designed, effectively solving the common problems of entrainment and adhesion of wet tobacco shreds during high-volume processing. To meet the need for high-precision stem positioning and removal, a refined airflow field and structural flow guidance design were adopted, significantly improving the positioning and removal accuracy of stems while also increasing the recovery rate. Fourth, regarding the real-time monitoring and feedback of stem content, a stem content detection device was developed, enabling rapid separation and measurement of stem content, supporting process sampling and setpoint verification. In improving the quality of stem recycling, a series of process innovations were proposed, such as rehydration, expansion, drying, and air separation technologies. These technologies reduce residual tobacco loss during the removal process, significantly improving the quality of stem recycling.

[0007] The shortcomings and deficiencies of existing technologies in the removal and process control of stems (including small stems) are as follows: First, regarding the separation efficiency of small stems, existing multi-stage air separation systems exhibit low separation efficiency when handling small stems, especially in the case of wet tobacco, where small stems are easily trapped or adhered, resulting in poor removal. Second, regarding the balance between recovery rate and purity, although some progress has been made in improving stem separation efficiency, balancing recovery rate and purity remains a challenge. Over-optimizing separation efficiency can lead to a decrease in recovery rate, thus affecting the effective utilization of resources. Third, the real-time response speed and accuracy of existing stem content detection devices are still unsatisfactory, failing to meet the needs of more precise process control in actual production. Finally, existing equipment still has shortcomings in adaptability and stability, especially when facing different humidity, density, and stem content conditions. The stability and adaptability of the equipment urgently need further optimization to ensure efficient operation under various conditions. Summary of the Invention

[0008] (1) Purpose of the invention

[0009] To address the problems of inaccurate material sorting, low processing efficiency, and excessive waste and substandard materials generated during tobacco processing, this invention proposes a tobacco quality improvement and classification method with dynamic screening and multi-stage air separation control.

[0010] The first problem to be solved by the tobacco shreds quality improvement and classification method with dynamic screening and multi-stage air separation control described in this invention is the inaccurate sorting. Traditional sorting methods often cannot effectively separate tobacco shreds of different shapes, such as the mixture between long shreds, shred clusters, and coarse stems and short shreds and fine stems, resulting in unsatisfactory subsequent processing effects.

[0011] The second problem to be solved by the tobacco shreds quality improvement and processing classification method with dynamic screening and multi-stage air separation control described in this invention is low processing efficiency. If the tobacco shreds are not classified in a timely and accurate manner during the sorting and processing process, it is easy to cause excessive processing time, increased equipment burden, and ultimately affect output and processing efficiency.

[0012] The third problem to be solved by the tobacco shreds quality improvement and classification method with dynamic screening and multi-stage air separation control described in this invention is the excessive amount of waste and unqualified materials. That is, during the tobacco shreds processing, it is difficult to completely remove waste and unqualified materials that have not undergone strict sorting, such as small stems and large stems, which leads to unstable quality of the final tobacco shreds and even increases the waste of unqualified materials.

[0013] Furthermore, the present invention provides a tobacco shreds quality improvement and classification method with dynamic screening and multi-stage air separation control. The motivation for this invention is based on the problems of low sorting efficiency, large amount of unqualified tobacco shreds, and waste in the current tobacco shreds processing. By introducing dynamic screening and multi-stage air separation control technology, the sorting accuracy can be improved, the processing efficiency can be increased, and waste can be effectively reduced, thereby further improving the quality of tobacco shreds and the processing output.

[0014] Furthermore, the tobacco shreds quality improvement and classification method with dynamic screening and multi-stage air separation control described in this invention aims to effectively improve the quality of tobacco shreds by implementing precise screening, air separation and combing of broken shreds, while reducing the generation of waste and unqualified tobacco shreds, enhancing the automation level and resource utilization of tobacco shreds processing, and ultimately optimizing and improving the tobacco shreds processing technology to meet the market demand for high-quality tobacco shreds products.

[0015] Specifically, the present invention provides a classification method for tobacco shreds with dynamic screening and multi-stage air separation control. The first objective is to provide a classification control and sorting method, that is, to sort the tobacco shreds according to the physical form of the materials, such as long filaments, shred bundles, large stems, short filaments, and small stems, so as to ensure that each type of tobacco shred material is properly processed.

[0016] Specifically, the second objective of the tobacco shreds quality improvement and classification method with dynamic screening and multi-stage air separation control described in this invention is to provide a method for combing shreds and cutting long filaments to a fixed length. That is, by using shred combing and cutting technology to refine the long filaments and shreds, unqualified parts are removed to ensure that the long filaments and shreds meet the standard requirements.

[0017] Specifically, the third objective of the present invention is to provide a method for classifying and improving tobacco shreds with dynamic screening and multi-stage air separation control. This method effectively separates short shreds and fine stems through a multi-stage air separation system. The system can precisely adjust the air force and air speed to achieve efficient sorting of short shreds and fine stems.

[0018] Specifically, the fourth objective of the present invention is to provide a method for removing and eliminating coarse stems from tobacco shreds, namely, using air separation technology to separate coarse stems from tobacco shreds and remove them from the production line, ensuring that the final product does not contain unqualified stems and improving the overall quality of tobacco shreds.

[0019] Specifically, the fifth objective of the present invention is to provide a method for precise control based on the morphology and process requirements of tobacco materials. That is, the system dynamically adjusts according to the physical characteristics of different materials, such as humidity, particle size, and density, to ensure the best processing effect for each material and reduce the generation of waste and unqualified materials.

[0020] (2) Inventive concept

[0021] This invention discloses a tobacco shred classification and processing method with dynamic screening and multi-stage air separation control. The core concept is to precisely classify and sort tobacco shreds based on their different physical forms (such as long filaments, clumps, large stems, short filaments, and small stems). Dynamic screening and multi-stage air separation control technology are employed to achieve efficient quality improvement and classification control of tobacco shreds. Specifically, this invention uses a series of innovative technical means to meticulously process each type of tobacco shred material, thereby improving the quality of tobacco shreds, reducing waste and substandard materials, and ultimately increasing overall production efficiency and resource utilization.

[0022] The present invention discloses a tobacco shreds quality improvement and classification method with dynamic screening and multi-stage air separation control. The key technical ideas include dynamic screening and multi-stage air separation control, precise adjustment of screening path, refined sorting and diversion control, multi-stage air separation and precise separation, and subsequent processing and reuse of unqualified materials.

[0023] Specifically, the dynamic screening and multi-stage air separation control utilizes a frequency-controlled multi-channel louvered screening device, combined with an adjustable vibrating screen structure and air separation equipment, to achieve preliminary classification and fine sorting of tobacco materials. During this process, different materials are sorted according to their physical differences, such as length, thickness, and moisture content, avoiding mixing and improving the efficiency and accuracy of subsequent processing.

[0024] Specifically, the precise adjustment of the screening path is achieved through a PLC control system, fuzzy control algorithm, and AI optimization algorithm. Based on real-time collected humidity, thickness, and temperature parameters, the system dynamically adjusts the screening path, screen angle, vibration frequency, and wind speed to optimize the sorting ratio and ensure that materials are processed as needed. This dynamic adjustment not only improves processing efficiency but also guarantees a short fiber recovery rate (no less than 95%) and controls the mismixing rate to below 2%.

[0025] Specifically, the refined sorting and diversion control involves using a multi-stage air separation system during the tobacco processing to further refine and divert the tobacco material, particularly focusing on the precise sorting of short fibers and small stems. The three-stage air separation system adjusts air velocity, air pressure, and feeding frequency to achieve efficient separation and recovery of different materials. This refined sorting and diversion control process recovers mixed tobacco fibers, reduces waste, and improves resource utilization.

[0026] Specifically, the multi-stage air separation and precise separation involves the following steps: the first stage of air separation performs initial diversion, separating short filaments from stems; the second stage of air separation further refines the separation, completely separating short filaments from small stems; and the third stage of air separation performs recycling, recovering the tobacco filaments mixed in with the small stems, ensuring that the tobacco filaments finally discharged from the production line meet high-quality standards.

[0027] The subsequent processing and reuse of substandard materials involve ensuring that qualified tobacco shreds are processed in subsequent stages to guarantee that the quality meets standards. Substandard materials (such as large or small stems) are discharged through an air separation system, and a dedicated waste reprocessing path is established to transform them into reusable resources (such as reconstituted tobacco, industrial fibers, and fuel), thereby improving resource utilization and environmental friendliness.

[0028] like Figure 1As shown, the present invention discloses a tobacco shreds upgrading and processing classification method with dynamic screening and multi-stage air separation control. The process is based on material type, dividing the production line into three functional areas and clearly defining the destinations of qualified products and waste: At the starting end, "tobacco shreds" from the left enter the "tobacco shreds classification and sorting" area, which is divided into two paths: one for long shreds, shred bundles, and coarse stems; the other for short shreds and fine stems. In the upper long shreds or shred bundles processing area, "combing, shred bundle breaking, and fixed-length shred cutting" produces tobacco shreds and coarse stems. Then, through "coarse stem air separation," the coarse stems are directionally discharged from the production line, and the recovered qualified shreds are incorporated into the main line. In the lower "short shreds and fine stem separation" area, purification is achieved through three-stage air separation. The first-stage air classification obtains qualified short fibers, relatively obvious stems, and a mixture of "small stems + short fibers". The second-stage air classification further separates the qualified short fibers into a residual mixture. The third-stage air classification recovers the residual short fibers and discharges the small stems from the production line. All qualified short fibers recovered at each stage are fed into the main line. Finally, the qualified short fibers or qualified fibers from the two paths merge on the main line and are sent to the "subsequent processing" on the right. Waste materials are discharged separately through two ports: the upper "coarse stem discharge line" and the lower "small stem discharge line". This forms a closed-loop process of "classification - long fiber combing and coarse stem removal - short fiber three-stage air classification recovery - qualified fiber collection and processing, and waste stem diversion and discharge".

[0029] (3) Specific technical solutions

[0030] The present invention discloses a method for classifying and improving tobacco shreds with dynamic screening and multi-stage air separation control, comprising the following steps:

[0031] S1. Tobacco shred classification and sorting: Through a multi-channel louvered screening device with frequency conversion control and an adjustable screening path system, combined with PLC and AI algorithms, the vibration frequency, screen angle and wind speed are dynamically adjusted to achieve intelligent sorting control based on the physical characteristics of tobacco shreds.

[0032] S1.1 Vibrating Screening: By using a multi-channel louvered screening device with variable frequency control and different screen hole structures, efficient physical grading of tobacco materials according to length can be achieved.

[0033] S1.2 Adjust the screening path: Based on the characteristics of the tobacco material, the sorting ratio is controlled by adjusting the position and path length of the material entering the sorting and classification equipment and the vibration screening frequency, thereby adjusting the sorting ratio of long filaments, clumps, and coarse stems to short filaments and fine stems.

[0034] S2. Separation of long filaments, skeins, and coarse stems from short filaments and fine stems: By linking the results of the vibrating sieve with the material distribution device, and combining the wind power control and flow guidance system, the synchronous grouping and physical isolation of long filaments and short filaments can be achieved.

[0035] S2.1 Separation Output: By coordinating the results of the vibrating screening with the material distribution device, the long filament and short filament materials are synchronously grouped and output to independent processing paths according to the physical classification results. The long filaments, spools, and coarse stems are output in one group, while the short filaments and fine stems are output in another group.

[0036] S2.2 Avoid mixing problems: By setting up a precise flow diversion device and wind control system, dynamic isolation and path limitation of the flow direction of tobacco shreds of different shapes are achieved after sorting, separating short shreds from long shreds and removing small stems;

[0037] S3. Processing of short filaments and fine stems: By constructing a three-stage vertical air separation system with feedback adjustment channels, and integrating PLC, fuzzy control and AI algorithms to dynamically adjust the wind speed, feeding frequency and path angle, high-precision separation of short filaments and fine stems and tobacco filament recycling are achieved under complex raw material conditions.

[0038] S3.1 Multi-stage air separation: The mixture of short filaments and fine stems is separated by air separation and passed through a three-stage air separation system in sequence;

[0039] S3.2 Recycling of small stems: By setting up a fine sorting stage in the three-stage air separation system specifically for recycling mixed tobacco shreds, and combining dynamic air pressure control and path feedback mechanism, the efficient extraction and reuse of residual tobacco shreds in small stems can be achieved.

[0040] S4. Combing and fixed-length filament breakage treatment of filaments and filament balls: Through the coordinated operation of combing rollers and fixed blades, combined with tension control, photoelectric ranging, stepper motors and PLC systems, the entire process of filament rejection and millimeter-level fixed-length cutting is intelligently controlled.

[0041] S4.1 Combing treatment: Combing rollers and fixed blades are used to comb the filaments, and tension control and abnormal resistance alarm mechanisms are introduced to achieve combing and physical stabilization of filaments and yarn bundles.

[0042] S4.2 Fixed-Length Tobacco Cutting: Through the cooperation of the combing roller and the fixed blade, fixed-length tobacco cutting is performed during the combing process, establishing a high-precision tobacco cutting control mechanism that supports multiple specification switching; the cut tobacco shreds form a shape proportion suitable for subsequent processing.

[0043] S5. Removal of coarse stems: Through a primary air separation device integrating a variable speed fan, precision air duct and multi-sensor acquisition system, dynamic control of wind speed, wind pressure, wind direction and feeding cycle is achieved to accurately distinguish and remove coarse stems.

[0044] S5.1 Primary air separation: The long filaments and filament bundles after combing and fixed-length breaking are subjected to primary air separation, which effectively separates the coarse stems by utilizing the difference between wind force and material suspension velocity.

[0045] S5.2 Discharge of coarse stems: By integrating the identification and discharge of coarse stems into the primary air separation system, and with the help of a precisely controlled air separation mechanism, coarse stems are separated and discharged from the production line.

[0046] S6. Removal of unqualified materials: By constructing an air separation and stem removal system linked to the sorting system, and setting up independent separation channels for coarse and fine stems and dedicated collection and reprocessing paths, unqualified coarse and fine stems are discharged through the air separation system to ensure the quality of the final product tobacco.

[0047] Furthermore, the tobacco shreds quality improvement and classification method with dynamic screening and multi-stage air separation control described in this invention, wherein S3.1 multi-stage air separation includes three stages of air separation, specifically:

[0048] S3.11 Primary air separation: In the same air separation stage, a "three-way diversion" strategy based on aerodynamic differences and wind speed-wind pressure linkage control is introduced to separate the mixture of short filaments and fine stems into three categories: short filaments, stems, and a mixture of short filaments and stems.

[0049] S3.12 Secondary air separation: Fine separation of the mixture of short filaments and fine stems, separating the short filaments from the fine stems; Based on the primary air separation, fine air field shaping and dynamic pressure difference threshold control are introduced, and the "narrow band" precise separation is achieved by using the slight difference in "density-morphology-drag coefficient" to finely separate the mixture of short filaments and fine stems.

[0050] S3.13 Three-stage air separation: After the first two stages of separation, the fine stems are further separated by a fine air field with "recovery priority". Through dynamic air pressure, air speed compensation and discharge channel directional control, the separated fine stems are air-separated for recovery, and the tobacco shreds mixed in are recovered and discharged from the production line.

[0051] Furthermore, in the tobacco shreds quality improvement and classification method with dynamic screening and multi-stage air separation control described in this invention, in the vibrating screening of S1.1, the multi-channel louvered screening equipment controlled by frequency conversion has multiple sizes of screen holes arranged along the material flow direction.

[0052] Furthermore, the tobacco shreds quality improvement and classification method with dynamic screening and multi-stage air separation control described in this invention, wherein S1.2 adjusting the screening path is based on the collected tobacco shreds material humidity, thickness, temperature and air separation recovery rate, and automatically adjusting the diameter length and vibration frequency to ensure that the short shred recovery rate is not less than 90% and the mismixing rate is not more than 5%.

[0053] Furthermore, in the tobacco shreds quality improvement and classification method of the present invention with dynamic screening and multi-stage air separation control, in the separation of long filaments, shred bundles, coarse stems and short filaments and fine stems in S2, the separation process adopts closed-loop control based on PLC, and combines fuzzy control and optimization algorithms based on historical data and real-time data to adjust the diameter length, vibration frequency and wind speed in a linkage manner.

[0054] The path length control is achieved by changing the position of the feed inlet, the feeding direction, and the effective passage distance of the screen surface, so as to balance the sorting efficiency and sorting accuracy. The path length L is obtained by online estimation of the movement time, displacement, and vibration response of the tobacco material on the screen surface. The estimation adopts at least one of photoelectric, visual, and vibration response signals.

[0055] The classification ratio is achieved through real-time adjustment of the effective screen path length L, and L is determined by at least two of the following: the feed inlet position, the feed angle and height, the screen tilt angle and the feeding direction. A one-to-one control mapping relationship is established with the short fiber recovery rate and the mismixing rate per unit time.

[0056] The feed inlet can be switched between multiple preset stations at the front, middle, and rear of the screen. The front station is used to shorten the path to process short filaments and small strands; the middle and rear stations are used to extend the path to process long filaments and clumps. The height of the feed inlet is adjustable to change the initial distribution width and sliding initiation energy of the material: a higher height corresponds to an extended path, suitable for long filaments and clumps; a lower height corresponds to a shortened path, suitable for short filaments and small strands.

[0057] The feed inlet achieves coordinated control of path length and residence time through paired optimization of "screen angle - vibration frequency". That is, when the target is fine separation of long filaments, the screen angle is reduced and the vibration frequency is lowered; when the target is rapid separation of short filaments, the screen angle is increased and the vibration frequency is raised.

[0058] The feeding direction and angle are controlled by changing the feeding direction and feeding angle to horizontal, inclined and vertical zones, respectively, so that the initial movement trajectory of the material on the screen surface is controlled, so that long filaments and filament balls correspond to a smaller feeding angle to extend the path, while short filaments and fine stems correspond to a larger feeding angle to shorten the path.

[0059] The real-time indicator trigger path adjustment uses the real-time changes in short fiber recovery rate and mismixing rate as the trigger quantity. When the short fiber recovery rate is lower than the set threshold, the path of the second type of material on the screen surface is extended first and the feeding speed is reduced. When the mismixing rate rises above the threshold, the path of the second type of material is shortened first and the wind speed and diversion angle are linked.

[0060] Furthermore, in the present invention, a tobacco shreds quality improvement and classification method with dynamic screening and multi-stage air separation control is described, wherein: S3. In the processing of short shreds and small stems, the sorting system in the multi-stage air separation is equipped with tobacco shreds material thickness monitoring, humidity and temperature sensors, and air separation recovery rate and mismixing rate detection modules to realize real-time monitoring and feedback adjustment of the tobacco shreds material processing status;

[0061] The secondary air separation unit has a programmable air pressure distribution profile and a controllable residence time, so as to achieve complete separation by utilizing the density or suspension critical velocity difference between short filaments and fine stems;

[0062] The three-stage air separation and recycling unit is equipped with a short filament recycling channel and a separate discharge channel for fine stems. The recycling channel is connected to a dust collection device, and a purity monitoring sensor is installed at the recycling port.

[0063] When the control unit detects that the short filament recovery rate is lower than the threshold or the mixing rate increases, it opens the interstage feedback channel to return the mixture and residual material from the second or third stage to the previous stage or parallel bypass for re-sorting. The control unit adopts multi-objective coordinated optimization to balance "short filament recovery rate ≥90%, mismixing rate ≤5%, minimization of unit energy consumption and stability of unit throughput", and outputs the optimal combination of wind speed, wind pressure and feeding cycle of each stage.

[0064] The online detection includes at least one of photoelectric recognition, visual recognition component ratio detection, mass flow meter and wind pressure and wind speed sensor, which can estimate the short filament ratio and error rate of each output material in real time.

[0065] Furthermore, in the tobacco shreds quality improvement and classification method with dynamic screening and multi-stage air separation control described in this invention, in the S4. combing and fixed-length broken shreds treatment of long filaments and shred bundles, when a decrease in the short filament recovery rate is detected, the control unit adjusts the second-stage and third-stage air pressure distribution and feeding vibration frequency in conjunction to improve the recovery capacity of mixed short filaments.

[0066] When an increase in the mismixing rate is detected, the control unit reduces the feed rate and adjusts the matching relationship between the diversion angle and the wind speed to allow the residual short fibers in the fine stems to be recycled a second time.

[0067] The second type of tobacco material is separated into short shreds, stems, and a mixture of short shreds and stems by the first-stage air separation. The second-stage air separation further refines the mixture, and the third-stage air separation recovers the short shreds from the fine stems and discharges them.

[0068] Preferably, in the tobacco shreds quality improvement and classification method of the present invention with dynamic screening and multi-stage air separation control, in step S5. removal of coarse stems, the fixed-length broken shreds are controlled by photoelectric induction ranging and stepper motor feeding in conjunction with PLC counting logic, supporting multiple length specifications for switching, the length specifications including one or more of 5mm, 10mm, 15mm, 20mm and 25mm.

[0069] Preferably, the tobacco raw material of the present invention, which has dynamic screening and multi-stage air separation control, is applicable to tobacco raw materials with a moisture content of 10% to 25%, a particle size of 2.5 mm to 100 mm, and a stem content of up to 30%.

[0070] Preferably, the tobacco shreds quality improvement and classification method of the present invention with dynamic screening and multi-stage air separation control achieves a short shred recovery rate of ≥90% and a mismixing rate of ≤5% under the target configuration, and a coarse stem mismixing rate of ≤2% and an air separation recovery rate of ≥95%.

[0071] (4) Technical principles

[0072] The present invention discloses a tobacco shreds quality improvement and processing classification method with dynamic screening and multi-stage air separation control, which includes four aspects: first, the technical means of tobacco shreds classification and sorting; second, the processing method of short shreds and small stems; third, the processing method of long shreds, shred bundles and large stems; and fourth, the dynamic adjustment of the overall system.

[0073] Firstly, the technical principles of tobacco sorting and separation specifically include the technical principles of frequency conversion controlled multi-channel louvered screening equipment and the technical principles of adjusting the screening path and airflow.

[0074] The technical principle of the frequency-controlled multi-channel louvered screening equipment is as follows: The tobacco shred sorting method utilizes a frequency-controlled multi-channel louvered screening device, combined with dynamic adjustment of the screening path and airflow, aiming to improve the sorting accuracy and efficiency of tobacco shreds. The technical principle of the frequency-controlled multi-channel louvered screening equipment includes screen surface design and frequency conversion control. The screen surface design of the frequency-controlled multi-channel louvered screening equipment uses a louvered design, divided into multiple zones, with the screen aperture size gradually changing from large to small in each zone. During material flow, long filaments and clumps, due to their larger particle size, are retained on the screen surface; while smaller short filaments and fine stems fall through the screen apertures and enter the next conveying stage. The frequency conversion control of the frequency-controlled multi-channel louvered screening equipment aims to adjust the operating parameters of the screening equipment, such as vibration amplitude and screen passage time, according to the real-time status of the material. Through frequency conversion control, the screening process of tobacco shreds can be dynamically adjusted according to actual conditions to ensure optimal separation of different materials.

[0075] The technical principles behind adjusting the screening path and airflow are as follows: The tobacco shred sorting method utilizes adjustments to the screening path and airflow, including dynamic adjustment and real-time optimization. For dynamic adjustment, real-time monitoring of the material layer thickness, moisture content, and temperature is implemented before the material enters the screening equipment. Based on the monitored data, the operating parameters of the screening equipment, such as the screen vibration amplitude and the time it takes for the tobacco shreds to pass through the screen, are dynamically adjusted. These adjustments are achieved through frequency conversion control. For real-time optimization, the screening equipment intelligently adjusts its operating state based on the moisture content, temperature, and thickness characteristics of the tobacco shreds. Especially for tobacco shreds with high humidity or significant temperature variations, the screening effect can be optimized based on these changes, improving the accuracy and efficiency of tobacco shred sorting.

[0076] Therefore, the classification and sorting principle achieves efficient separation, precise control, and improved processing efficiency through real-time monitoring of tobacco materials and dynamic adjustment of the screening equipment's operating parameters. Long filaments, clumps, short filaments, and small stems can be effectively separated based on their different physical characteristics (such as particle size), avoiding cross-contamination and ensuring the efficiency of subsequent processing stages. Dynamic adjustment of the screening path and airflow allows the equipment to adapt to changes in the tobacco material in real time, ensuring the sorting process is always performed under optimal conditions, thereby improving the accuracy of the sorting effect. Due to the optimization of the sorting process, unnecessary processing steps can be reduced, such as avoiding the mixing of long and short filaments and the mishandling of small stems, thus improving overall production efficiency.

[0077] Secondly, the technical principle of the processing method for short tobacco fibers and fine stems mainly involves processing these materials through a multi-stage vertical diversion air separation system, divided into three stages: primary air separation, secondary air separation, and tertiary air separation. Each stage has different functions and roles, and combined with wind speed regulation and special equipment design, it ensures precise separation and efficient recycling, ultimately improving the quality of tobacco fibers and reducing waste.

[0078] In the primary air separation stage, the function and separation mechanism of air separation are discussed. The function of air separation is to feed the mixture of short fibers and fine stems into the primary air separation chamber. At this stage, a relatively high air velocity (2.5 m / s-3 m / s) separates the material into three categories: short fibers, stems, and a mixture of both. The separation mechanism works by using strong airflow to separate the loose short fibers and stems. Short fibers, being lighter, are more easily carried away by the airflow, while the relatively heavier stems remain in the air separation chamber. The short fibers are discharged separately, while the mixture of stems and short fibers enters the next stage of finer air separation. Regarding air velocity adjustment, a relatively high air velocity (2.5 m / s-3 m / s) is set for primary air separation to effectively separate the looser short fibers and stems. This higher air velocity helps to quickly separate the lighter short fibers from the heavier stems, improving the initial separation efficiency.

[0079] Secondary air separation includes fine separation and airflow regulation. Secondary air separation further separates the mixture of short fibers and stems separated after primary air separation; the air velocity is set at a lower level (2-2.5 m / s). This lower air velocity allows for finer separation, completely separating the short fibers and fine stems. Secondary air separation, with its lower air velocity, accurately separates fine stems and short fibers, ensuring complete separation. Furthermore, airflow regulation allows the material to enter the air separation zone more smoothly, reducing the blowing away of lighter materials and ensuring separation accuracy. Regarding airflow regulation, the secondary air separation uses a lower air velocity (2-2.5 m / s), making the fine separation process more stable and allowing for more thorough separation of short fibers and fine stems, ensuring they are not mixed.

[0080] In addition, a specially designed air separation device is used in the secondary air separation stage. This device is equipped with a conical impactor to disperse clumps of material. Especially for sticky stems and tobacco shreds, the impactor uses mechanical impact to separate them, preventing them from getting caught and affecting the separation effect. A material guide device is installed at the bottom of the secondary air separation chamber to guide the material falling along the straight pipe wall to the center of the chamber, thus achieving more efficient air separation.

[0081] The three-stage air separation process includes recovering tobacco shreds from the small stem sticks and the overall air separation function. After the two-stage air separation, the small stem sticks enter the third-stage air separation phase. At this point, the air speed is adjusted again (2-3 m / s) to recover any remaining tobacco shreds from the small stem sticks and to remove any substandard small stem sticks. The purpose of the three-stage air separation is to ensure effective recovery of tobacco shreds from the small stem sticks by readjusting the air speed, while simultaneously eliminating substandard small stem sticks through efficient sorting, thus ensuring the high quality of the final product. Regarding air speed adjustment, the three-stage air separation further improves the tobacco recovery rate by adjusting the air speed again (2-3 m / s) to recover tobacco shreds from the small stem sticks, ensuring the complete removal of small stem sticks.

[0082] Thirdly, the technical principle of the processing method for long filaments, clumps, and large stems utilizes an integrated "combing-cutting-stem separation" device. This integrated device combines a combing roller with a fixed blade to comb and cut the long filaments while effectively removing large stems. The purpose of this processing method is to improve the quality of tobacco processing and ensure the standardization and efficiency of the final product. This method requires the integrated combing-cutting-stem separation device, the combination of combing and fixed-length cutting, and the removal of large stems; it also necessitates dynamic adjustment through air separation.

[0083] The technical principle of the integrated combing-cutting-filament separation device includes a combing roller, a fixed-blade device, and a combination of combing and fixed-length cutting. The combing roller combs the filaments and spools, separating impurities (such as stalks) from the filaments through mechanical rotation, while simultaneously making the filaments smoother for subsequent processing. The fixed-blade device cuts the combed filaments to a predetermined length, ensuring uniform length for each filament and meeting processing requirements. The combination of combing and fixed-length cutting integrates the combing roller and the fixed-blade device, enabling both combing and removing large stalks during the combing process, thus improving processing efficiency and avoiding additional combing or cutting steps.

[0084] The technical principle of combining combing and length-cutting involves precise length control and simultaneous combing and cutting. This combination uses a fixed-blade device to cut the combed filaments to a preset length, ensuring consistent length for each filament. This process not only cuts the filaments but also removes defective portions, improving overall processing efficiency and quality. Furthermore, the simultaneous combing and cutting processes ensure filament processing quality while effectively reducing process complexity and equipment workload.

[0085] The technical principle behind removing large stems and stalks includes the removal of these stems and the precision of the combing process. Regarding the removal of large stems and stalks, the combing rollers, during the combing process, not only comb the long filaments but also effectively remove large stems and stalks. Through their mechanical action, the combing rollers separate larger, defective materials (such as large stems and stalks) from the tobacco. In terms of combing precision, the combing rollers, through a precise combing process, ensure the separation of stems and stalks from the tobacco, preventing large stems and stalks from being mixed into the finished tobacco product.

[0086] Furthermore, the dynamic adjustment of air classification ensures the effective separation of long filaments, clumps, and coarse stems by adjusting equipment parameters (such as roller speed and airflow). This is because, based on the flow rate and separation effect of different tobacco materials, the equipment can adjust operating parameters in real time to cope with material fluctuations and optimize the sorting effect. The technical principle of dynamic adjustment in air classification includes the principle of the air classification system and dynamic adjustment.

[0087] The technical principle of the air separation system mainly involves adjusting the roller speed and airflow. Roller speed adjustment controls the flow of material during the air separation process by regulating the roller speed. The roller speed affects the conveying speed and pressure of the tobacco material, thereby controlling the residence time and trajectory of the material in the air separation zone. Higher speeds result in faster material passage during screening, suitable for handling lighter short fibers or small stems. Lower speeds result in longer material residence times, aiding in the separation of heavier materials (such as large stems). Airflow adjustment uses airflow to separate the material from the airflow. The airflow can then be adjusted according to the characteristics of the tobacco material (such as density and size) to optimize the separation effect. Higher airflow helps separate lighter short fibers, while lower airflow helps retain heavier materials (such as large stems). Operators or the system adjust the roller speed based on the feed flow rate. When the tobacco material flow rate is high, the speed is increased to accelerate material passage; when the tobacco material is denser, the speed is decreased to increase the material residence time, aiding in more precise separation.

[0088] The principle of dynamic adjustment is to monitor the flow rate, humidity, and temperature parameters of the tobacco material in real time. The system automatically adjusts the rotation speed and airflow of the beating rollers to adapt the sorting process to the characteristics of different tobacco materials. Fluctuations in the tobacco material (such as changes in humidity, weight, or particle size) are fed back to the system via sensors, and the system dynamically adjusts the airflow and rotation speed to ensure that each type of material can be accurately and effectively separated. The system adjusts the airflow based on changes in the density and shape of the material. For short fibers, small stems, and light materials, the system increases the airflow to improve their separation effect; for heavier, larger stems, the airflow is relatively smaller to prevent them from being blown away.

[0089] Fourth, the technical principle of dynamic adjustment of the overall system is to achieve dynamic adjustment of the overall system through a closed-loop control system, so as to ensure that the air separation process can be optimized in real time according to the material characteristics and fluctuations.

[0090] The technical principle of a closed-loop control system is an adaptive control mechanism. The system dynamically adjusts operating parameters (such as wind force, wind pressure, and wind speed) based on real-time feedback information (such as material flow rate, wind speed, and separation effect), thereby optimizing the entire processing. Applied to the tobacco shreds upgrading and processing classification method with dynamic screening and multi-stage air separation control described in this invention, closed-loop control is used in the air separation system. By adjusting wind force and wind pressure, it ensures that the separation process at each stage adapts to material fluctuations, ultimately achieving the best separation effect. The operation of the closed-loop control system involves pipeline material transportation and wind force and wind pressure adjustment. Pipeline material transportation refers to the transportation of tobacco shreds between different levels of the air separation system, ensuring the continuity of tobacco shreds flow and reducing the negative impact of interruptions or flow rate changes. Wind force and wind pressure are important factors affecting the air separation effect. The closed-loop control system can adjust wind force and wind pressure based on real-time material flow rate, humidity, and density data. The closed-loop control system also adjusts corresponding parameters based on the material flow state, such as changes in tobacco shreds flow rate or density differences between different materials, to ensure the stability of the separation effect. Furthermore, the core of a closed-loop control system primarily lies in its feedback mechanism and automatic adjustment. The closed-loop control system uses sensors, such as flow meters, humidity sensors, and anemometers, to collect real-time data on material flow rate, humidity, and density, transmitting this data to the control system. The control system analyzes this data, determines the current air separation effect, and adjusts the airflow and pressure as needed. Automatic adjustment involves the system automatically adjusting airflow and pressure based on real-time data from the sensors; for example, when the material flow rate is too high, the system increases the airflow to maintain the separation effect; if the material flow rate is too low or the material humidity increases, the system reduces the airflow to avoid over-blowing.

[0091] The key characteristics of the dynamic adjustment principle of the overall system lie in the regulation of material flow rate and separation effect, the synchronous regulation of wind force and wind pressure, and the adaptability to fluctuations in material characteristics (such as humidity and particle size). Firstly, the regulation of tobacco material flow rate and separation effect involves the control system dynamically adjusting the wind force based on real-time monitoring of the material flow rate and separation effect. This wind force adjustment ensures the sorting effect of each piece of tobacco material; for example, lighter materials (such as short shreds) will be blown away under stronger winds, while heavier materials (such as large stems) require lower winds to prevent them from being mistakenly blown away. Secondly, the synchronous regulation of wind force and wind pressure is crucial, as wind force and wind pressure are two key parameters affecting the air separation effect. The closed-loop control system can synchronously adjust wind force and wind pressure to adapt to the characteristics of the material; for example, when the density or humidity of the material changes, the system will simultaneously adjust the wind force and wind pressure to maintain consistent sorting results. Third, the overall system can cope with fluctuations in the characteristics of tobacco materials (such as humidity and particle size), dynamically adjust equipment settings, and ensure that each type of tobacco material can be effectively separated. Whether it is tobacco with high humidity or tobacco material with large changes in flow rate, the overall system can adjust operating parameters according to the actual situation to ensure a stable and efficient sorting process.

[0092] (5) Technical effects

[0093] This invention discloses a tobacco shred classification and processing method with dynamic screening and multi-stage air separation control. Through a multi-channel louvered screening device controlled by frequency conversion and dynamic adjustment of the screening path and airflow, it can accurately and efficiently classify and sort tobacco shreds. The core advantage of this tobacco shred classification and sorting method lies in its ability to optimize and adjust in real time according to different material states (such as moisture and temperature), ensuring the best screening effect, improving the precision and efficiency of tobacco shred processing, providing a more flexible and intelligent processing solution, and significantly improving product quality and production efficiency.

[0094] Firstly, the tobacco processing and sorting method with dynamic screening and multi-stage air separation control described in this invention can achieve precise sorting and material diversion on a frequency-controlled multi-channel louvered screening device. Initially, long filaments and clumps, due to their larger particle size, are easily retained on the screen surface, while short filaments and small stems can pass smoothly through the screen holes, thus achieving preliminary sorting. Next, the tobacco processing and sorting method with dynamic screening and multi-stage air separation control, through the combination of the louvered screen surface and frequency conversion control, can effectively separate different material forms, such as long filaments, clumps, short filaments, and small stems, ensuring that each material is diverted to a different processing path. Furthermore, the frequency-controlled multi-channel louvered screening device can achieve precise real-time control, exhibiting strong adaptability. Dynamically adjusting the screening path and airflow allows the sorting process to be optimized according to the different characteristics of the materials. For example, tobacco with high moisture content will affect the screening effect, but by adjusting the equipment parameters in real time, the screening process can be ensured to be unaffected by external changes, ensuring the accuracy of sorting. In addition, by optimizing in real time based on the actual state of the incoming material (such as humidity and temperature), the equipment can adapt to various material changes, improving the system's flexibility and efficiency.

[0095] Secondly, the tobacco shreds quality improvement and classification method described in this invention, which features dynamic screening and multi-stage air separation control, improves the removal efficiency of short shreds and small stems through precise air separation design and optimization, reduces the mixing of unqualified materials, and thus significantly improves the quality of tobacco shreds.

[0096] The primary air separation stage achieves initial separation and improves efficiency. The tobacco processing and classification method with dynamic screening and multi-stage air separation control described in this invention uses primary air separation to initially separate the mixture of short fibers and stems. Short fibers are discharged independently, while the mixture of stems and short fibers is sent to the next stage of processing. Furthermore, primary air separation initially separates short fibers and stems, helping to avoid excessive cross-interference of materials in subsequent air separation stages and improving subsequent sorting efficiency. The secondary air separation stage achieves refined sorting and improves the quality of the tobacco product. In the tobacco processing and classification method with dynamic screening and multi-stage air separation control described in this invention, short fibers and fine stems are effectively separated through refined air separation in the secondary air separation stage, avoiding mixing of short fibers and fine stems. Secondary air separation improves the separation accuracy of short fibers and fine stems. Secondary air separation ensures that fine stems and short fibers are not mixed in the final tobacco product through precise sorting, thereby improving the quality of the final product. The tertiary air separation stage reduces waste and removes unqualified stems. This invention discloses a tobacco shreds processing and classification method with dynamic screening and multi-stage air separation control. Through three-stage air separation, residual tobacco shreds in small stems can be effectively recovered, reducing waste and increasing the tobacco shreds recovery rate. The three-stage air separation effectively removes unqualified small stems, ensuring that the final tobacco product does not contain excessive small stem impurities, thereby improving the purity and quality of the product.

[0097] During the air separation process, wind speed adjustment optimizes sorting efficiency through targeted wind speed control. This invention describes a tobacco shreds upgrading and processing classification method with dynamic screening and multi-stage air separation control. Different wind speed settings at each stage ensure that materials with different characteristics can be effectively processed at each stage, and wind speed adjustment maximizes sorting accuracy. Thus, through precise wind speed adjustment, a balance between material flowability and wind force is ensured, achieving optimal sorting results.

[0098] In the secondary air classification stage, the equipment is equipped with a conical impact device, and a material guiding device is installed at the bottom of the air classification chamber. The conical impact device helps to disperse clumps of material, avoiding the snagging of stems and tobacco shreds, thereby improving the classification effect and efficiency. The material guiding device at the bottom of the air classification chamber enhances material flowability. The tobacco material guiding device guides the material flow towards the center of the air classification chamber, ensuring that each material particle receives uniform airflow, thus optimizing the classification effect.

[0099] This invention discloses a tobacco shred classification method with dynamic screening and multi-stage air separation control. Through the application of three-stage air separation and wind speed adjustment technology, it effectively improves the removal efficiency of small stems and twigs. This technology can accurately separate short shreds and small stems and twigs while recovering tobacco shreds, reducing waste. The optimized air separation process ensures that the wind speed and equipment design at each stage provide accurate material sorting, thereby improving the overall sorting effect. Ultimately, the obtained tobacco shred product is purer, with a significantly reduced content of small stems and twigs, which not only improves product quality but also enhances the tobacco's competitiveness in the market.

[0100] Thirdly, the tobacco processing and classification method described in this invention, featuring dynamic screening and multi-stage air separation control, achieves efficient processing of long filaments, clumps, and large stems through an integrated combing-cutting-skewer separation device. The key technology of this method lies in integrating combing, cutting, and stem removal into a unified process, improving production efficiency and tobacco quality. This method not only enhances production precision and speed but also provides higher-quality raw materials for subsequent tobacco processing. The key technologies of this method include the use of an integrated combing-cutting-skewer separation device, the combination of combing and fixed-length cutting, and the removal of large stems.

[0101] The integrated combing-cutting-shred separation device achieves the combing and processing of long filaments and clumps, fixed-length cutting, and removal of large stems and stalks. Combing and processing effectively opens the clumps and cuts the opened clumps and filaments to a fixed length, releasing any large stems and stalks trapped within. These large stems and stalks are then removed through shred separation. Fixed-length cutting uses a fixed-blade device to precisely cut the filaments to the specified length, ensuring each filament meets standards and improving the uniformity of the tobacco. During the combing process, large stems and stalks are removed, preventing these substandard materials from mixing into the final tobacco, thus improving the purity and quality of the tobacco.

[0102] The combination of combing and fixed-length cutting improves production efficiency and ensures processing consistency. By simultaneously combing and cutting, multiple steps can be completed in the same process, reducing equipment switching and manual intervention, thus improving overall work efficiency. Furthermore, the uniform cutting of long filaments ensures that the length and quality of each tobacco shred are consistent, meeting the requirements of subsequent processing techniques.

[0103] Removing large stems and stalks improves the purity of tobacco and reduces waste. This invention describes a tobacco processing and classification method with dynamic screening and multi-stage air separation control. By effectively removing large stems and stalks, the purity of the final tobacco is greatly improved, avoiding the negative impact of large stems and stalks on tobacco quality and smoking experience. Furthermore, the timely removal of large stems and stalks reduces unnecessary waste and the mixing of substandard materials in subsequent processing.

[0104] In terms of dynamic adjustment of air separation, the processing methods for long filaments, clumps, and large stems can improve separation accuracy, processing efficiency, and the quality of tobacco products. Firstly, improving separation accuracy requires adapting to material fluctuations and optimizing the separation of long filaments and clumps. Dynamic adjustment technology allows the equipment to react to different material characteristics (such as flow rate and humidity), ensuring that the air separation system maintains optimal separation even under significant material fluctuations. This dynamic adjustment ensures that each type of material (such as long filaments, clumps, and large stems) is accurately sorted. Optimizing the separation of long filaments and clumps is achieved by adjusting the airflow and rotation speed, ensuring effective separation of long filaments and clumps and preventing them from mixing with other materials, which would affect the quality of subsequent processing. Secondly, improving processing efficiency reduces waste and increases processing speed. Dynamic adjustment ensures accurate separation of materials during the air classification process, preventing unqualified materials (such as large stems) from mixing with qualified materials and reducing waste. Furthermore, by adjusting equipment parameters in a timely manner when processing long filaments, clumps, and large stems, the air classification system can operate efficiently under different material characteristics. This not only improves production efficiency but also reduces excessive processing steps, making the entire sorting process faster and more efficient. Thirdly, it improves the quality of tobacco products by reducing unqualified materials and ensuring that each type of material meets process requirements. Dynamic adjustment prevents unqualified large stems or mixed short filaments from being introduced into the next process, ensuring that the final tobacco product meets standards. After long filaments, clumps, and large stems are separated, they are sent to subsequent processing stages, effectively preventing the mixing of tobacco of different forms and improving the purity and uniformity of the final tobacco.

[0105] Therefore, the tobacco processing and classification method with dynamic screening and multi-stage air separation control described in this invention achieves efficient processing of long filaments, clumps, and large stems through an integrated combing-cutting-separation device. Firstly, it achieves efficient separation and processing; by combining the combing roller and the fixed-blade device, long filaments, clumps, and large stems are processed on the same equipment, greatly improving work efficiency. Precise operation ensures the consistency of long filament length and effectively removes large stems, reducing the mixing of substandard materials. Secondly, by removing large stems and optimizing the length of long filaments, the final product meets process requirements, improving the purity, uniformity, and user experience of the tobacco. Thirdly, the combination of combing and fixed-length cutting is completed in one device, simplifying the process, reducing multiple operations and equipment changes, and improving production line efficiency. Fourthly, the processing of long filaments and clumps, along with the removal of large stems, are carried out in the same process, reducing material processing time and process complexity, making the production process smoother.

[0106] Fourthly, the tobacco shreds upgrading and processing classification method with dynamic screening and multi-stage air separation control described in this invention optimizes the overall system through the dynamic adjustment of a closed-loop control system. By adjusting the wind force and air pressure in real time, the system can automatically adjust the equipment settings according to changes in material flow rate, humidity, and density to ensure stable and efficient sorting results. The introduction of the closed-loop control system makes the entire processing process more intelligent and automated, while improving production efficiency and product quality and reducing manual intervention. Firstly, regarding the stability of the sorting effect, the tobacco shreds upgrading and processing classification method with dynamic screening and multi-stage air separation control described in this invention, through closed-loop control, allows the system to adjust the wind force and air pressure in real time according to the flow characteristics of the material, ensuring that each type of material can be effectively separated. This allows the system to maintain consistent sorting results even under conditions of large material fluctuations, avoiding excessive mixing of unqualified materials into the finished product. Secondly, regarding improved processing efficiency, the tobacco shreds upgrading and processing classification method described in this invention, featuring dynamic screening and multi-stage air separation control, ensures that each air separation stage operates under optimal conditions, avoiding over- or under-separation during the air separation process. For example, when the material flow rate is high, the system automatically increases the airflow to ensure rapid separation of lighter materials without affecting the processing effect of heavier materials, thereby improving sorting efficiency. Thirdly, regarding reduced manual intervention, the closed-loop control system automatically adjusts the airflow and air pressure, making the operation process more intelligent and reducing the need for manual intervention. This not only improves operational efficiency but also reduces instability or operational errors caused by human factors. Fourthly, regarding adaptability to different material characteristics, the tobacco shreds upgrading and processing classification method described in this invention, featuring dynamic screening and multi-stage air separation control, automatically adjusts the system according to the humidity, flow rate, and density characteristics of different materials, ensuring that the sorting effect remains optimal regardless of changes in the material's state. Furthermore, through real-time adjustment, the system can adapt to various material fluctuations, avoiding the tedious operation of manually adjusting equipment parameters. Fifthly, it improves product quality. The tobacco shreds quality improvement and classification method described in this invention, which features dynamic screening and multi-stage air separation control, ensures the quality of tobacco shreds through stable sorting effect and efficient processing flow. Furthermore, by effectively separating unqualified materials such as long filaments, clumps, and coarse stems, the purity and uniformity of the final product are greatly improved. Attached Figure Description

[0107] Figure 1 This is an overall flowchart of a tobacco shreds quality improvement and classification method with dynamic screening and multi-stage air separation control as described in this invention;

[0108] Figure 2 This is an exploded view of the core structure of the tobacco shredding device in step 4 of the tobacco shredding and fixed-length broken shredding treatment method with dynamic screening and multi-stage air separation control described in this invention.

[0109] Figure 3 This is a longitudinal sectional view of the core structure of the tobacco shredding device in step 4 of the tobacco shredding and fixed-length broken shredding treatment in the tobacco shredding and sorting method with dynamic screening and multi-stage air separation control described in this invention.

[0110] Figure 4 This is a top external view of the shredding device in step 4 of the tobacco shredding and fixed-length broken shredding treatment in the tobacco shredding and sorting method with dynamic screening and multi-stage air separation control described in this invention.

[0111] Figure 5 This is a structural diagram of the tobacco shreds combing and fixed-length broken shreds treatment device in step 4 of the tobacco shreds upgrading and processing classification method with dynamic screening and multi-stage air separation control described in this invention.

[0112] Figure 6 This is a front view (frontal perspective) of the beating roller assembly (knife roller) in the tobacco shreds quality improvement and classification method with dynamic screening and multi-stage air separation control described in this invention.

[0113] Figure 7 This is a top-view perspective of the beating roller assembly (knife roller) in the tobacco shreds upgrading and sorting method with dynamic screening and multi-stage air separation control described in this invention. Figure 1 (right front angle);

[0114] Figure 8 This is a top-view perspective of the beating roller assembly (knife roller) in the tobacco shreds upgrading and sorting method with dynamic screening and multi-stage air separation control described in this invention. Figure 2 (Left rear angle);

[0115] Figure 9 This is a top-down perspective view of the entire production line of the tobacco shreds upgrading and processing classification method with dynamic screening and multi-stage air separation control described in this invention (mainly showing the feeding and output systems).

[0116] [Explanation of Figure Markers]:

[0117] Cutting tool assembly 1; Moving tool assembly shaft 2; Moving tool assembly 3; Fixed tool assembly 4; Wire breaking mechanism 5; Moving tool assembly section 6; Fixed tool holder 7;

[0118] 8. Primary air separation mechanism; 9. Primary air separation outlet; 10. Primary air separation nozzle; 11. Secondary air separation mechanism; 12. Secondary air separation outlet;

[0119] 13. Secondary air separation outlet; 14. Tertiary air separation mechanism; 15. Feed inlet; 16. Primary settling box; 17. Primary dust removal fan; 18. Secondary settling box;

[0120] 19. Secondary air classifier dust collector fan; 20. Discharge belt conveyor; 21. Primary air classifier blower; 22. Primary air classifier dust collector fan; 23. Local dust collector;

[0121] 24. Primary air classifier fan; 25. Secondary air classifier dust removal fan; 26. Qualified short fiber conveyor belt. Detailed Implementation

[0122] This invention discloses a tobacco shred classification and processing method with dynamic screening and multi-stage air separation control. The core objective is to maximize the quality of tobacco shreds through refined sorting and processing, ensuring the purity and consistency of the final product to meet quality standards. Simultaneously, dynamic screening, multi-stage air separation, and precise sorting control reduce the generation of waste and substandard materials, thereby effectively improving resource utilization. To enhance production efficiency, this invention introduces an intelligent control and automated processing system to optimize the processing, reduce manual intervention, and improve processing accuracy and stability. Furthermore, this invention emphasizes resource recycling by reprocessing substandard materials to avoid resource waste and achieve sustainable development goals.

[0123] Figure 1 This is an overall flowchart of the tobacco shreds upgrading and processing classification method with dynamic screening and multi-stage air separation control as described in this invention. It shows the overall path of tobacco shreds upgrading and processing from left to right, mainly divided into three functional areas: the first is a processing unit for long filaments, shred bundles, and coarse stems, including combing, shred bundle breaking, and fixed-length filament cutting; the second is a multi-stage air separation unit for short filaments and fine stems, which separates, purifies, and recovers short filaments through primary, secondary, and tertiary air separation; the third is a coarse stem removal unit, which uses an air separation device to identify and directionally discharge coarse stems. The qualified short filaments and qualified filaments generated by the above units are collected on the main line and uniformly sent to subsequent processing stages, realizing centralized processing of qualified products and effective diversion of unqualified materials.

[0124] Figure 1The overall process of a tobacco shreds quality improvement and processing classification method with dynamic screening and multi-stage air separation control is shown below. The main steps are as follows: First, the tobacco shreds enter the production line and are divided into two categories through the "tobacco shreds classification and sorting" process: long shreds, shred bundles, and coarse stems, and short shreds and fine stems. They are then processed along two paths: Path 1 is the long shreds and shred bundles processing path, where the long shreds and shred bundles undergo physical treatments such as combing, shred bundle breaking, and fixed-length shred cutting to produce qualified tobacco shreds and coarse stems; subsequently, the coarse stems are further separated by an air separation device, directing the coarse stems out of the production line, and collecting the qualified tobacco shreds from them for subsequent processes. Path 2 is a multi-stage air separation path for short filaments and fine stems, involving first, second, and third-stage air separation sequentially: First-stage air separation initially separates the mixture of short filaments and fine stems into qualified short filaments and a mixture of "fine stems + a small amount of short filaments"; second-stage air separation further separates this mixture, obtaining qualified short filaments and fine stems still containing a small amount of short filaments; third-stage air separation continues to recover residual short filaments from the fine stems and finally discharges the fine stems from the production line. All qualified tobacco recovered from the two paths is finally collected and enters the "subsequent processing" process for cutting, drying, and other production processing. The material discharged from the production line includes two types: firstly, coarse stems from the "coarse stem air separation" process, which are directly discharged from the production line after separation according to regulations; secondly, fine stems from the "third-stage air separation" process, which are also discharged from the production line through a separate channel after the recovery of residual short filaments.

[0125] Figure 2 This is an exploded view of the core structure of the beating device in step 4 of the tobacco shreds upgrading and processing classification method with dynamic screening and multi-stage air separation control, as described in this invention. The exploded view shows the beating device, including a top locking ring and positioning plates; a central core structure (blade-type rotor); and a row of fixed blades on the right side. The exploded view of the beating device visually demonstrates the assembly relationship of each component; it clarifies that the rotating blade group and the fixed blade group are separate structures, facilitating maintenance and cleaning. The exploded view of the beating device illustrates how the invention achieves the breaking up and fixed-length cutting of long filaments and clumps of tobacco.

[0126] Figure 3 This is a longitudinal sectional view of the core structure of the tobacco shredding device in step 4, combing and fixed-length broken shredding, of the tobacco shredding classification method with dynamic screening and multi-stage air separation control described in this invention. The vertical cross-section shows the dense arrangement of the internal structure; the blades are evenly distributed and densely packed from top to bottom; the fixed blade area is visible on the right side; the outer shell is an integrally enclosed structure. The longitudinal sectional view of the tobacco shredding device shows the movement trajectory of the tobacco material during operation; it emphasizes that after the long shredder enters, it undergoes multiple stages of impact or cutting from top to bottom, ultimately outputting uniform, fixed-length tobacco material.

[0127] Figure 4This is a top external view of the beating device in step 4 of the tobacco shreds upgrading and processing method with dynamic screening and multi-stage air separation control, as described in this invention. The top view of the beating device shows the external connection structure without any sectioning; the center is the main shaft positioning hole; and there are multiple guide blocks around the perimeter. The top external view of the beating device describes the connection method between the top and the feed and protective cover; it also shows the connection method of the top cover or locking ring structure.

[0128] Figure 5 This diagram illustrates the structure of the beating device in step S4 of the tobacco shreds upgrading and processing method with dynamic screening and multi-stage air separation control, as described in this invention. The overall structure is a vertical column with multiple comb teeth or blades arranged at intervals from top to bottom. The device contains rows of comb teeth or fixed blades; the top is the feed inlet, and the bottom is the discharge channel, forming a multi-layered dispersing channel. The beating device corresponds to process step S4—combing and fixed-length cutting—and primarily achieves refined shaping and specification control of long filaments and clumps. Internally, it features multi-stage arranged blades or comb teeth. After entering the device from the top feed inlet, the tobacco shreds fall step by step along the vertical channel. With the combined action of multiple comb teeth and fixed blades, the long filaments and clumps are physically combed. This effectively removes tangled clumps and irregular materials, ensuring a loose and uniform tobacco structure. Meanwhile, during the combing process, the tobacco shredding device also achieves fixed-length tobacco cutting through a multi-stage cutting mechanism, ensuring that the tobacco shreds are continuously cut at different falling heights, thereby precisely controlling the length of the tobacco shreds and avoiding excessive length or unevenness. The design of the tobacco shredding device ensures that the output tobacco shred length meets the process requirements, providing a standardized raw material basis for subsequent air classification and blending processing. Figure 8 The tobacco shredding device in this system demonstrates significant engineering and technological value in its structural design. Employing a longitudinal modular layout, it creates a continuous, gentle, and directional tobacco processing channel through a multi-stage shredding structure, adaptable to tobacco materials of varying densities and lengths, thus enhancing the process's adaptability and stability. In terms of high-efficiency processing, rows of combs or blades ensure thorough combing and shaping of the tobacco during its descent, effectively improving the uniformity of the tobacco and the processability of subsequent steps. Simultaneously, the shredding device achieves balanced distribution, with each layer of blades or tooth rows rationally distributed and consistently spaced, avoiding localized over-cutting or processing dead zones, thereby ensuring stable tobacco quality and consistent structure. The overall structural design of the shredding device balances processing efficiency and product quality, making it a key core component in the tobacco combing and length control process.

[0129] Figures 6-9The display shows the three-dimensional structure and partial cross-sectional view of the three-stage vertical air classifier, which is the core mechanism for separating short filaments and fine stems in the entire production line. It is responsible for efficiently separating the screened short filaments and fine stems, and effectively recovering the tobacco shreds from the separated fine stems.

[0130] Figure 6 This is a front view (frontal perspective) of the three-stage air separation device in the tobacco shreds upgrading and processing classification method with dynamic screening and multi-stage air separation control described in this invention. It shows two vertical cylindrical devices (vertical air separation cylinders) installed side-by-side on a platform. In the front view of the beating roller assembly (knife roller), the upper feed inlet is funnel-shaped; there is a rectangular observation window in the middle; and the lower part connects to the motor drive device; the two devices share a platform. The front view of the beating roller assembly (knife roller) demonstrates the secondary and tertiary air separation devices of the multi-stage vertical air separation equipment, used for the separation and recovery of fine stems and short filaments; the lower motor drive is used to adjust the wind speed or operate the induced draft fan; the observation window facilitates inspection of whether there is material blockage or dust accumulation inside the cylinder.

[0131] Figure 7 This is a top-view perspective of the three-stage air separation device in the tobacco shreds upgrading and processing classification method with dynamic screening and multi-stage air separation control described in this invention. Figure 1 (Right front angle) Fully displaying the dual-cylinder air separator, feeding system, blower, platform structure, and conveyor channel. In the top-view perspective of the wire-beating roller assembly (knife roller), the two cylindrical air separators on the left and the two square boxes at the top represent the screening or primary air separation device; the main sorting bin in the middle has multiple discharge ports; conveyors and air ducts connected from different directions are visible. This is a typical modular, multi-stage sorting structure.

[0132] Figure 8 This is a top-view perspective of the three-stage air separation device in the tobacco shreds upgrading and processing classification method with dynamic screening and multi-stage air separation control described in this invention. Figure 2 (Left rear angle) It is also a panoramic view, but the entire device is viewed from the opposite direction. Figure 8 The discharge port, collection pipe and bottom air classifier are clearly visible; the fan, platform, control motor and screw or belt conveyor are also clearly visible; all discharge ports are concentrated at the bottom of the equipment for easy unified processing. Figure 8 It more clearly shows the connection between the air separation system and the conveying device; it is a view of the overall line structure from the "post-processing direction", and the entire equipment also supports the output integration of S6 subsequent processing.

[0133] Figure 9 This is a top-view perspective view of the three-stage air separation device in the tobacco shreds upgrading and processing classification method with dynamic screening and multi-stage air separation control described in this invention (mainly showing the feeding and output system). Figure 9In the middle section, a feeding conveyor system is located on the left, used to send raw tobacco shreds into the main processing unit via a conveyor belt; the core processing area of ​​the entire line is in the middle, including a vibrating screen device (S1.1); and the finished product output system is located on the right, responsible for conveying the qualified tobacco shreds obtained after multi-stage processing to subsequent processing stages. The entire set of equipment adopts a modular design, with each processing unit arranged independently yet interconnected, and a clear material flow direction, forming a continuous process flow from raw material feeding and sorting to finished product output.

[0134] Example 1: Specific Implementation of the Tobacco Shavings Quality Improvement and Classification Method with Dynamic Screening and Multi-stage Air Separation Control as Described in this Invention

[0135] The present invention discloses a method for classifying and improving tobacco shreds with dynamic screening and multi-stage air separation control. The main operation steps include tobacco shred classification, sorting, combing, and air separation. The specific operation steps are as follows:

[0136] S1. Tobacco Shred Classification and Sorting: A multi-channel louvered screening device with variable frequency control and an adjustable screening path system, combined with PLC and AI algorithms, dynamically adjusts the vibration frequency, screen angle, and wind speed to achieve intelligent sorting control based on the physical characteristics of the tobacco shreds. This ensures a short shred recovery rate of ≥90% and a mismixing rate of ≤5%, breaking through the limitations of traditional static screening.

[0137] Technical bottlenecks due to poor adaptability to raw materials;

[0138] S1.1 Vibrating Screening: Using vibration, tobacco shreds are divided into two main categories based on their physical shape (such as length and thickness): long shreds, shred bundles, and large stems, and short shreds and small stems. By using a multi-channel louvered screening device with frequency conversion control and different screen hole structures, efficient physical grading of tobacco shreds based on length and thickness is achieved. This breaks through the bottlenecks of traditional screening methods in terms of accuracy and adaptability in multi-dimensional particle shape recognition and primary screening of compound materials, significantly improving subsequent sorting efficiency and material purity.

[0139] The vibrating screening operation uses a multi-channel louvered screening device with frequency conversion control to vibrate the tobacco material through the screen surface. The screen surface has screen holes of different specifications, and the material is divided into two main categories according to its length and thickness: long filaments, clumps, and large stems, and short filaments and small stems.

[0140] The vibrating screening equipment is a frequency-controlled multi-channel louvered screening equipment that divides tobacco materials into two main categories: long filaments, clumps, and coarse stems, and short filaments and fine stems.

[0141] The purpose of the vibrating screen is to initially separate the tobacco into different material types through vibrating screen, which can reduce material mixing during the processing and improve the efficiency of subsequent processing.

[0142] The significance of the vibrating sieve is to achieve preliminary sorting and ensure that different materials can be treated in a targeted manner during subsequent processing. That is, through this sieve method, long filaments, clumps, and coarse stems are sent to different processing stages, while short filaments and fine stems are sent to different processing stages to avoid mixing.

[0143] S1.2 Adjusting the Screening Path: Based on the characteristics of the tobacco material, the sorting ratio is controlled by adjusting the position and path length of the material entering the sorting and classifying equipment. The sorting ratio of long filaments, clumps, and large stems is flexibly adjusted compared with that of short filaments and small stems. By introducing an intelligent control system based on real-time acquisition of multiple parameters, combined with PLC, fuzzy control and AI algorithms, the screen angle, vibration frequency and wind speed are adjusted in a coordinated manner. This achieves dynamic optimization control of the tobacco path length and feeding position, thus breaking through the problems of static and unadjustable screening paths and fixed sorting ratios in traditional methods, and significantly improving the adaptive screening accuracy and recovery efficiency under complex material conditions.

[0144] The operation method of adjusting the screening path is to adjust the position and path length of the material entering the classification and sorting equipment according to the different physical characteristics of the tobacco material, such as humidity and particle size. In this way, the material sorting ratio can be controlled by adjusting the path length.

[0145] The operation of adjusting the screening path also includes: based on the real-time parameters of the collected tobacco material humidity, thickness, temperature and air separation recovery rate, automatically adjusting the screen angle, vibration frequency and wind speed through PLC control system, fuzzy control algorithm or AI algorithm, so as to achieve a short fiber recovery rate of not less than 90% and control the mismixing rate to below 5%.

[0146] The operating device for adjusting the screening path is an adjustable vibrating screen device, which has an adjustable vibrating screen structure for adjusting the screen surface angle or vibration frequency; the adjustable vibrating screen device has a screen surface angle adjustment mechanism, a vibration frequency adjustment module, and an air separation auxiliary system (such as an air speed adjustment module), which can adjust the operating status in real time according to control commands.

[0147] The system is equipped with a variety of sensors and data acquisition modules to monitor the following key parameters in real time: the thickness distribution, humidity and temperature of the tobacco material, the tobacco recovery rate after air separation during the sorting process, and the proportion and mixing rate of various materials after sorting.

[0148] The control system for adjusting the screening path adopts a PLC control system, combined with fuzzy control and AI algorithm, to achieve intelligent optimization and adjustment of key parameters such as screen angle, vibration frequency, and wind speed; the AI ​​algorithm learns and optimizes the processing strategies for different tobacco characteristics based on real-time collected data and historical operation models, thereby improving automation and adaptability.

[0149] The purpose of adjusting the screening path is to flexibly control the classification ratio of different types of tobacco shreds, ensuring that the materials can achieve the best separation effect during the sorting process and meet the process requirements.

[0150] The dynamic adjustment of key parameters for the screening path includes: when the material moisture content increases, the control system automatically reduces the vibration frequency and increases the screen angle to slow down the material movement speed, increase the screening time, and prevent wet material from sticking together and causing incomplete sorting; when the tobacco thickness exceeds the standard, the system increases the wind speed and vibration frequency to enhance the air separation capability and screening efficiency; when the recovery rate decreases or the mixing rate increases, the system calls the optimal screen angle and wind speed combination recommended by the AI ​​model to automatically adjust the screening path and material conveying position to achieve real-time optimization.

[0151] The significance of adjusting the screening path is that it allows for flexible adjustment of the classification ratio, ensuring that the sorting ratio of various materials meets the requirements of subsequent processing, thereby improving the processing effect and efficiency.

[0152] S2. Separation of long filaments, clumps, and coarse stems from short filaments and fine stems: By linking the results of the vibrating sieve with the material distribution device, and combining the wind power control and flow guidance system, the synchronous grouping and physical isolation of long filaments and short filaments are achieved, effectively preventing mismixing and improving the accuracy of material flow. This breaks through the inherent limitations of traditional processes where different types of tobacco filaments are easily mixed, affecting processing efficiency.

[0153] S2.1 Separation Output: The sorted and classified long filaments, clumps, and coarse stems are output in one group, while short filaments and fine stems are output in another group, avoiding mixing of short filaments and fine stems; by coordinating the results of vibrating screening with the material distribution device, long filaments and short filaments are simultaneously grouped and output to independent processing paths according to the physical classification results, achieving flow direction control based on particle morphology differences, breaking through the limitations of cross-flow and uncontrollable processing paths of materials after traditional screening, and significantly improving the separation accuracy and processing efficiency of subsequent processes;

[0154] The separation and output operation method is to divide the tobacco shreds after vibrating screening into two groups according to the classification results: one group is long shreds, shred bundles, and coarse stems, and the other group is short shreds and fine stems, and each group is output to different processing equipment.

[0155] The purpose of the separation output is to ensure that long filaments, clumps, and coarse stems are effectively separated from short filaments and fine stems, avoiding mixing and preventing them from affecting processing efficiency and quality in subsequent processing.

[0156] The separation and output equipment is a vibrating screen and a material distribution device, which can separate the tobacco shreds after vibrating and screening into categories. One group of long shreds, shred bundles, and large stems are output, and another group of short shreds and small stems are output.

[0157] The significance of the separation output is to ensure that different types of tobacco materials are effectively separated, and to avoid mixing of different types of tobacco materials in subsequent processes, which would affect processing efficiency and tobacco quality.

[0158] S2.2 Avoid Mixing Issues: By separating, short fibers are ensured not to mix with long fibers, preventing long fibers from increasing the flow rate during processing and affecting processing efficiency; at the same time, small stems are prevented from entering the long fiber processing stage, ensuring the rejection effect; by setting up a precise flow diversion device and wind power control system, dynamic isolation and path limitation of the flow direction of different shaped tobacco fibers after sorting are achieved, breaking through the problem of material mixing due to gravity or inertia after traditional screening, ensuring that short fibers and small stems do not mistakenly enter the long fiber processing stage, and guaranteeing the efficiency and rejection accuracy of subsequent processing from the source;

[0159] The aforementioned method for avoiding mixing issues involves using appropriate material guiding devices to ensure that short filaments and long filaments do not mix, thus preventing any impact on subsequent long filament processing. At the same time, by rationally allocating the flow rate, short filaments and small stems are prevented from entering processes that should not be processed.

[0160] The purpose of avoiding mixing issues is to ensure that different materials are processed as needed, thereby improving processing efficiency. For example, short fibers should not be included in the processing flow of long fibers to avoid affecting the processing efficiency of long fibers;

[0161] The operating equipment mentioned above to avoid mixing problems is a diversion device or a wind control system. The diversion device or wind control system is used to prevent short filaments and small stems from mixing with long filaments and spools.

[0162] The significance of avoiding mixing issues is to prevent the flow rate from increasing during the processing of long filaments, which would affect processing efficiency; at the same time, it ensures that short filaments and small stems do not enter the long filament processing stage, thus ensuring the removal effect.

[0163] S3. Processing of short filaments and fine stems: By constructing a three-stage vertical air separation system with feedback adjustment channels, and integrating PLC, fuzzy control and AI algorithms to dynamically adjust the wind speed, feeding frequency and path angle, high-precision separation of short filaments and fine stems and tobacco filament recovery are achieved under complex raw material conditions, breaking through the limitations of traditional air separation technology in the fine separation and adaptive control of mixtures.

[0164] S3.1 Multi-stage air separation: The mixture of short filaments and fine stems is separated by air separation and passed through a three-stage air separation system. By constructing an integrated three-stage vertical air separation system with adjustable wind speed duct, vibrating feeding and feedback adjustment channel, combined with PLC, fuzzy control and AI algorithm to adaptively and dynamically adjust wind speed, wind pressure and feeding path, high-precision classification and recycling of short filaments and fine stems mixture is achieved, breaking through the technical bottleneck of traditional air separation system's slow response to humidity fluctuations and material density differences and high mismixing rate.

[0165] The purpose of the multi-stage air separation is to effectively separate short tobacco fibers and small stems through the multi-stage air separation system, maximize the recovery of mixed tobacco fibers, and remove unqualified small stems to improve the quality of tobacco fibers.

[0166] The multi-stage air separation operation involves feeding a mixture of short filaments and fine stems into a three-stage air separation system for diversion and fine separation.

[0167] The multi-stage air separation equipment is a multi-stage vertical air separator, which separates short filaments and fine stems by diverting the mixture of short filaments and fine stems, and recovers the mixed tobacco filaments.

[0168] The multi-stage vertical air classifier has an internal adjustable air duct structure and is combined with a vibrating feeding device to achieve efficient diversion, grading and air separation of the mixture of short filaments and fine stems; and there is a feedback adjustment channel between each stage of the air classifier to achieve adaptive adjustment of the sorting path.

[0169] The multi-stage air separation process uses PLC, fuzzy control, and AI optimization algorithms to jointly control the wind speed, feeding vibration frequency, and air separation path. Based on the collection of key parameters such as material thickness, humidity, and short fiber recovery rate after air separation, the system dynamically adjusts the operating status to maintain a short fiber recovery rate of no less than 95% and a mismixing rate of no more than 2%. When abnormal indicators are detected, the system adjusts the air pressure distribution, feeding angle, and vibration frequency to achieve accurate separation and efficient recovery of short fibers and small stems.

[0170] The control parameter acquisition module of the multi-stage air separation system is equipped with a variety of sensors and online detection devices to collect and monitor the following key parameters in real time, including the thickness, temperature and humidity of the material before it enters, the recovery rate of tobacco after each stage of air separation, the proportion and purity of short filaments and fine stems in each output stream and the mismixing rate, energy consumption data and operating indicators.

[0171] The multi-stage air separation control method involves the system control unit adopting a PLC control system, combined with fuzzy control logic and AI optimization algorithm, to dynamically adjust parameters based on real-time collected data, including the air speed and air pressure of each stage of air separation, the frequency and amplitude of the vibrating feeder, and the feeding speed and diversion channel angle of the tobacco material; the system performs predictive adjustments based on historical data and current detection results, realizing adaptive control of the system for different batches and characteristics of tobacco.

[0172] The key parameters of the multi-stage air separation process are dynamically adjusted, including: when the material moisture content is high, the system automatically reduces the wind speed to prevent wet tobacco from adhering and agglomerating during the air separation process, affecting the separation effect, while increasing the vibration frequency to speed up the conveying; when the short filament recovery rate decreases, the AI ​​control module automatically adjusts the air pressure distribution of the second and third stages in the three-stage air separation system to enhance the recovery of mixed short filaments; when the mismixing rate increases, the system automatically slows down the feeding speed and adjusts the matching relationship between the diversion angle and the wind speed to re-recover the residual short filaments in the fine stems; when the temperature rises and causes a change in tobacco density, the AI ​​algorithm adjusts the wind speed level according to the model to achieve precise compensation.

[0173] The significance of the multi-stage air separation is to improve the separation efficiency of short tobacco fibers and fine stems, while recovering tobacco fibers from fine stems to avoid waste and improve resource utilization.

[0174] S3.11 Primary Air Classification: The mixture of short fibers and fine stems is separated into three categories: short fibers, stems, and a mixture of short fibers and stems. In the same air classification stage, a "three-way separation" strategy based on aerodynamic differences (density / morphology / specific surface area) and wind speed-pressure linkage control is introduced to separate the mixture into short fibers, stems, and short fiber-stem mixtures in one go. This is matched with subsequent cascaded feedback to minimize the loss of short fibers, breaking through the technical limitations of traditional primary air classification, which can only separate into two categories and is difficult to balance recovery rate and purity.

[0175] The purpose of the first-stage air separation is to initially separate the mixture of short fibers and fine stems into three categories: short fibers, stems, and a mixture of short fibers and stems.

[0176] The short filaments refer to the separated short filament material;

[0177] The term "stem" refers to the separated coarse stem material;

[0178] The mixture of short filaments and stems refers to a mixture in which the short filaments and stems cannot be completely separated and still require further processing;

[0179] The function of the primary air separation is to initially separate short fibers and stems by adjusting the air force, providing a basis for subsequent fine processing. That is, the primary air separation controls the air speed and air pressure to initially separate materials of different densities (such as short fibers and stems).

[0180] S3.12 Secondary air separation: This process performs fine sorting on the mixture of short filaments and fine stems, separating the short filaments from the fine stems. Based on the primary air separation, it introduces fine air field shaping and dynamic differential pressure threshold control. It utilizes the slight differences in density, morphology, and drag coefficient between the short filaments and fine stems to achieve precise "narrow band" separation. It is also linked with the feedback parameters of the cascaded systems to balance high purity and high throughput, breaking through the technical bottleneck of traditional secondary air separation in that it is difficult to optimize purity and capacity at the same time.

[0181] The purpose of the secondary air separation operation is to further separate the short filaments and fine stems from the mixture obtained after the primary air separation.

[0182] The purpose of the secondary air separation is to use more precise airflow control to completely separate short fibers from fine stems. At this time, the density difference between short fibers and fine stems allows them to be excluded separately during the air separation process. Through fine separation, the mixture between short fibers and stems is processed more thoroughly, thereby improving the effect of subsequent processing.

[0183] S3.13 Three-stage air separation: The separated small stems are air-separated for recycling, recovering the tobacco shreds mixed in, and the small stems are discharged from the production line; after the first two stages of separation, the small stems are further sorted by a fine air field with "recycling priority" in the fine air field branch. Through dynamic air pressure, air velocity compensation and discharge channel directional control, residual short fibers are efficiently recovered from the small stems and the small stems are discharged at the end of the process at the same time. This takes into account both resource recovery rate and product purity, and breaks through the limitation of traditional final-stage air separation which can only remove single components and is difficult to recover.

[0184] The purpose of the three-stage air separation operation is to recover the small stems separated after the two-stage air separation, recover the tobacco shreds mixed in, and discharge the small stems from the production line;

[0185] The three-stage air separation process is required to recover mixed tobacco shreds and remove small stems;

[0186] The recovery of the mixed tobacco shreds refers to the process where, during the secondary air separation, some fine tobacco shreds are still mixed in with the small stems. At this point, the tertiary air separation, through further air force adjustment, can recover these residual tobacco shreds from the small stems, maximizing the utilization of all usable tobacco shreds.

[0187] The removal of small stems is achieved through air separation, which ultimately removes the small stems to ensure that the subsequent products do not contain substandard materials and improve the purity of the tobacco.

[0188] 3.2 Recycling of small stems: By setting up a fine sorting stage in the three-stage air separation system specifically for recycling mixed tobacco shreds, and combining dynamic air pressure control and path feedback mechanism, the residual tobacco shreds in small stems can be efficiently extracted and reused. This overcomes the technical shortcomings of traditional processes where small stems are easily removed as a whole, resulting in raw material waste, and significantly improves resource utilization and economic benefits.

[0189] The recycling of the small stem sticks is carried out by using a three-stage air separation system to sort and recycle the small stem sticks, ensuring that the tobacco shreds in the small stem sticks are recycled and used for subsequent processing;

[0190] The purpose of the small stem sticks is to recycle usable tobacco from them, avoid waste, and improve resource utilization.

[0191] The operating equipment for the fine stem sticks is a three-stage air separator. In the three-stage air separator system, the impurities in the fine stem sticks are recovered by air separation, and the fine stem sticks are finally discharged.

[0192] The significance of the small stems is to maximize the recovery of usable tobacco from the small stems, reduce waste, and improve the utilization rate of tobacco. Furthermore, with the three-stage air separation for tobacco recovery, the air separation speed can be appropriately reduced in the first and second stage air separation processes, which is beneficial for the removal of stems by the system.

[0193] S4. Combing and fixed-length cutting of filaments and clumps: Through the coordinated operation of combing rollers and fixed blades, combined with tension control, photoelectric ranging, stepper motors and PLC systems, the entire process of unwinding filaments and clumps, removing and discarding large stems, and cutting to a fixed length in millimeters is intelligently controlled. This breaks through the technical bottlenecks of traditional combing processes, such as low cutting accuracy, uncontrollable tension and inflexible length specification switching, and significantly improves the consistency and industrial adaptability of tobacco processing.

[0194] S4.1 Combing Process: Combing rollers and fixed blades are used to comb the filaments, remove unqualified parts, and perform fixed-length filament breakage to ensure that the filaments meet specifications. By designing the combing rollers and fixed blades in a coordinated manner and introducing tension control and abnormal resistance alarm mechanisms, the process achieves the expansion of filaments and clumps, the detachment and removal of coarse stems, and physical stabilization. This overcomes the technical limitations of insufficient control over fiber damage and incomplete removal of unqualified materials in traditional combing processes, significantly improving the quality of finished tobacco and the stability of the processing.

[0195] The combing process involves using a combing roller and a fixed blade to comb the filaments and clumps. The combing roller rotates at high speed to expand and separate the material, while the fixed blade removes unqualified coarse stems and clumps.

[0196] The purpose of the combing process is to remove substandard parts from the filaments and clumps, thereby improving the overall quality of the tobacco.

[0197] The combing process equipment consists of a combing roller and a fixed blade device. The combing roller and the fixed blade work together to comb the filaments and spools, allowing the filaments and spools to spread out and be cut to a fixed length, while also separating the stems and thorns trapped in the spools. In addition, a defective material collection device is placed. To ensure processing stability, the system is equipped with an anti-winding mechanism and an abnormal resistance alarm module.

[0198] The significance of the combing process is to adjust the ratio of filament shape by expanding and opening the filament bundles and setting the length of long filaments to short filaments. At the same time, the stems and twigs wrapped in the long filaments and filament bundles are separated and removed during the combing process, ensuring that the processed filament shape meets the requirements of subsequent processing and improving the quality of tobacco.

[0199] S4.2 Fixed-Length Wire Cutting: By cooperating with the combing roller and the fixed blade, fixed-length wire cutting is performed during the combing process to avoid excessively long filaments affecting subsequent processing. By organically integrating photoelectric induction ranging, a "stepper motor + PLC system" and a mechanical fixed-length cutter, a high-precision wire cutting control mechanism that supports multiple specification switching is constructed. This enables dynamic and precise cutting of long filaments during the combing process, overcoming the problems of low control accuracy and inflexible specification switching in traditional wire cutting methods, and significantly improving the consistency of finished products and process adaptability.

[0200] The fixed-length filament breaking operation method involves using a moving and fixed blade in conjunction during the combing process to perform fixed-length filament breaking, ensuring that the length of the filaments meets the process requirements.

[0201] The purpose of the fixed-length wire cutting is to adjust the wire shape, avoid excessively long wires and clumps from affecting subsequent processing, and at the same time avoid excessively long wires causing defects such as too many empty ends in cigarettes.

[0202] The fixed-length wire cutting device is a combing roller and fixed knife combination device. During the combing process, the fixed-length wire is effectively cut by adjusting the gap between the fixed knife and the moving knife (the specific gap can be adjusted according to the process requirements, such as 5mm, 10mm, 15mm, 20mm, etc.) so that the wire shape ratio meets the process requirements.

[0203] The wire breakage length control mechanism achieves high-precision control through the following methods: photoelectric induction ranging control, a stepper motor + PLC system, a mechanical fixed-length cutter, and support for switching between multiple wire breakage lengths, such as 5mm, 10mm, 15mm, 20mm, and 25mm; achieving millimeter-level control. The mechanical fixed-length cutter is based on a fixed-pitch synchronous wheel structure and is suitable for standard wire breakage. The support for switching between multiple wire breakage lengths is achieved by switching gear modules or replacing the cutter roller module.

[0204] The significance of fixed-length filament cutting is to ensure that the length of the filaments meets the standard and to avoid excessively long filaments affecting subsequent tobacco processing. During the filament combing and fixed-length filament cutting process, high-precision control of the length of the filaments can be achieved, and rapid switching between multiple length specifications can be supported. This not only improves the consistency and quality control of the finished tobacco, but also enhances the flexibility and intelligence of the system, and has good industrial adaptability and promotion value.

[0205] S5. Removal of coarse stems: Through a primary air separation device integrating a variable speed fan, precision air duct and multi-sensor acquisition system, combined with PLC, fuzzy control and AI optimization algorithm, dynamic control of wind speed, wind pressure, wind direction and feeding cycle is achieved, accurately distinguishing and removing coarse stems. Even under the conditions of batch differences of tobacco and environmental fluctuations, it can still maintain a mismixing rate of ≤2% and a recovery rate of ≥95%, breaking through the technical limitations of traditional air separation in adapting to heterogeneous materials.

[0206] S5.1 Primary Air Separation: The primary air separation process is used to separate the filaments and filament bundles after combing and length-cutting. By utilizing the difference in wind force and material suspension velocity, coarse stems are effectively separated. By integrating a variable speed fan, precision air duct, and multi-parameter sensing module, and combining PLC, fuzzy control, and AI algorithms, intelligent linkage adjustment of wind speed, wind pressure, wind direction, and feeding frequency is achieved. Based on the material suspension characteristics, coarse stems are accurately removed. This overcomes the technical difficulties of traditional air separation systems, such as slow response to humidity fluctuations and particle differences, and low sorting accuracy, and significantly improves the purity of filaments and the adaptability of air separation.

[0207] The operation method of the first-stage air separation process is as follows: the long filaments and filament bundles after combing and fixed-length breaking are subjected to first-stage air separation, and the large stems are separated from the tobacco shreds by air force based on the difference in suspension speed between the long filaments and the large stems.

[0208] The purpose of the first-stage air separation process is to effectively remove large stems and stalks, ensuring that no large stems or stalks are mixed in with the long filaments and clumps, thereby improving the quality of the subsequent tobacco shreds.

[0209] The primary air separation equipment is a primary air separator. After combing and length-limited filament breaking, the long filaments and clumps are separated from the coarse stems by the primary air separator. The primary air separator combines a variable-speed fan, a precision air duct control module, and an automatic feeding device, supporting dynamic adjustment of air pressure, air speed, and air direction angle. It is also equipped with a feedback loop and a data acquisition module to adapt to changes in different batches of materials.

[0210] The control parameter acquisition for the primary air separation process is to achieve precise air separation and adaptive control. The system is equipped with the following sensors and detection modules, including real-time thickness monitoring of tobacco material (to determine the uniformity of feeding); humidity and temperature sensors (to identify whether the state of the tobacco material affects the air separation characteristics); detection of short filament recovery rate of material after air separation; detection of residual rate and mismixing rate of coarse stems after separation; and online monitoring and recording of operating parameters such as wind speed, wind pressure, and vibration frequency.

[0211] The primary air separation process collects key parameters such as material thickness, humidity, and recovery rate after air separation. Combined with a PLC control system, fuzzy control, and AI algorithm, it dynamically adjusts wind speed, wind pressure, and vibration frequency to achieve efficient separation of coarse stems from filaments or clumps, ensuring that the mismixing rate of coarse stems is ≤2% and the recovery rate is ≥95%.

[0212] The control method for the primary air separation process employs a multi-strategy fusion control approach, including a PLC program control system, a fuzzy control algorithm, and an AI optimization control algorithm. The PLC program control system implements basic control of wind speed, feeding, and sorting cycle time. The fuzzy control algorithm provides a flexible response to nonlinear operating conditions (such as sudden changes in humidity or abnormal stem conditions). The AI ​​optimization control algorithm, based on historical data and a real-time feedback model, intelligently optimizes key parameters such as wind speed, wind pressure, and vibration frequency to achieve predictive adjustment and adaptive control.

[0213] The key parameters of the primary air separation process are dynamically adjusted as follows: When the humidity of the tobacco material increases, the AI ​​control system identifies the downward trend in air separation efficiency and automatically increases the wind speed by 5%-10%, while simultaneously increasing the vibration feeding frequency to prevent the accumulation of wet tobacco material from causing air separation deviation; when the air separation recovery rate is detected to be decreasing, the system lowers the air duct angle, reduces the air pressure difference, and temporarily extends the suspension time of the tobacco material in the air field to enhance the separation resolution; when the system identifies an increase in the misclassification rate (exceeding the 2% threshold), it automatically activates the feedback mechanism, adjusts the wind speed level, and links with the front-end feeding angle to achieve overall optimization; for batches of tobacco material with frequent particle size changes, the system calls the AI ​​recommendation model to pre-set the optimal air separation strategy based on the current temperature, humidity, and thickness parameters.

[0214] The significance of the first-stage air separation process is to remove large stems and ensure that no large stems or stalks are mixed in with the long filaments and clumps, so as to avoid affecting subsequent processing and the final quality of tobacco.

[0215] S5.2 Discharge of coarse stems: After primary air separation, coarse stems are separated and discharged from the production line. By integrating the identification and discharge functions of coarse stems into the primary air separation system, and with the help of a precisely controlled air separation mechanism, the coarse stems are discharged synchronously and in a directional manner after sorting. This breaks through the traditional process that requires additional transportation or manual intervention to remove coarse stems, and improves the automation level and purity assurance capability of the tobacco production line.

[0216] The operation method for discharging coarse stems involves separating the coarse stems from the production line after primary air separation.

[0217] The purpose of removing large stems is to remove them, ensuring that the tobacco output from the production line meets the standards and preventing large stems from affecting subsequent processes.

[0218] The equipment for discharging coarse stems is an air separation system. After air separation, the separated coarse stems are discharged from the production line.

[0219] The significance of removing large stems is to ensure the purity of the final product, ensuring that the tobacco is not affected by large stems and meets quality standards.

[0220] S6. Subsequent processing: By constructing a post-processing system that integrates tobacco shred ratio control, online quality monitoring and intelligent feedback adjustment, the optimal mixing and closed-loop control of qualified long filaments, shred bundles and short filaments can be achieved. At the same time, intelligent identification and diversion paths for unqualified materials are set up, and the resource-based reuse of coarse and fine stems is supported. This breaks through the technical bottlenecks in traditional tobacco shred processing, such as rigid processing ratios, large quality fluctuations and extensive waste disposal.

[0221] S6.1 Subsequent processing of qualified tobacco shreds: The processed qualified long filaments, shred bundles and short filament mixtures are sent to the subsequent processing system for further processing; by integrating a long and short filament ratio control unit and a real-time quality monitoring feedback module into the subsequent processing system, combined with online detection of tobacco moisture content, length distribution and draw resistance prediction, the automatic adjustment and closed-loop control of the qualified tobacco shred mixing ratio can be realized, breaking through the limitations of traditional processing links where the ratio depends on experience, quality fluctuates greatly and lacks data-driven optimization, and significantly improving product consistency and process intelligence level;

[0222] The subsequent processing of the qualified tobacco shreds involves sending the qualified filaments, shred bundles, and short filament mixture into the subsequent processing system for further processing.

[0223] The purpose of the subsequent processing of the qualified tobacco is to perform final processing on the qualified tobacco to ensure that the quality meets the standards.

[0224] The control of the ratio of long to short filaments in the qualified tobacco shreds is achieved by the processing system through screening the ratio of long and short filaments. The tobacco shred structure is adjusted by adjusting and controlling the rotation speed and spacing of the long filaments and the fixed-length broken filaments in the shred bundles, so as to control the draw resistance parameters, filling density and rolling quality of the cigarette products.

[0225] The quality monitoring and feedback system for qualified tobacco shreds includes an online detection module for real-time data acquisition and feedback adjustment. The indicators include the moisture content (moisture content) of the finished tobacco shreds, the length distribution of the tobacco shreds, the stem content (residual large and small stems), and the predicted cigarette draw resistance. The collected data can be fed back to the front-end sorting system and the air separation parameter control module to achieve closed-loop quality control.

[0226] The significance of the subsequent processing of the qualified tobacco is to complete the final processing of the tobacco, ensure that it meets the quality standards, and prepare it for the production process.

[0227] S6.2 Removal of Non-conforming Materials: Non-conforming coarse and fine stems are discharged through the air separation system to ensure the quality of the final product. By constructing an air separation stem removal system linked to the sorting system, and setting up independent separation channels for coarse and fine stems as well as dedicated collection and reprocessing paths, the system achieves efficient removal and resource utilization of non-conforming materials. This overcomes the problems of high mixing risk and crude waste treatment in traditional waste discharge processes, and significantly improves product purity, system closed-loop performance, and resource utilization.

[0228] The method for removing non-conforming materials is to use an air separation system to remove non-conforming coarse and fine stems, thereby ensuring the purity of the final product.

[0229] The purpose of removing non-conforming materials is to improve the overall quality of tobacco and ensure that the final product meets the requirements.

[0230] The equipment for removing non-conforming materials is an air separation system. The air separation system removes non-conforming coarse and fine stems, and uses a stem discharge pipe and collection device connected to the aforementioned sorting system to establish independent separation channels for different types of stems to prevent contamination of qualified materials.

[0231] The waste reprocessing path for the aforementioned non-conforming materials is that the non-conforming materials are not directly discarded. A dedicated reprocessing system can be established, including coarse stems and fine stems. The coarse stems can be used for re-crushing and, after screening, prepared into reconstituted tobacco or industrial-grade plant fiber raw materials. The fine stems can be separated and used for biomass fuel and low-value resource utilization in recycled papermaking.

[0232] Therefore, the present invention provides a tobacco shreds quality improvement and processing classification method with dynamic screening and multi-stage air separation control, which includes preliminary classification, fine sorting, fine processing and subsequent processing of tobacco shreds. Through air separation, combing and breaking, the method achieves effective separation and processing of tobacco shreds of different forms, thereby improving the quality of tobacco shreds and reducing the generation of waste and unqualified materials.

[0233] The tobacco processing system provided by this invention has broad applicability to raw materials and excellent adaptability to various working conditions. It is suitable for various types of tobacco raw materials, including but not limited to flue-cured tobacco, expanded tobacco, blended tobacco, reconstituted tobacco, and recycled tobacco, such as tobacco scraps and waste materials recovered during cigarette production. The system can process materials with a moisture content of 10% to 28% and a particle size range of 4.5 mm to 100 mm, and can adapt to raw materials with a stem content as high as 30%. Even under such complex raw material conditions, it can still achieve stable air classification, screening, and separation operations. For extreme working conditions such as high humidity, high temperature, uneven particle size, or high stem content, the system ensures the sorting accuracy and tobacco recovery rate during the material processing process through dynamic adjustment of wind speed, vibration frequency, and feeding angle parameters, thereby guaranteeing the continuous and stable operation and industrial adaptability of the system in diverse production environments.

[0234] Example 2: Specific Implementation of the Path Length Adjustment Controlling Classification Ratio in the Tobacco Processing Classification Method with Dynamic Screening and Multi-stage Air Separation Control as Described in this Invention

[0235] In the tobacco shreds quality improvement and processing classification control method described in this invention, adjusting the path length to control the classification ratio is a key step to ensure that different types of tobacco shreds can be accurately classified according to their physical characteristics, avoid mixing, and optimize the effect of subsequent processing.

[0236] 2.1 Adjusting the vibration frequency: According to the physical characteristics of the tobacco material, the vibration frequency is adjusted appropriately to control the sorting ratio; if a higher proportion of short fibers needs to be screened out, the vibration frequency is increased, and if a lower proportion of short fibers needs to be screened out, the vibration frequency is decreased.

[0237] 2.2 Implementation of Path Length Adjustment: In the tobacco shreds quality improvement and processing classification control method described in this invention, the purpose and significance of adjusting the screening path are as follows: The purpose of adjusting the screening path is to control the material sorting ratio according to the characteristics of the tobacco shreds (such as humidity, particle size, and density) and the process sorting requirements, ensuring that the best separation effect can be achieved during the sorting process, meeting the process requirements. This control method allows different tobacco shreds to be sorted in different proportions, improving processing efficiency and avoiding material mixing that could affect subsequent processes.

[0238] The following methods can be used to adjust the screening path length based on the different physical properties of the tobacco materials:

[0239] 2.1 Selection of Screening Equipment: An adjustable frequency-controlled multi-channel louvered screening equipment shall be selected, and it shall be ensured that the frequency-controlled multi-channel louvered screening equipment has the functions of vibration frequency adjustment and screen surface angle adjustment; and different specifications of screen holes shall be installed on the frequency-controlled multi-channel louvered screening equipment to facilitate the separation of long filaments, clumps, and coarse stems into two categories, and short filaments and fine stems, according to the characteristics of the materials.

[0240] 2.2 Adjusting the filter path length:

[0241] The path length adjustment method is to control the material sorting ratio by adjusting the feeding position and path length of the screening equipment before the material enters the frequency-controlled multi-channel louvered screening equipment; the path length of the material through the screen surface can be changed by adjusting the position of the feeding port, such as changing the feeding direction or adjusting the feeding starting point.

[0242] The principle of path length control is that the longer the path length, the longer the material sorting time and the more refined the sorting effect; a short path length can speed up the sorting speed, but it will result in some materials not being completely classified; therefore, adjusting the path length can balance sorting efficiency and sorting accuracy, and ensure that the classification ratio meets the process requirements.

[0243] The specific adjustment method involves setting different path lengths, which can appropriately extend the sorting path for filaments and clumps, ensuring that filaments and clumps can be screened more thoroughly. Specifically, adjusting the path length is one of the key factors in optimizing the sorting effect during the tobacco shredding process. By adjusting the feeding position and path length before the material enters the vibrating screen, the sorting time on the screen surface can be flexibly controlled, thereby adjusting the sorting ratio.

[0244] S1. Change the feeding direction: Control the movement trajectory of the material on the screen surface by adjusting the feeding angle to optimize the sorting time;

[0245] After the feeding direction is changed, the residence time and passage path of the tobacco material on the screen surface will change, thereby affecting the material sorting effect.

[0246] S2. Adjust the feeding start point position: By adjusting the position of the feed inlet, the length of the material sorting path can be controlled, which can control the length of the material path through the screen surface and balance the processing speed and sorting accuracy.

[0247] By adjusting the starting point position, precise control of the sorting ratio can be achieved. For example, the processing of long filaments and spools can be ensured by appropriately extending the path to ensure complete separation; while the processing of short filaments and small stems can be improved by shortening the path to increase processing speed and avoid wasting time.

[0248] For example, moving the feed inlet towards the beginning of the screen can shorten the material's path; conversely, moving the feed inlet to the middle or rear of the screen can increase the path length of the tobacco material and extend the material sorting time.

[0249] S3. Feed inlet height and angle adjustment: The flow pattern of tobacco material on the screen surface can be further optimized by adjusting the height and angle of the feed inlet;

[0250] The height and angle adjustment of the feed inlet can precisely control the flow of tobacco materials on the screen surface by adjusting the height and angle of the feed inlet, so that tobacco materials of different shapes can be sorted at the appropriate time.

[0251] S4. Automated Adjustment System: The path length is adjusted in real time through an automated control system to ensure the flexibility and accuracy of the sorting process;

[0252] The aforementioned automated control is intended to make path length adjustment more precise and efficient. An automated control system can be used to monitor the material's flow rate, humidity, and other characteristics in real time, and automatically adjust the feed inlet position, path length, and screening frequency based on this data.

[0253] The automated control system uses sensors and feedback mechanisms to automatically adjust the feeding direction, feeding start point, or screen angle according to changes in the material, thereby achieving dynamic adjustment.

[0254] The significance of the automated control system is that it can adapt to changes in materials in real time, ensuring that the path length and sorting effect are always at their best. This not only improves production efficiency but also reduces the need for manual intervention.

[0255] Furthermore, the implementation method of the path length control principle is based on the path length control principle, which states that adjusting the path length can affect the residence time of the material on the screen surface, thereby controlling the sorting accuracy and speed. In practical applications, it is necessary to comprehensively consider the material flowability, screening accuracy, and processing efficiency.

[0256] Firstly, the specific steps in the mechanical operation of path length control are as follows:

[0257] S1. Start the screening equipment and initialize the system: Start the screening equipment and set the initial screen surface angle and vibration frequency.

[0258] S2. Adjust the path length according to material characteristics:

[0259] S2.1 For materials requiring high screening ratios: Adjust the feed inlet position, extend the material path length, and increase the sorting time;

[0260] S2.2 For materials requiring low-ratio screening: By adjusting the feeding start point and screen angle, the path length can be shortened and the sorting speed accelerated;

[0261] S3. Real-time monitoring and automatic adjustment: Using an automated control system, the path length is automatically adjusted based on information from sensor feedback to ensure that the material sorting accuracy and efficiency are always at their best.

[0262] Secondly, adjusting the path length is a key step in optimizing the sorting effect, and it can be implemented in the following ways:

[0263] S1. Adjusting the feed inlet position: This controls the path length of the material through the screen surface, ensuring that each type of material receives an appropriate sorting time. Adjusting the feed inlet position controls the path length of the material after entering the screen surface. The feed inlet position can be adjusted in different ways to affect the material throughput and sorting time.

[0264] The effect of adjusting the position of the feed inlet is to precisely control the transit time of the tobacco material.

[0265] S1.1 Front-end feeding: By placing the feed inlet close to the beginning of the screen surface, the material has a longer path through the screen surface, resulting in a longer screening length and more thorough screening.

[0266] S1.2 Rear-end feeding: The feed inlet is set in the middle and rear end of the screen surface, so that the path length of the material through the screen surface is short and the length of the screening section through which the material passes is short.

[0267] S2. Adjust the feeding start point: flexibly shorten or extend the path length according to the characteristics of the tobacco material to meet different sorting ratio requirements;

[0268] The adjustment of the feeding start point affects the material's path on the screen surface by adjusting the position of the feeding start point; the longer the path, the longer the material sorting time, enabling finer sorting; the shorter the path, the shorter the sorting time, suitable for processing materials with low sorting ratios.

[0269] The effect of adjusting the feeding start point is that by changing the feeding start point, the sorting time can be flexibly adjusted according to the properties of the material.

[0270] S2.1 Path shortening: By adjusting the position of the starting point, the path of material flow across the screen surface is shortened, reducing the sorting ratio;

[0271] S2.2 Path Extension: The feed inlet is moved further back to extend the residence time of the material on the screen surface and increase the sorting ratio;

[0272] S3. Adjust the screen angle and vibration frequency: Optimize the sorting effect by changing the movement trajectory and residence time of the tobacco material;

[0273] The effect of adjusting the screen angle and vibration frequency can finely adjust the sorting path length of tobacco materials, ensuring that the sorting accuracy and speed of different tobacco materials are matched.

[0274] S3.1 Screen Angle Adjustment: By changing the screen angle, the sliding trajectory of the tobacco material on the screen surface will also change, affecting the path length of the material passing through the screen surface; a smaller angle can increase the sliding time of the material, making the path longer, while a larger angle can accelerate the flow of the tobacco material and reduce the path length.

[0275] S3.2 Vibration frequency adjustment: The vibration frequency determines the movement speed and residence time of the tobacco material on the screen surface;

[0276] S4. Combined with an automated control system: Dynamic adjustment is performed, and equipment parameters are automatically adjusted based on real-time feedback data to ensure the best sorting effect;

[0277] The automated path length adjustment is achieved by equipping the device with sensors and an automated control system to monitor parameters such as material flow rate and humidity in real time, and to automatically adjust the feeding position, feeding start point, screen angle, and vibration frequency.

[0278] The implementation effect of the automated control system is that the path length can be dynamically adjusted according to real-time data to ensure that each type of material can be sorted according to the sorting ratio required by the process, so as to achieve the best sorting effect.

[0279] S4.1 High-density tobacco control: When the material has high moisture content or high density, the system can extend the material path length to ensure that the tobacco material has enough time for fine sorting.

[0280] S4.2 High-flow-rate tobacco control: When the flow rate of tobacco material increases, the automatic system will increase the path length to improve the sorting effect.

[0281] Furthermore, path length adjustment is implemented to optimize the sorting effect of long filaments, clumps, short filaments, and small stems, based on the stated objectives.

[0282] Furthermore, in the tobacco shreds quality improvement and processing classification control method of the present invention, the equipment adopts a multi-channel louvered screening device with frequency conversion control, combined with an adjustable vibrating screen device that adjusts the vibration frequency and screen surface angle; the control system adopts automatic control, which can monitor the physical characteristics of tobacco shreds in real time, and automatically adjust the screening path and vibration frequency according to data feedback, thereby achieving precise control of the sorting ratio; the control system can monitor humidity and particle size parameters through sensors, and adapt to the changes of different batches of tobacco shreds by adjusting equipment settings.

[0283] Furthermore, in the tobacco shreds quality improvement and processing classification control method described in this invention, the effect of adjusting and controlling the classification ratio is achieved by flexibly adjusting the screening path and vibration frequency, which can efficiently classify tobacco shreds materials, ensuring that the ratio of long filaments, shred bundles, and coarse stems to short filaments and fine stems meets the requirements of subsequent processing, thereby improving the sorting accuracy and optimizing the efficiency of subsequent processing, ensuring that the quality of tobacco shreds meets production standards.

[0284] Therefore, the tobacco shred classification method with dynamic screening and multi-stage air separation control described in this invention, through the above-mentioned implementation method of adjusting the path length and controlling the classification ratio, can achieve precise sorting of tobacco shreds, avoid mixing of tobacco shreds during processing, and ensure the improvement of tobacco shred quality. Adjusting the path length and controlling the classification ratio provides a flexible, precise, and efficient control means for tobacco shred processing, which helps to improve the processing efficiency of the entire production line and the quality of tobacco shreds.

[0285] Example 3: Specific Implementation of the "Three-Stage Air Classification and Recovery Mechanism" in the Tobacco Processing and Classification Method with Dynamic Screening and Multi-Stage Air Classification Control as Described in this Invention

[0286] The specific implementation of the three-stage air separation and recycling mechanism in the tobacco shred quality improvement and classification control method of the present invention aims to sort and recycle short shreds and small stems in tobacco shreds through a multi-stage air separation system, and finally discharge unqualified small stems, so as to improve the quality of tobacco shreds and resource utilization.

[0287] The purpose of combining the three-stage air separation and recycling mechanism in the tobacco shreds quality improvement and processing classification method with dynamic screening and multi-stage air separation control described in this invention is to finely separate the mixture of short shreds and fine stems through the three-stage air separation system, maximize the recovery of the tobacco shreds mixed in, and remove unqualified fine stems, thereby improving the quality of tobacco shreds, reducing waste, and improving resource utilization efficiency.

[0288] In the tobacco shreds quality improvement and classification method with dynamic screening and multi-stage air separation control described in this invention, the significance of combining three-stage air separation treatment with the recovery mechanism is that the three-stage air separation mechanism ensures the recovery rate and purity of tobacco shreds, avoids the waste of small stems, and improves the overall efficiency and output value of tobacco shreds processing through efficient sorting.

[0289] Furthermore, the present invention provides a method for classifying and improving tobacco shreds with dynamic screening and multi-stage air separation control, wherein the operation process and implementation steps of the three-stage air separation system are as follows:

[0290] Phase 1: Primary Wind Selection

[0291] In the air separation system for tobacco upgrading and processing, primary air separation is an important preliminary separation stage; that is, through the operation of the primary air separation stage, the mixture of short filaments and fine stems can be roughly separated, laying the foundation for the subsequent secondary and tertiary air separation.

[0292] The primary air classification stage performs coarse sorting of the mixture, preparing it for subsequent secondary and fine air classification. This coarse sorting aims to separate short fibers, stems, and their mixtures through initial airflow separation. This stage is relatively coarse, primarily separating materials that roughly conform to the classification criteria to reduce the burden on subsequent air classification systems. Subsequent fine classification occurs because the airflow used in primary air classification is relatively simple and coarse, leaving some short fibers and stems unseparated. The material from primary air classification is then sent to secondary air classification for more refined sorting. In secondary air classification, the tobacco materials are completely separated through more precise airflow control. Thus, through the coarse sorting in the primary stage, subsequent secondary and tertiary air classification can process relatively purer short fibers and stems, thereby improving the efficiency and accuracy of the entire air classification process.

[0293] The operation method of the first-stage air separation is as follows: the mixture of short tobacco and fine stems is sent into the air separation system, and the air force is adjusted so that the short tobacco, stems and the mixture of short tobacco and stems are separated by the air force; the first-stage air separation is mainly to perform preliminary diversion of the mixture, and to separate the tobacco into three categories: short tobacco, stems and the mixture of short tobacco and stems.

[0294] The air separation system contains a fan or air force control device. By adjusting the fan's speed and pressure parameters, the airflow intensity is changed, thereby affecting the separation of materials. In the first stage of air separation, the mixed tobacco material (including short filaments and small stems) is first sent into the air separation system. At this time, the tobacco material has been roughly classified by the vibrating screen, but it is still mixed together, so it needs to be further separated by air force.

[0295] Furthermore, the sorting principle of the first-stage air separation is mainly based on the adjustment of the air force according to the density difference between the short filaments and the stems, that is, the air force is adjusted according to the density difference between the short filaments and the stems, so that the short filaments and the stems can be initially separated.

[0296] The wind force is adjusted according to the density difference between short filaments and stems, specifically by the difference in physical properties between short filaments and stems, the effect of wind force, and the diversion of short filaments and stems.

[0297] S1. Differences in physical properties between short filaments and stems: Short filaments have a lower density than stems because they are generally lighter and softer, while stems are harder and heavier. This density difference is a key factor in the air separation process.

[0298] S2. The role of wind: The air separation system adjusts the wind speed so that the less dense short fibers are affected by the wind and float to the top of the air separation equipment or are carried to other paths; while the denser stems are less affected by the wind due to the strong gravity and remain in place or settle along a lower path; specifically, the operator can precisely control the separation of short fibers and stems by adjusting the wind strength; stronger winds will cause the lighter short fibers to be blown further, while the heavier stems will be less affected by the wind due to their higher density and will eventually separate.

[0299] S3. Separation of short filaments and stems: In this stage, short filaments, stems, and mixtures of the two will be separated into different flow directions; under the influence of different densities and wind speeds, short filaments and stems form obvious stratification and flow along different paths;

[0300] Thus, through the coarse sorting in the first stage, short filaments and stems are roughly separated, and any mixture that is not completely separated (such as a mixture of short filaments and stems) will enter the subsequent second stage of air separation. The first stage of air separation provides a good foundation for the subsequent fine air separation process, enabling the air separation system to continue to work with higher precision, thereby improving the quality of tobacco and recycling efficiency.

[0301] It can be demonstrated that primary air separation, by adjusting the air force, initially separates short filaments and stems according to density differences, preparing for subsequent more refined separation. Primary air separation is the first step in the entire air separation process. Although the separation of primary air separation is relatively coarse, it plays a key role in improving the overall separation effect and optimizing subsequent processing steps.

[0302] Phase Two: Secondary Wind Selection

[0303] In tobacco processing, secondary air separation is a crucial stage for further refining the mixture of short fibers and fine stems after primary air separation. The purpose of secondary air separation is to completely separate the short fibers and fine stems, laying the foundation for subsequent tertiary air separation and recycling. Secondary air separation is a key step in refining the mixture of short fibers and fine stems obtained after primary air separation; by increasing airflow and relying on the differences in density and suspension velocity between the two, secondary air separation can achieve complete separation, thus laying the foundation for subsequent tertiary air separation and recycling, and helping to improve tobacco quality and resource utilization efficiency.

[0304] The secondary air separation operation method is to further refine the mixture of short filaments and fine stems obtained after the primary air separation.

[0305] The key to the secondary air separation is to adjust the intensity of the airflow so that short fibers and fine stems can be completely separated.

[0306] The separation principle of the secondary air separation is that short filaments and fine stems are separated by the difference in density and suspension velocity under the action of wind. At this time, the fine stems are heavier and the short filaments are lighter. Under the action of wind, the short filaments will be blown to the top of the air separation equipment, while the fine stems will be guided to the other side of the equipment.

[0307] The purpose of the secondary air separation is to separate the fine stems from the short fibers as much as possible. On one hand, the secondary air separation uses more precisely controlled airflow to separate the fine stems from the short fibers. To further improve sorting accuracy, the separated stems will contain a certain amount of tobacco shreds. On the other hand, the secondary air separation provides a foundation for the tertiary air separation process. After the secondary air separation, the short fibers and fine stems are relatively pure, making the recovery of tobacco shreds from the fine stems more efficient when entering the tertiary air separation system. The mixed tobacco shreds in the fine stems will be further recovered, thereby improving resource utilization. Furthermore, the secondary air separation improves sorting efficiency and quality. Through a precise air separation process, it effectively improves sorting efficiency and tobacco quality, reduces the difficulty of subsequent processing stages, and ensures the purity of the final product.

[0308] The secondary air separation system comprises air separation equipment and an automated control system. The air separation equipment uses a high-efficiency air separator and a wind power control system. The equipment must have strong wind adjustment capabilities, precisely controlling wind speed and force according to the characteristics of the material to meet the separation requirements of short fibers and fine stems. The automated control system monitors changes in wind force and material flow in real time, ensuring wind accuracy and efficient material separation during the separation process. The control system automatically adjusts the parameters of the air separation equipment based on the material's moisture content and particle size characteristics to ensure optimal separation results.

[0309] The secondary air classification process further refines the mixture of short fibers and fine stems obtained after the primary air classification. In the primary air classification stage, the short fibers and fine stems are initially separated, but due to the relatively high wind intensity, more noticeable stems are initially removed, primarily serving a diversion function. Some short fibers and stems remain after the primary air classification. Therefore, the secondary air classification further refines the wind control and the classification process to ensure complete separation of short fibers and fine stems.

[0310] The operation of the secondary air separation is to send the mixture after the primary air separation (i.e., short filaments and fine stems) into the secondary air separation system; at this time, the air force control of the secondary air separation system is higher than that of the primary air separation, so that the short filaments and fine stems can be finely separated according to the difference in suspension velocity.

[0311] The key to adjusting the wind force in the secondary air separation is to adjust the wind force by adjusting the wind intensity to ensure that the wind force can more accurately separate materials of different densities according to their density and suspension velocity differences.

[0312] Furthermore, the separation principle of the secondary air separation is mainly based on the fact that short filaments and fine stems are separated under the action of wind due to differences in density and suspension velocity;

[0313] S1. Density difference: Short filaments are lighter than fine stems, so they are more easily blown upwards or further away by wind. Fine stems, on the other hand, are harder and denser than short filaments, making them less susceptible to being blown by strong winds.

[0314] S2. The difference in suspension velocity is the basic principle of the air classification process. It is the difference in the suspension velocity of tobacco materials in the airflow. The lower density of short fibers means that their suspension velocity is higher. Therefore, short fibers will be carried by the wind to the top of the air classification system or away from the feeding area. On the other hand, the higher density of fine stems makes the suspension velocity of fine stems lower. Under the action of the wind, fine stems will settle or flow along the other side of the air classification equipment.

[0315] Furthermore, the separation principle of the secondary air separation is also to further separate short filaments and fine stems by adjusting the intensity and speed of the wind. Specifically, the separation of short filaments is achieved because, due to their lighter weight, they are blown upwards or away from the conveying channel by the wind. The separation of fine stems is achieved because, being heavier, they are less affected by the wind and thus remain at a lower position or are guided to the other side of the equipment by the air separation system, thereby completing the separation.

[0316] Phase 3: Three-stage air separation and recovery

[0317] In the tobacco shred upgrading process, three-stage air separation and recycling is the final crucial step to ensure tobacco purity and resource recovery rate. Three-stage air separation and recycling effectively recovers tobacco shreds mixed in with small stems while ensuring that substandard materials (such as small stems) are removed, ultimately improving tobacco quality and recycling efficiency. This stage involves precise adjustment of air force and speed to ensure efficient recovery of tobacco shreds mixed in with small stems, while removing substandard small stems from the production line, guaranteeing the final tobacco quality and resource utilization rate. Through this three-stage air separation and recycling process, the recycling mechanism not only improves the tobacco recovery rate but also avoids the impact of small stems on subsequent processing, thus optimizing the entire tobacco shred upgrading process.

[0318] The three-stage air separation and recycling operation method is to send the small stems after the two-stage air separation process into the three-stage air separation system for air separation and recycling. That is, by adjusting the wind force and wind speed, the tobacco shreds mixed in the small stems will be effectively recycled.

[0319] The three-stage wind separation and recycling mechanism involves adjusting the wind force to an appropriate level during the three-stage wind separation phase to ensure that the remaining tobacco shreds in the small stems are completely recycled. These tobacco shreds mixed in with the small stems are separated by the wind force, and the recycled tobacco shreds are transported to the tobacco recycling system.

[0320] The aforementioned three-stage air separation and recycling equipment configuration utilizes a three-stage air separator in conjunction with an air separation and recycling system to precisely sort the tobacco shreds. During the recycling process, a wind power control system ensures that tobacco shreds mixed with small stems are efficiently recycled, while the small stems are removed from the production line, ensuring that quality is not affected.

[0321] The configuration of the three-stage air separator and recycling system includes the three-stage air separator and a wind power control system. The three-stage air separator needs to ensure precise adjustment of wind force and speed during the three-stage air separation process to effectively separate fine stems and mixed tobacco shreds. The three-stage air separator is typically equipped with multiple wind force adjustment devices, capable of adjusting the wind strength in real time to adapt to the characteristics of different materials. The wind power control system is the core component of the three-stage air separation system. Through automated control devices, it monitors wind speed and pressure parameters in real time during the air separation process to ensure maximum recycling efficiency. The control system can automatically adjust according to material characteristics (such as humidity and particle size) to guarantee recycling accuracy and efficiency.

[0322] The three-stage air separation device's recycling system includes a dust collection system and a discharge device. The dust collection system, or other dedicated material conveying equipment, guides the recycled tobacco from the air separation system to the tobacco recycling channel, ensuring the continuity and efficiency of the recycling process. The discharge device handles small stems and stalks, which are considered substandard material. After the three-stage air separation, these stems and stalks are guided by a pneumatic system to the discharge device and ultimately discharged from the production line.

[0323] The three-stage air separation and recycling process effectively removes substandard tobacco materials. Specifically, after the tobacco in the small stems is recycled, the small stems are discharged from the production line as substandard tobacco materials, ensuring the purity of the tobacco in subsequent processing.

[0324] The three-stage air separation and recycling operation involves sending the small stems that have undergone two-stage air separation into the three-stage air separation system for air separation and recycling, and then further adjusting the wind force and wind speed.

[0325] The process of sending the fine stems, after secondary air separation, into the tertiary air separation system for recycling occurs during the secondary air separation stage, when short tobacco fibers and fine stems have already been separated. The material entering the tertiary air separation system mainly consists of fine stems, which still contain some tobacco fibers that have not been completely separated.

[0326] The specific operation of sending the fine stems after the secondary air separation process into the tertiary air separation system for air separation and recycling is as follows: the fine stems after the secondary air separation process are sent into the tertiary air separation equipment; the tertiary air separation system uses a higher intensity of air force to recover the tobacco shreds in the fine stems; at this time, the fine stems are treated separately as unqualified materials, while the tobacco shreds mixed in are recovered by air force.

[0327] The three-stage air separation and recycling process requires adjustment of airflow force and speed. Regarding airflow adjustment, the three-stage air separation equipment precisely adjusts the airflow intensity to ensure that impurities in the fine stems are effectively recycled. With appropriate airflow, lighter tobacco shreds are carried away, while heavier, finer stems remain in place or are guided to other areas of the equipment. Furthermore, regarding airflow speed adjustment, the airflow speed is optimized based on the characteristics of the fine stems, ensuring that the airflow speed during the sorting process can both recycle impurities and not affect the discharge of fine stems.

[0328] The three-stage air separation recovery mechanism includes an air force adjustment and recovery mechanism and fine sorting. The air force adjustment and recovery mechanism includes the recovery of mixed tobacco shreds and a recovery system.

[0329] S1. Wind power adjustment and recovery mechanism:

[0330] S1.1 Recycling of Mixed Tobacco Shreds: The small stem sticks contain a certain amount of tobacco shreds, which need to be recycled by the fine airflow in the three-stage air separation system; the adjustment of the airflow will separate the tobacco shreds from the small stem sticks and bring them to the recycling channel;

[0331] S1.2 Recycling System: The recycled tobacco is sent to the tobacco recycling system, which usually uses a dust collection system or other material conveying devices to transfer the recycled tobacco to the next processing stage or for reprocessing.

[0332] S2. Fine sorting:

[0333] S2.1 Ensure sorting accuracy: The key to the three-stage air separation system is to accurately control the air force to ensure that the tobacco shreds mixed in with the small stems are recovered to the greatest extent, rather than being discharged with the small stems.

[0334] S2.2 Purity of the recovered tobacco: Due to the high precision of the three-stage air separation system, the recovered tobacco contains fewer impurities and is of relatively pure quality.

[0335] S3. Discharge of non-conforming materials: Small stems and bits are discharged from the production line as non-conforming materials;

[0336] S3.1 Discharge of non-conforming materials: Small stems are considered non-conforming materials and cannot be used for subsequent tobacco processing. Therefore, these small stems will be guided out of the production line by wind.

[0337] S3.2 Ensure the purity of the tobacco: The discharged fine stems are the final substandard material and do not contain any recyclable tobacco. This step ensures that the tobacco processed subsequently is pure and meets quality standards.

[0338] Furthermore, the three-stage air-separation recycling mechanism optimizes recycling efficiency, maximizing the utilization of usable tobacco shreds in small stems, reducing waste, and improving resource utilization. To achieve more precise sorting and recycling, the air speed and pressure of the air-separation equipment can be adjusted according to real-time material characteristics (such as humidity and particle size), thereby avoiding unnecessary waste. In addition, through an advanced automated control system, the air-separation process can be monitored and adjusted in real time, ensuring that the recycling mechanism operates in a highly efficient and stable state, improving overall sorting accuracy and resource recovery rate.

[0339] This demonstrates that the three-stage air separation and recovery mechanism, through precise airflow control, can efficiently recover tobacco shreds trapped in small stems, reducing resource waste and improving production efficiency. Simultaneously, by recovering tobacco shreds from small stems and removing substandard materials, the purity and quality of the tobacco shreds are ensured, effectively preventing the impact of small stems on subsequent processing stages. The system also improves sorting efficiency and recovery rate, ensuring the smooth operation of subsequent processing stages, thereby optimizing the efficiency of the entire production line.

[0340] Therefore, the tobacco shreds classification method with dynamic screening and multi-stage air separation control described in this invention achieves efficient separation of short shreds and fine stems through a combination of three-stage air separation and a recovery mechanism. Simultaneously, it recovers impurities in the tobacco shreds, avoiding resource waste and improving the overall quality and recovery rate of the tobacco shreds. The specific implementation of the three-stage air separation and recovery mechanism not only optimizes the efficiency of tobacco shreds processing but also effectively improves product quality, meeting the high standards required in the production process.

[0341] Example 4: Specific implementation of the tobacco shred upgrading and processing classification method with dynamic screening and multi-stage air separation control described in this invention, which dynamically adjusts the screening process based on the moisture content, temperature, and material layer thickness of the tobacco shreds.

[0342] Example 4 provides a specific implementation method for "a tobacco shreds quality improvement and processing classification method with dynamic screening and multi-stage air separation control as described in this invention—dynamic adjustment of the screening process based on the moisture content, temperature, and material layer thickness of the tobacco shreds." This implementation method, without changing the original process route (S1 vibrating screening + S1.2 adjusting the screening path + subsequent air separation / combing), adds online detection and closed-loop control, enabling the screening process to adapt in real time to the incoming material status, thereby stabilizing the sorting ratio and improving the efficiency and quality consistency of subsequent processing.

[0343] Example 4 illustrates the implementation path of the tobacco shreds upgrading and processing classification method with dynamic screening and multi-stage air separation control described in this invention, which is "dynamically adjusting the screening process according to the moisture content, temperature, and material layer thickness of the tobacco shreds". It can be seamlessly connected with the S1 to S6 processes of the tobacco shreds upgrading and processing classification method with dynamic screening and multi-stage air separation control described in this invention.

[0344] Furthermore, the tobacco shreds quality improvement and classification method described in this invention, which features dynamic screening and multi-stage air separation control, includes a measurement unit, an execution unit, and a control unit in order to achieve dynamic adjustment of the moisture, temperature, and material layer thickness of the tobacco shreds during screening.

[0345] The measuring unit includes an online moisture sensor (such as a near-infrared or microwave sensor) with a range of 5% to 50% (absolute moisture), installed above the feed of the vibrating screen for monitoring the moisture content of the incoming material; a non-contact infrared thermometer and thermocouple array with a range of 10 to 90°C, arranged above the feed of the vibrating screen for monitoring the temperature; a material layer thickness sensor (such as a laser displacement or ultrasonic sensor) to monitor the material layer height on the screen surface with a range of 0 to 80 mm; and a belt scale to verify the consistency between the material layer and the feed, ensuring precise control of the production process.

[0346] The execution unit includes several key components, including a vibration drive system (variable frequency motor + double eccentric vibrator), which can adjust the vibration frequency f (15-40Hz) and amplitude A (0.8-1.8mm).

[0347] The control unit consists of an industrial controller (PLC or IPC) with a sampling period of 0.5 to 1 second. It can process data in real time and view the system's operating status in real time, ensuring ease of operation and system stability.

[0348] The screening process in the tobacco shreds upgrading and classification method of the present invention, which features dynamic screening and multi-stage air separation control, can adapt online according to the material state: when the moisture, temperature, and material layer thickness fluctuate, the system automatically coordinates the vibration parameters, screen angle, and path length, thereby improving the overall line efficiency and finished product quality.

[0349] Example 5: Specific Implementation of the Dynamic Air Classification and Closed-Loop Control System in the Tobacco Processing and Classification Method with Dynamic Screening and Multi-Stage Air Classification Control of the Present Invention

[0350] This implementation involves introducing online detection and automatic control technology to achieve dynamic adjustment and closed-loop control of wind speed, wind pressure, airflow angle, and sorting position parameters in the air separation stage of tobacco processing (S3 multi-stage air separation, S5 coarse stem air separation, and S6 rejection of unqualified materials), ensuring optimal sorting of different materials and improving tobacco recovery rate and finished product purity.

[0351] The dynamic air separation and closed-loop control system in the tobacco shreds quality improvement and processing classification method with dynamic screening and multi-stage air separation control described in this invention includes a measurement and feedback unit, an execution unit, and a control unit;

[0352] Firstly, the measurement and feedback unit is used to monitor the flow rate of tobacco shreds passing through the air classifier, ensuring that the material flow rate matches the wind force set by the air classifier; and can provide feedback on the sorting status and sorting effect of the material through machine vision or weight sensing.

[0353] Secondly, the execution unit includes an air separation system, a feedback control regulator, a variable frequency air supply fan, and an adjustable air duct structure. The air separation system includes multi-stage air separators with airflow adjustment devices; each air separator can independently adjust its wind speed and pressure, separating short fibers and fine stems by precisely controlling air ducts with different wind speeds. The feedback control regulator, based on sensor feedback data, adjusts the working state of the air separation equipment and dynamically regulates the wind speed through a PID controller. The variable frequency air supply fan provides a stable airflow with adjustable wind speed and pressure (wind speed range: 2–6 m / s). The adjustable air duct structure includes guide vanes, air outlet opening, and air outlet angle (0–45°).

[0354] Thirdly, the control unit includes a PLC control system and an HMI interface. The PLC control system is responsible for collecting data from sensors and controlling the actions of the execution units according to the set targets. The PLC control system can integrate wind speed, wind pressure, and other key parameters into a closed-loop feedback system. The HMI interface provides an interactive interface between the operator and the control system, displaying parameter status in real time and allowing for manual or automatic adjustment.

[0355] In the execution and control module, the PLC main control system, embedded PID controller, and HMI touch screen user interface are crucial. The PLC main control system can acquire sensor data in real time and calculate adjustment parameters; the HMI touch screen user interface is used to set target parameters, process recipes, and display operating status.

[0356] Furthermore, the working principle of the dynamic wind speed regulation and closed-loop control system in the tobacco shreds quality improvement and processing classification method with dynamic screening and multi-stage air separation control described in this invention is as follows:

[0357] Regarding initial condition settings, the system automatically or manually sets the initial wind speed and pressure parameters of the air separation system upon startup, based on the characteristics of the material (such as moisture, temperature, and flow rate). For example, for tobacco with high moisture content, the wind speed can be appropriately reduced to prevent material breakage due to excessive wind speed. The control system maps humidity and temperature data to a preset wind speed range through input from humidity and temperature sensors and optimizes adjustments based on the flow rate requirements of the tobacco.

[0358] The closed-loop control system's workflow includes wind speed and humidity linkage control, real-time feedback and adjustment, and monitoring of feedback data and sorting effect.

[0359] Firstly, regarding the linkage control of wind speed and humidity, when the system detects changes in the humidity of the material (such as excessively high or low moisture content), it will dynamically adjust the wind speed of the air separator. For example, when the humidity is high, adjusting the wind speed ensures the accuracy of tobacco sorting and avoids material sticking or incomplete filtration due to excessive humidity. Secondly, regarding real-time feedback and adjustment, the PLC control system receives data from the wind speed sensor and monitors changes in wind speed. If the wind speed deviates from the set value (e.g., poor sorting effect for short fibers and small stems), the PLC controller will automatically adjust the wind speed to restore the best sorting effect. The wind speed monitoring process has a rapid response capability, completing the adjustment within seconds. Thirdly, regarding feedback data and sorting effect monitoring, a visual or weight-sensing monitoring system monitors in real time whether the sorted material has been separated according to the preset ratio. If the sorting is incomplete, the system will adjust the wind speed and force to meet the predetermined requirements.

[0360] Regarding wind speed regulation and sorting optimization, the wind separation system is adjusted to recover short tobacco fibers and fine stems. The wind speed is gradually adjusted through a three-stage wind separation system. The first stage of wind separation uses a lower wind speed to prevent heavier materials (such as coarse stems) from being carried away, ensuring effective separation. The second stage of wind separation increases the wind speed to continue separating lighter short tobacco fibers and fine stems, ensuring that unqualified materials (such as fine stems) are removed through precise wind control. The third stage of wind separation adjusts the wind speed again to recover tobacco fibers mixed in with fine stems, ultimately ensuring that all fine stems are completely discharged.

[0361] In terms of feedback and adaptive control, this includes dynamically adjusting the coordinated operation of the path and wind speed, and prioritizing wind speed adjustments. The dynamic adjustment of the path and wind speed, under certain special circumstances, such as rapid changes in humidity or temperature, involves the control system not only adjusting the wind speed but also adjusting the path length, such as by adjusting the screening path time through a path length adjustment device, thus making the tobacco sorting process more precise. The wind speed adjustment priority is determined by the control system based on the characteristics of the material, such as excessively high or low humidity, to decide the priority of wind speed adjustment. For example, when humidity is high, the wind speed will be adjusted first to ensure that the air separation effect is not affected by humidity.

[0362] Regarding system alarms and automatic adjustment, the system has an automatic alarm function. When the material sorting effect is not ideal or the equipment malfunctions, the system will automatically trigger an alarm according to the set alarm parameters and adjust the relevant equipment, such as reducing the wind speed or stopping the air separation, to prevent the problem from escalating.

[0363] Furthermore, in the dynamic wind speed regulation and closed-loop control system of the tobacco shreds quality improvement and processing classification method with dynamic screening and multi-stage wind separation regulation described in this invention, the basic implementation steps of the control process and regulation logic are concentrated in S3.1 dynamic wind speed control in multi-stage wind separation, S5.1 dynamic adjustment in primary wind separation processing, and S6.2 intelligent identification and wind separation coordination in the removal of unqualified materials.

[0364] Firstly, in the dynamic wind speed control of the S3.1 multi-stage wind separation, the main function is to achieve coarse separation, fine separation, and residue recovery through multi-stage wind separation adjustment.

[0365] Primary air separation adjustment (coarse separation)

[0366] The goal of the primary air separation adjustment is to initially separate the mixture into short filaments, stems, and the mixture itself.

[0367] The adjustment logic of the first-level air separation is that when the proportion of stems is detected to be too high (high density), the system increases the air pressure and angle to enhance the projection of light materials and separate them from heavy materials.

[0368] The closed-loop parameters of the primary wind selection adjustment include the wind speed adjustment range, the wind angle adjustment range, and the control frequency.

[0369] Secondary air separation adjustment (precision separation)

[0370] The goal of the secondary air separation adjustment is to finely separate short filaments from small stems.

[0371] Three-stage air separation adjustment (tobacco shred recovery)

[0372] The goal of the three-stage air separation adjustment is to recover residual tobacco from the small stems.

[0373] The adjustment logic of the three-stage air separation system is that the system monitors the content of tobacco shreds in the outlet air separation residue. When the content exceeds the standard, the system increases the wind speed or finely adjusts the angle of the air guide plate to further throw out and recycle the mixed tobacco shreds. At the same time, the system controls the discharge air pressure to prevent useful materials from being discharged together.

[0374] The wind speed control range of the three-stage wind separation adjustment is 3–6 m / s, which is combined with low-angle (<20°) airflow.

[0375] The three-stage wind separation adjustment recovery monitoring method adopts "visual inspection + weighing feedback" to make trend judgment on the quality of recovered tobacco.

[0376] Secondly, in the dynamic adjustment of the S5.1 primary air separation process, the main function is to achieve coarse separation, fine separation and tobacco shred recovery through multi-stage air separation adjustment.

[0377] The goal of dynamic adjustment in the primary air separation process is to remove coarse stems from filaments and spools.

[0378] The dynamic adjustment strategy in the primary air separation process is to reduce the air velocity when a decrease in rejection efficiency is detected (stem residue ≥2%); and to appropriately increase the air pressure and fine-tune the air duct if the filament content in the identification tag increases.

[0379] Through the above embodiments, the tobacco shreds quality improvement and classification method of the present invention with dynamic screening and multi-stage air separation control, the dynamic wind speed adjustment and closed-loop control system can automatically adjust the wind speed and other processing parameters according to the real-time characteristics and sorting effect of the tobacco shreds, so as to achieve accurate sorting and optimization of tobacco shreds, and improve the stability and sorting efficiency of the system.

Claims

1. A tobacco leaf upgrading processing classification method with dynamic screening and multi-stage air classification regulation, characterized in that, The method for classifying and upgrading tobacco shreds includes the following steps: S1. Tobacco shred classification and sorting: Through a multi-channel louvered screening device with frequency conversion control and an adjustable screening path system, combined with PLC and AI algorithms, the vibration frequency, screen angle and wind speed are dynamically adjusted to achieve intelligent sorting control based on the physical characteristics of tobacco shreds. S1.1 Vibrating Screening: By using a multi-channel louvered screening device with variable frequency control and different screen hole structures, efficient physical grading of tobacco materials according to length can be achieved. S1.2 Adjust the screening path: Based on the characteristics of the tobacco material, the sorting ratio is controlled by adjusting the position and path length of the material entering the sorting and classification equipment and the vibration screening frequency, thereby adjusting the sorting ratio of long filaments, clumps, and coarse stems to short filaments and fine stems. S2. Separation of long filaments, skeins, and coarse stems from short filaments and fine stems: By linking the results of the vibrating sieve with the material distribution device, and combining the wind power control and flow guidance system, the synchronous grouping and physical isolation of long filaments and short filaments can be achieved. S2.1 Separation Output: By coordinating the results of the vibrating screening with the material distribution device, the long filament and short filament materials are synchronously grouped and output to independent processing paths according to the physical classification results. The long filaments, spools, and coarse stems are output in one group, while the short filaments and fine stems are output in another group. S2.2 Avoid mixing problems: By setting up a precise flow diversion device and wind control system, dynamic isolation and path limitation of the flow direction of tobacco shreds of different shapes are achieved after sorting, separating short shreds from long shreds and removing small stems; S3. Processing of short filaments and fine stems: By constructing a three-stage vertical air separation system with feedback adjustment channels, and integrating PLC, fuzzy control and AI algorithms to dynamically adjust the wind speed, feeding frequency and path angle, high-precision separation of short filaments and fine stems and tobacco filament recycling are achieved under complex raw material conditions. S3.1 Multi-stage air separation: The mixture of short filaments and fine stems is separated by air separation and passed through a three-stage air separation system in sequence; S3.2 Recycling of small stems: By setting up a fine sorting stage in the three-stage air separation system specifically for recycling mixed tobacco shreds, and combining dynamic air pressure control and path feedback mechanism, the efficient extraction and reuse of residual tobacco shreds in small stems can be achieved. S4. Combing and fixed-length filament breakage treatment of filaments and filament balls: Through the coordinated operation of combing rollers and fixed blades, combined with tension control, photoelectric ranging, stepper motors and PLC systems, the entire process of filament rejection and millimeter-level fixed-length cutting is intelligently controlled. S4.1 Combing treatment: Combing rollers and fixed blades are used to comb the filaments, and tension control and abnormal resistance alarm mechanisms are introduced to achieve combing and physical stabilization of filaments and yarn bundles. S4.2 Fixed-Length Tobacco Cutting: Through the cooperation of the combing roller and the fixed blade, fixed-length tobacco cutting is performed during the combing process, establishing a high-precision tobacco cutting control mechanism that supports multiple specification switching; the cut tobacco shreds form a shape proportion suitable for subsequent processing. S5. Removal of coarse stems: Through a primary air separation device integrating a variable speed fan, precision air duct and multi-sensor acquisition system, dynamic control of wind speed, wind pressure, wind direction and feeding cycle is achieved to accurately distinguish and remove coarse stems. S5.1 Primary air separation: The long filaments and filament bundles after combing and fixed-length breaking are subjected to primary air separation, which effectively separates the coarse stems by utilizing the difference between wind force and material suspension velocity. S5.2 Discharge of coarse stems: By integrating the identification and discharge of coarse stems into the primary air separation system, and with the help of a precisely controlled air separation mechanism, coarse stems are separated and discharged from the production line. S6. Removal of unqualified materials: By constructing an air separation and stem removal system linked to the sorting system, and setting up independent separation channels for coarse and fine stems and dedicated collection and reprocessing paths, unqualified coarse and fine stems are discharged through the air separation system to ensure the quality of the final product tobacco.

2. A tobacco upgrading processing classification method with dynamic screening and multi-stage air classification regulation according to claim 1, characterized in that, The S3.1 multi-stage air separation includes three stages of air separation, specifically: S3.11 Primary air separation: In the same air separation stage, a "three-way diversion" strategy based on aerodynamic differences and wind speed-wind pressure linkage control is introduced to separate the mixture of short filaments and fine stems into three categories: short filaments, stems, and a mixture of short filaments and stems. S3.12 Secondary air separation: Fine separation of the mixture of short filaments and fine stems, separating the short filaments from the fine stems; Based on the primary air separation, fine air field shaping and dynamic pressure difference threshold control are introduced, and "narrow band" precise separation is achieved by utilizing the slight difference in "density-morphology-drag coefficient" to finely separate the mixture of short filaments and fine stems. S3.13 Three-stage air separation: After the first two stages of separation, the fine stems are further separated by a fine air field with "recovery priority". Through dynamic air pressure, air speed compensation and discharge channel directional control, the separated fine stems are air-separated for recovery, and the tobacco shreds mixed in are recovered and discharged from the production line.

3. The method for classifying and improving tobacco shreds with dynamic screening and multi-stage air separation control as described in claim 1, characterized in that, In the S1.1 vibrating screen, the frequency-controlled multi-channel louvered screening equipment has multiple screen holes of varying sizes along the material flow direction.

4. The method for classifying and improving tobacco shreds with dynamic screening and multi-stage air separation control as described in claim 1, characterized in that, The S1.2 adjustment of the screening path is based on the collected tobacco material humidity, thickness, temperature and air separation recovery rate, and automatically adjusts the diameter and vibration frequency to ensure that the short fiber recovery rate is not less than 90% and the mismixing rate is not more than 5%.

5. The method for classifying and upgrading tobacco shreds with dynamic screening and multi-stage air separation control according to claim 1, characterized in that, In the separation of long filaments, filament bundles, coarse stems and short filaments, and fine stems in S2, the separation process adopts closed-loop control based on PLC, and combines fuzzy control with optimization algorithms based on historical and real-time data to adjust the diameter length, vibration frequency and wind speed in a coordinated manner. The aforementioned diameter length adjustment is achieved by changing the position of the feed inlet, the feeding direction, and the effective passing distance of the screen surface, in order to balance the sorting efficiency and sorting accuracy. The path length L is obtained by online estimation of the movement time, displacement and vibration response of the tobacco material on the screen surface. The estimation adopts at least one of photoelectric, visual and vibration response signals. The classification ratio is achieved through real-time adjustment of the effective screen path length L, and L is determined by at least two of the following: the feed inlet position, the feed angle and height, the screen tilt angle and the feeding direction. A one-to-one control mapping relationship is established with the short fiber recovery rate and the mismixing rate per unit time. The feed inlet can be switched between multiple preset stations at the front, middle, and rear of the screen. The front station is used to shorten the path to process short filaments and small strands; the middle and rear stations are used to extend the path to process long filaments and clumps. The height of the feed inlet is adjustable to change the initial distribution width and sliding initiation energy of the material: a higher height corresponds to an extended path, suitable for long filaments and clumps; a lower height corresponds to a shortened path, suitable for short filaments and small strands. The feed inlet achieves coordinated control of path length and residence time through paired optimization of "screen angle - vibration frequency". That is, when the target is fine separation of long filaments, the screen angle is reduced and the vibration frequency is lowered; when the target is rapid separation of short filaments, the screen angle is increased and the vibration frequency is raised. The feeding direction and angle are controlled by changing the feeding direction and feeding angle to horizontal, inclined and vertical zones, respectively, so that the initial movement trajectory of the material on the screen surface is controlled, so that long filaments and filament balls correspond to a smaller feeding angle to extend the path, while short filaments and fine stems correspond to a larger feeding angle to shorten the path. The real-time indicator trigger path adjustment uses the real-time changes in short fiber recovery rate and mismixing rate as the trigger quantity. When the short fiber recovery rate is lower than the set threshold, the path of the second type of material on the screen surface is extended first and the feeding speed is reduced. When the mismixing rate rises above the threshold, the path of the second type of material is shortened first and the wind speed and diversion angle are linked.

6. The method for classifying and upgrading tobacco shreds with dynamic screening and multi-stage air separation control according to claim 1, characterized in that, S3. In the processing of short filaments and small stems, the sorting system in the multi-stage air separation is equipped with tobacco material thickness monitoring, humidity and temperature sensors, and a module for detecting recovery rate and mismixing rate after air separation, so as to realize real-time monitoring and feedback adjustment of the tobacco material processing status. The secondary air separation unit has a programmable air pressure distribution profile and a controllable residence time, so as to achieve complete separation by utilizing the density or suspension critical velocity difference between short filaments and fine stems; The three-stage air separation and recycling unit is equipped with a short filament recycling channel and a separate discharge channel for fine stems. The recycling channel is connected to a dust collection device, and a purity monitoring sensor is installed at the recycling port. When the control unit detects that the short filament recovery rate is lower than the threshold or the mixing rate increases, it opens the interstage feedback channel to return the mixture and residual material from the second or third stage to the previous stage or parallel bypass for re-sorting. The control unit adopts multi-objective coordinated optimization to balance "short filament recovery rate ≥90%, mismixing rate ≤5%, minimization of unit energy consumption and stability of unit throughput", and outputs the optimal combination of wind speed, wind pressure and feeding cycle of each stage. The online detection includes at least one of photoelectric recognition, visual recognition component ratio detection, mass flow meter and wind pressure and wind speed sensor, which can estimate the short filament ratio and error rate of each output material in real time.

7. The method for classifying and improving tobacco shreds with dynamic screening and multi-stage air separation control as described in claim 1, characterized in that, In the S4. combing and fixed-length broken filament processing of long filaments and filament balls, when a decrease in the short filament recovery rate is detected, the control unit adjusts the second-stage and third-stage air pressure distribution and feeding vibration frequency in conjunction to improve the recovery capacity of mixed short filaments. When an increase in the mismixing rate is detected, the control unit reduces the feed rate and adjusts the matching relationship between the diversion angle and the wind speed to allow the residual short fibers in the fine stems to be recycled a second time. The second type of tobacco material is separated into short shreds, stems, and a mixture of short shreds and stems by the first-stage air separation. The second-stage air separation further refines the mixture, and the third-stage air separation recovers the short shreds from the fine stems and discharges them.

8. The method for classifying and improving tobacco shreds with dynamic screening and multi-stage air separation control according to claim 1, characterized in that, In the process of removing coarse stems in S5, the fixed-length broken wires are controlled by photoelectric induction ranging and stepper motor feeding in conjunction with PLC counting logic, which supports switching between multiple length specifications, including one or more of 5mm, 10mm, 15mm, 20mm and 25mm.

9. The method for classifying and improving tobacco shreds with dynamic screening and multi-stage air separation control according to claim 1, characterized in that, The applicable range of the tobacco raw materials includes tobacco raw materials with a moisture content of 10% to 25%, a particle size of 2.5 mm to 100 mm, and a stem content of up to 30%.

10. The method for classifying and improving tobacco shreds with dynamic screening and multi-stage air separation control according to claim 1, characterized in that, The method achieves a short filament recovery rate of ≥90%, a mismixing rate of ≤5%, a coarse stem mismixing rate of ≤2%, and an air-classification recovery rate of ≥95% under the target configuration.

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