A method for analyzing and evaluating process performance of a key equipment for tobacco production

Abstract

The application discloses a cigarette production silk production key equipment process performance analysis and evaluation method, comprising the following steps: determining process tasks and control systems of each process of a cigarette production silk production line; determining multi-level equipment performance evaluation items of each process; classifying and testing the equipment performance evaluation items; respectively performing equipment performance evaluation on each process according to the equipment performance evaluation item classification and testing method; if the equipment performance evaluation result meets the requirement, respectively performing index carding and classification on each process according to the process parameters, and respectively performing process performance evaluation on each process according to the process index classification result; if the equipment performance evaluation result does not meet the requirement, performing maintenance on the process equipment with a lower evaluation result, and then returning to the equipment performance evaluation step. The cigarette production silk production key equipment process performance analysis and evaluation method can improve the equipment process performance, guarantee the product processing quality consistency and improve the fine processing production level.

Description

Technical Field

[0001] This invention relates to the field of process performance analysis technology for cigarette production equipment, and more specifically, to a method for process performance analysis and evaluation of key equipment in cigarette manufacturing. Background Technology

[0002] In the production processes of many industries such as tobacco, chemicals, and food, the idea has always been that equipment ensures process quality and process quality ensures quality. This is especially true in the cigarette manufacturing process, where the production line is long and has many points of connection, and all the equipment is connected in series. If a key piece of equipment malfunctions, the entire production line will stop. Therefore, the performance analysis and evaluation of equipment to ensure process quality is of paramount importance.

[0003] Therefore, there is an urgent need for a method for analyzing and evaluating the process performance of key equipment in cigarette manufacturing. Summary of the Invention

[0004] The purpose of this invention is to provide a method for analyzing and evaluating the process performance of key equipment in cigarette manufacturing, so as to solve the problems in the prior art.

[0005] This invention provides a method for analyzing and evaluating the process performance of key equipment in cigarette manufacturing, comprising:

[0006] Determine the technological tasks and control systems for each process in the cigarette manufacturing line;

[0007] Based on the technological tasks of each process, the control system of each process is divided into hierarchical levels to determine the multi-level equipment performance evaluation items for each process.

[0008] Based on the multi-level equipment performance evaluation items of each process, the equipment performance evaluation items are classified and tested.

[0009] Based on the classification of equipment performance evaluation items and testing methods, the equipment performance of each process is evaluated separately.

[0010] If the equipment performance evaluation results meet the requirements, then the indicators of each process are sorted and classified according to the process parameters, and the process performance is evaluated according to the process indicator classification results.

[0011] If the equipment performance evaluation results do not meet the requirements, the equipment in the process with the lower evaluation results shall be repaired, and then the process shall return to the equipment performance evaluation step.

[0012] The method for analyzing and evaluating the process performance of key equipment in cigarette manufacturing, as described above, preferably includes the following: The determination of the process tasks and control system for each step of the cigarette manufacturing line includes:

[0013] For the loosening and rehydration process, feeding process and drying process in the silk processing, the main process tasks and control system of each process are determined. The drying process includes HT+ drum drying and CTD drying.

[0014] The method for analyzing and evaluating the process performance of key equipment in cigarette manufacturing as described above, preferably, includes the following process tasks corresponding to the loosening and rehydration process: material moisture content, material temperature, and material looseness rate; and the control system corresponding to the loosening and rehydration process includes: material flow control, material moisture content control, material temperature control, and material residence time control.

[0015] The process tasks corresponding to the feeding process include: material moisture content, material temperature and feeding accuracy. The control system corresponding to the feeding process includes: material flow control, material moisture content control, material temperature control, feeding accuracy control and material residence time control.

[0016] The process tasks corresponding to the HT+ drum drying in the drying process include: material moisture content, material temperature, tobacco filling performance and tobacco morphology. The control system corresponding to the HT+ drum drying in the drying process includes: material flow control, material moisture content control, material temperature control and material residence time control.

[0017] The process tasks corresponding to CTD drying in the drying process include: material moisture content, material temperature, tobacco filling performance and tobacco morphology. The control system corresponding to CTD drying in the drying process includes: material flow control, material moisture content control, material temperature control and material residence time control.

[0018] The method for analyzing and evaluating the process performance of key equipment in cigarette manufacturing, as described above, preferably involves, according to the process tasks of each process, decomposing the control system of each process into hierarchical levels to determine the multi-level equipment performance evaluation items for each process, including:

[0019] The control systems for each process are broken down into levels such as primary functional control system, secondary execution control system, parameters / indicators, and execution elements / meters, in order to determine the multi-level equipment performance evaluation items for each process.

[0020] The method for analyzing and evaluating the process performance of key equipment in cigarette manufacturing as described above, preferably, includes the following primary functional control system in the loosening and rehydration process: material flow control, material moisture content control, material temperature control, and material residence time control.

[0021] The primary functional control system of the control system for the feeding process includes: material flow control, material moisture content control, material temperature control, feeding accuracy control, and material residence time control.

[0022] The primary function control system of the HT+ drum dryer in the drying process includes: material flow control, material moisture content control, material temperature control, and material residence time control.

[0023] The primary functional control system of the CTD drying process includes: material flow control, material moisture content control, material temperature control, and material residence time control.

[0024] The method for analyzing and evaluating the process performance of key equipment in cigarette manufacturing, as described above, preferably includes classifying and testing the equipment performance evaluation items according to the multi-level equipment performance evaluation items of each process, including:

[0025] Based on the hierarchy of primary functional control system, secondary execution control system, parameters / indicators, and execution elements / measuring components, the equipment performance evaluation location, index characteristics, and calibration methods for each process are determined. According to the correlation and influence of process processing quality and the degree of quality risk, and combined with the characteristics of different equipment, the performance-related evaluation items of each equipment are divided into four categories: A, B, C, and D, and tested using national standards, industry standards, or customized methods.

[0026] The method for analyzing and evaluating the process performance of key equipment in cigarette manufacturing, as described above, preferably includes the following classification criteria for the equipment performance-related evaluation items: Category A consists of key parameters that directly affect product quality; Category B consists of important parameters that affect process stability; Category C consists of minor parameters or qualitative indicators; and Category D consists of auxiliary parameters that have no significant impact on the process.

[0027] The above-described method for analyzing and evaluating the process performance of key equipment in cigarette manufacturing includes, preferably, the evaluation items for equipment performance evaluation: equipment reliability, non-steady-state index, and overall effective operating rate.

[0028] The equipment performance is evaluated for each process according to the equipment performance evaluation item classification and testing methods, including:

[0029] Data acquisition and processing: Data is acquired through central control system. Missing data is read by instruments or manually inspected. For each quality characteristic item, the start and end conditions for data acquisition are determined.

[0030] Determine the weight of the evaluation items for equipment performance evaluation in each process, the corresponding evaluation indicators for each evaluation item, the indicator weights and evaluation standards for each evaluation indicator;

[0031] Results Analysis: The test data were scored according to the evaluation criteria of the evaluation indicators of each process. The evaluation indicators of each evaluation item in each process were weighted and summed to obtain the score of each evaluation item. Then, the evaluation indicators of each evaluation item in each process were weighted and summed to obtain the equipment performance evaluation score of each process.

[0032] The method for analyzing and evaluating the process performance of key equipment in cigarette manufacturing, as described above, preferably includes, when the equipment performance evaluation results meet the requirements, the step of sorting and classifying the indicators of each process according to the process parameters, and evaluating the process performance of each process according to the classification results of the process indicators, including:

[0033] Based on the degree of influence of process parameters on product quality, process performance indicators are divided into three categories: A, B, and C. Among them, category A consists of key process performance indicators, category B consists of important process performance indicators, and category C consists of general process performance indicators.

[0034] Based on the classification results of process indicators, the process performance of each process is evaluated. No specific evaluation is conducted for Category B and Category C indicators. For Category A indicators, the weights of process quality and process capability, the indicator weights of each evaluation indicator corresponding to process quality and process capability, and the evaluation criteria are determined first, so as to evaluate the process performance of key yarn-making equipment from the two aspects of process capability and process quality.

[0035] The above-described method for analyzing and evaluating the process performance of key equipment in cigarette manufacturing includes, preferably, the following: In the loosening and rehydration process, the material outlet moisture content is classified as Class A, and the material outlet temperature and re-permeability are Class C. In the loosening and rehydration process, the return air temperature and material flow rate are Class A, while the water addition, compensating steam pressure, and compensating steam flow rate are Class B, and the hot air temperature, hot air fan frequency, exhaust velocity, drum speed, ejector steam pressure, and water temperature are Class C. In the feeding process, the material outlet moisture content, overall feeding accuracy, and instantaneous feeding ratio variation coefficient are Class A, while the material outlet temperature is Class C. In the feeding process, the material flow rate and return air temperature are Class A, while the atomization effect is Class B. The following parameters are also considered: instantaneous liquid flow rate, exhaust opening, drum speed, compensating steam pressure, ejector steam pressure, batch liquid accumulation, liquid temperature, and compressed air ejector pressure. The nozzle angle is a Class C indicator. In the process quality indicators of the HT+ drum drying process, the moisture content at the drying outlet is a Class A indicator, while the moisture content change, drying outlet temperature, tobacco morphology, leaf filling value, whole tobacco rate, broken tobacco rate, and inlet moisture content are Class C indicators. In the process capacity indicators of the HT+ drum drying process, the material flow rate, HT steam flow rate, hot air temperature, and drum wall temperature are Class A indicators, while the HT steam pressure, hot air velocity, and exhaust negative pressure are Class B indicators, and the exhaust opening, drum wall steam pressure, and drum speed are Class C indicators. In the process quality indicators of the CTD drying process, the moisture content at the drying outlet is a Class A indicator, while the moisture content change, drying outlet temperature, tobacco morphology, leaf filling value, whole tobacco rate, broken tobacco rate, and inlet moisture content are Class C indicators. In the process capacity indicators of the CTD drying process, the material flow rate, process gas flow rate, and process gas temperature are Class A indicators, the exhaust process gas flow rate is a Class B indicator, and the exhaust opening is a Class C indicator.

[0036] This invention provides a method for analyzing and evaluating the process performance of key equipment in cigarette manufacturing. It uses problems identified in the equipment's process performance evaluation as input for quality improvement, aiming to enhance equipment process performance, ensure consistent product quality, and improve the level of refined processing. The method focuses on evaluating the process performance of key equipment (loosening and rehydration, feeding, and drying) in the cigarette manufacturing process. It starts by assessing whether the equipment meets the process requirements, the design requirements of process parameters, and the effectiveness of online monitoring and metering devices. By determining evaluation items and methods and establishing evaluation standards, it ultimately forms a comprehensive process performance evaluation system for key cigarette manufacturing equipment that prioritizes ensuring the intrinsic quality of the product, uses stable process parameters as elements, and leverages the performance of key equipment. Attached Figure Description

[0037] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described below with reference to the accompanying drawings, wherein:

[0038] Figure 1 A flowchart illustrating an embodiment of the method for analyzing and evaluating the process performance of key equipment in cigarette manufacturing provided by the present invention;

[0039] Figure 2 The results of the equipment performance evaluation items for the loosening and rehydration process were summarized.

[0040] Figure 3 The results of the evaluation items related to the equipment performance of the feeding process were summarized.

[0041] Figure 4 The results of the evaluation of equipment performance related to the drying process (HT + drum) were summarized.

[0042] Figure 5 This document outlines the relevant evaluation items for equipment performance in the drying process (CTD drying). Detailed Implementation

[0043] Various exemplary embodiments of the present disclosure will now be described in detail with reference to the accompanying drawings. The descriptions of the exemplary embodiments are merely illustrative and are in no way intended to limit the present disclosure or its application or use. The present disclosure may be implemented in many different forms and is not limited to the embodiments described herein. These embodiments are provided so that the present disclosure will be thorough and complete, and will fully express the scope of the disclosure to those skilled in the art. It should be noted that, unless specifically stated otherwise, the relative arrangement of components and steps, the composition of materials, numerical expressions, and values ​​set forth in these embodiments should be interpreted as exemplary only and not as limiting.

[0044] The terms “first,” “second,” and similar terms used in this disclosure do not indicate any order, quantity, or importance, but are merely used to distinguish different parts. Terms such as “including” or “contains” mean that the element preceding the term encompasses the element listed after it, and do not exclude the possibility of encompassing other elements as well. Terms such as “above” and “below” are used only to indicate relative positional relationships; when the absolute position of the described object changes, this relative positional relationship may also change accordingly.

[0045] In this disclosure, when a specific component is described as being located between a first component and a second component, an intermediary component may or may not be present between the specific component and the first or second component. When a specific component is described as connecting to other components, the specific component may be directly connected to the other components without having an intermediary component, or it may not be directly connected to the other components but may have an intermediary component.

[0046] All terms used in this disclosure (including technical or scientific terms) have the same meaning as understood by one of ordinary skill in the art to which this disclosure pertains, unless otherwise specifically defined. It should also be understood that terms defined in a general dictionary, such as a dictionary, should be interpreted as having a meaning consistent with their meaning in the context of the relevant art, and not as having an idealized or highly formalized meaning, unless expressly defined herein.

[0047] Techniques, methods, and equipment known to those skilled in the art may not be discussed in detail, but where appropriate, they should be considered part of the specification.

[0048] like Figure 1 As shown, the method for analyzing and evaluating the process performance of key equipment in cigarette manufacturing provided in this embodiment includes the following steps in actual implementation:

[0049] Step S1: Determine the process tasks and control system for each process in the cigarette production line.

[0050] Specifically, for the three key processes in the yarn processing (loosening and rehydration, feeding, and drying), the main process tasks and control systems for each process are determined. The drying process includes HT+ roller drying and CTD drying. For example... Figure 2 As shown, the process tasks corresponding to the loosening and rehydration process include: material moisture content, material temperature and material looseness. The control system corresponding to the loosening and rehydration process includes: material flow control, material moisture content control, material temperature control and material residence time control.

[0051] like Figure 3 As shown, the process tasks corresponding to the feeding process include: material moisture content, material temperature and feeding accuracy. The control system corresponding to the feeding process includes: material flow control, material moisture content control, material temperature control, feeding accuracy control and material residence time control.

[0052] like Figure 4 As shown, the process tasks corresponding to the HT+ drum drying in the drying process include: material moisture content, material temperature, tobacco filling performance and tobacco morphology. The control system corresponding to the HT+ drum drying in the drying process includes: material flow control, material moisture content control, material temperature control and material residence time control.

[0053] like Figure 5As shown, the process tasks corresponding to CTD drying in the drying process include: material moisture content, material temperature, tobacco filling performance and tobacco morphology. The control system corresponding to CTD drying in the drying process includes: material flow control, material moisture content control, material temperature control and material residence time control.

[0054] Step S2: Based on the process tasks of each process, the control system of each process is divided into hierarchical levels to determine the multi-level equipment performance evaluation items for each process.

[0055] In this invention, the main process tasks of each process are analyzed. Starting from the process or equipment process tasks, the control system composition of each process is sorted out. According to the hierarchy of primary functional control system, secondary execution control system, parameters / indicators and execution elements / meters, the control system of each process is decomposed down level by level, and finally the multi-level equipment performance evaluation items of each process are comprehensively sorted out.

[0056] Specifically, such as Figure 2As shown, the primary functional control system of the loosening and rehydration process includes: material flow control, material moisture content control, material temperature control, and material residence time control. The secondary execution control system corresponding to material flow control includes a flow control system, whose parameters / indicators include instantaneous flow rate and cumulative material quantity. The actuators / meters corresponding to instantaneous flow rate and cumulative material quantity include belt scales. The secondary execution control system corresponding to material moisture content control includes a water supply system, whose parameters / indicators include water supply flow rate and water supply ratio. The actuators / meters corresponding to water supply flow rate and water supply ratio include water flow meters and water supply pneumatic diaphragm valves. The secondary execution control system corresponding to material temperature control includes a steam system, a hot air system, and a dehumidification system. The parameters / indicators corresponding to the steam system include steam pressure, steam flow rate, and steam dryness. The actuators / meters corresponding to steam pressure include steam pressure gauges, and the actuators / meters corresponding to steam flow rate include steam diaphragm valves and steam flow meters. The actuators / meters corresponding to steam dryness include a steam dryness meter; the parameters / indicators corresponding to the hot air system include: hot air temperature, hot air volume, return air temperature, and return air damper opening. The actuators / meters corresponding to hot air temperature include a temperature sensor; the actuators / meters corresponding to hot air volume include a fan frequency; the actuators / meters corresponding to return air temperature include a temperature sensor; and the actuators / meters corresponding to return air damper opening include a manual damper. The parameters / indicators corresponding to the dehumidification system include: dehumidification negative pressure, dehumidification air velocity, dehumidification opening, and filter cleanliness. The actuators / meters corresponding to dehumidification negative pressure include a dehumidification pressure gauge; the dehumidification air velocity is measured manually; the actuators / meters corresponding to dehumidification opening include a dehumidification damper; and the actuators / meters corresponding to filter cleanliness include a dehumidification filter. The secondary actuator control system corresponding to material residence time control includes a drum drive system. The parameters / indicators corresponding to the drum drive system include drum speed, and the actuators / meters corresponding to drum speed include a drum drive motor.

[0057] like Figure 3As shown, the primary functional control system of the feeding process includes: material flow control, material moisture content control, material temperature control, feeding accuracy control, and material residence time control. The secondary execution control system corresponding to material flow control includes a flow control system, whose parameters / indicators include instantaneous flow rate and cumulative material quantity. The actuators / meters corresponding to instantaneous flow rate and cumulative material quantity include belt scales. The secondary execution control system corresponding to material moisture content control includes a water addition system, whose parameters / indicators include water addition flow rate and water addition ratio. The actuators / meters corresponding to water addition flow rate and water addition ratio include water flow meters and pneumatic diaphragm valves for water addition. The material temperature... The secondary control system corresponding to the temperature control includes a steam system, a hot air system, a cylinder wall temperature control system, a rear chamber heating system, and a dehumidification system. The parameters / indicators corresponding to the steam system include steam pressure, steam flow rate, and steam dryness. The actuators / meters corresponding to steam pressure include a steam pressure gauge; those corresponding to steam flow rate include steam diaphragm valves and steam flow meters; and those corresponding to steam dryness include a steam dryness meter. The parameters / indicators corresponding to the hot air system include hot air temperature, hot air volume, cold air damper opening, return air temperature, and return air damper opening. The actuators / meters corresponding to hot air temperature include temperature sensors; and those corresponding to hot air volume include… The actuators / measuring devices corresponding to the hot air anemometer, cold air damper opening (including angle actuators), return air temperature (including temperature sensors), and return air damper opening (including servo cylinders) are all included. The parameters / indicators corresponding to the cylinder wall temperature control system include: feeding cylinder wall temperature, with a temperature sensor as the corresponding actuator / measuring device. The parameters / indicators corresponding to the rear chamber heating system include: rear chamber temperature, with a temperature sensor as the corresponding actuator / measuring device. The parameters / indicators corresponding to the dehumidification system include: dehumidification negative pressure, dehumidification air velocity, dehumidification opening, and filter cleanliness, with a dehumidification negative pressure actuator / measuring device including a dehumidification pressure gauge. The tidal air velocity is measured manually. The actuators / meters corresponding to the desiccation opening include the desiccation damper. The actuators / meters corresponding to the filter cleanliness include the desiccation filter. The secondary actuator control system corresponding to the feeding accuracy control includes: liquid temperature control system, tank heating steam system, liquid proportion control system, and ejector steam control system. The parameters / indicators corresponding to the liquid temperature control system include: liquid temperature and liquid stirring speed. The actuators / meters corresponding to the liquid temperature include temperature sensors. The actuators / meters corresponding to the liquid stirring speed include stirring motor frequency. The parameters / indicators corresponding to the tank heating steam system include steam pressure. The actuators / meters corresponding to the steam pressure include steam pressure gauges.The parameters / indicators corresponding to the liquid feed ratio control system include: liquid feed flow rate, feed ratio, nozzle angle, nozzle atomization effect, instantaneous feed accuracy, cumulative feed accuracy, and liquid weighing system; the actuators / meters corresponding to the liquid feed flow rate include the liquid feed flow meter and feed pump; the actuators / meters corresponding to the feed ratio include the liquid feed flow meter and material control belt scale; the actuators / meters corresponding to the nozzle angle include visual inspection / high-speed camera; the actuators / meters corresponding to the nozzle atomization effect include visual inspection / high-speed camera; the actuators / meters corresponding to the instantaneous feed accuracy and cumulative feed accuracy include the liquid feed flow meter and material control belt scale; the actuators / meters corresponding to the liquid weighing system include a static scale; the parameters / indicators corresponding to the ejector steam control system include steam pressure, and the actuators / meters corresponding to the steam pressure include a steam pressure gauge; the secondary execution control system corresponding to the material residence time control includes a drum drive system, the parameters / indicators corresponding to the drum drive system include drum speed, and the actuators / meters corresponding to the drum speed include the drum drive motor.

[0058] like Figure 4As shown, the primary functional control system of the HT+ drum dryer in the drying process includes: material flow control, material moisture content control, material temperature control, and material residence time control. The secondary execution control system corresponding to material flow control includes a flow control system, whose parameters / indicators include instantaneous flow rate and cumulative material quantity. The actuators / meters corresponding to instantaneous flow rate and cumulative material quantity include belt scales. The secondary execution control system corresponding to material moisture content control includes: an HT heating and humidification system, a drum wall temperature control system, and a hot air system. The parameters / indicators corresponding to the HT heating and humidification system include: heating and humidification steam application rate, heating and humidification steam pressure, and steam... The actuators / meters corresponding to steam dryness and the amount of heating and humidifying steam applied include steam flow meters; the actuators / meters corresponding to heating and humidifying steam pressure include steam pressure gauges; and the actuators / meters corresponding to steam dryness include steam dryness meters. The parameters / indicators corresponding to the cylinder wall temperature control system include drying cylinder wall temperature and drying cylinder wall steam pressure. The actuators / meters corresponding to drying cylinder wall temperature include saturated steam pressure conversion; and the actuators / meters corresponding to drying cylinder wall steam pressure include pressure sensors and pneumatic diaphragm valves. The parameters / indicators corresponding to the hot air system include hot air temperature, hot air volume, and hot air velocity. The actuators / meters corresponding to hot air temperature include temperature sensors. The sensor and diaphragm valve are used for control. The actuators / meters corresponding to the hot air volume include fan frequency; the actuators / meters corresponding to the hot air velocity include hot air anemometers and servo cylinder proportional distribution. The secondary control system corresponding to material temperature control includes a steam system and a dehumidification system. The parameters / indicators corresponding to the steam system include steam pressure and steam dryness. The actuators / meters corresponding to steam pressure include cylinder wall steam pressure gauges and heat exchanger steam pressure gauges; the actuators / meters corresponding to steam dryness include steam dryness meters. The parameters / indicators corresponding to the dehumidification system include dehumidification negative pressure, dehumidification air velocity, dehumidification temperature, dehumidification opening degree, and filter cleanliness. The actuators / meters corresponding to dehumidification negative pressure include... The actuators / meters include pressure sensors; the exhaust air velocity is measured manually; the actuators / meters corresponding to the exhaust temperature include mechanical thermometers; the actuators / meters corresponding to the exhaust opening include automatic exhaust dampers; and the actuators / meters corresponding to the filter cleanliness include exhaust filters. The secondary actuator control system corresponding to material residence time control includes a heating and humidification system and a drum drive system. The parameters / indicators corresponding to the heating and humidification system include the tunnel vibration frequency, and the actuators / meters corresponding to the tunnel vibration frequency include the vibration drive motor. The parameters / indicators corresponding to the drum drive system include the drum speed, and the actuators / meters corresponding to the drum speed include the drum drive motor.

[0059] like Figure 5As shown, the primary functional control system of the CTD drying control system in the drying process includes: material flow control, material moisture content control, material temperature control, and material residence time control. The secondary execution control system corresponding to material flow control includes a flow control system, whose parameters / indicators include instantaneous flow rate and cumulative material quantity. The actuators / meters corresponding to instantaneous flow rate and cumulative material quantity include belt scales. The secondary execution control system corresponding to material moisture content control includes: a process gas control system for airflow drying. The parameters / indicators corresponding to the process gas control system include: process gas flow rate, process gas temperature, expansion unit hot air volume, expansion unit hot air temperature, furnace temperature, return air temperature, oxygen content, water application rate, and sparks. The actuators / meters corresponding to process gas flow rate include gas flow meters; the actuators / meters corresponding to process gas temperature, expansion unit hot air temperature, furnace temperature, and return air temperature include temperature sensors; the actuators / meters corresponding to expansion unit hot air volume include fan frequency; the actuators / meters corresponding to oxygen content include oxygen content detectors; and the actuators / meters corresponding to water application rate include... The components / meters include water flow meters, and the corresponding actuators / meters include Mars probes; the secondary actuator control system corresponding to material temperature control includes a steam system, a dehumidification system, and inlet / outlet airlock sealing. The parameters / indicators corresponding to the steam system include steam pressure, steam flow rate, and steam dryness. The actuators / meters corresponding to steam pressure include steam pressure gauges, steam flow rate includes steam diaphragm valves and steam flow meters, and steam dryness includes a steam dryness meter; the parameters / indicators corresponding to the dehumidification system include dehumidification opening and dehumidification current. The actuators / meters corresponding to dehumidification opening include dehumidification dampers, and dehumidification current includes gas flow meters; the parameters / indicators corresponding to inlet / outlet airlock sealing include airlock gaps, and the actuators / meters corresponding to airlock gaps include feeler gauges; the secondary actuator control system corresponding to material residence time control includes a process gas flow control system for airflow drying. The parameters / indicators corresponding to the process gas flow control system include process gas flow rates, and the actuators / meters corresponding to process gas flow rates include gas flow meters.

[0060] Step S3: Classify and test the equipment performance evaluation items according to the multi-level equipment performance evaluation items of each process.

[0061] Specifically, based on the hierarchy of primary functional control system, secondary execution control system, parameters / indicators, and execution elements / measuring components, the performance evaluation location, indicator characteristics, and calibration methods for each process are determined. According to the relevance and impact on process quality, the degree of quality risk, and the characteristics of different equipment, the performance-related evaluation items for each piece of equipment are divided into four categories: A, B, C, and D. Testing is conducted using national standards, industry standards, or customized methods. The classification criteria for these performance-related evaluation items include: Category A: key parameters directly affecting product quality; Category B: important parameters affecting process stability; Category C: secondary parameters or qualitative indicators; and Category D: auxiliary parameters with no significant impact on the process. In practical implementation, the focus is on higher-level Category A and B evaluation items. A category characteristic analysis is conducted for each equipment performance evaluation item, such as gaseous media, liquid media, and solid materials, to establish comprehensive and easy-to-operate testing methods for each item. For the classification and testing methods of performance-related evaluation items for key yarn-making equipment, standard methods are used where national or industry standards exist; otherwise, new standard methods must be established.

[0062] For example, in the performance evaluation of key equipment in the loosening and rehydration process, the instantaneous flow rate of the flow control system for material flow control is detected before loosening, the index characteristic is quantitative, and the calibration item is: belt scale metering accuracy; the specific calibration method is: according to the simulated load method (weight method) for electronic belt scale metering accuracy in "13.2 Online Instrument Calibration" of the "Cigarette Process Specification" (2016 edition), its index grade is A. The cumulative material quantity is detected before loosening, the index characteristic is quantitative, and the calibration item is: belt scale metering accuracy; the specific calibration method is: according to the simulated load method (weight method) for electronic belt scale metering accuracy in "13.2 Online Instrument Calibration" of the "Cigarette Process Specification" (2016 edition), its index grade is C.

[0063] The water flow meter for the material moisture content controlled water supply system is located in the water supply pipeline. Its characteristic is quantitative, and the calibration item is flow meter accuracy. The calibration method is to refer to Cigarette Process Specification 13.2.4, and its grade is A. The water supply pneumatic diaphragm valve for the material moisture content controlled water supply system is located in the water supply pipeline. Its characteristic is quantitative, and the calibration method is as follows: CV value set to 0%, valve body and stem at the bottom; CV value set to 100%, valve body and stem at the top; CV value set to 50%, valve body and stem in the middle; CV values ​​set to 20% and 80%, with noticeable valve body and stem movement, and its grade is C. The water flow meter for the water supply ratio is located in the water supply pipeline. Its characteristic is quantitative, and the calibration item is flow meter accuracy. The calibration method is to refer to Cigarette Process Specification 13.2.4, and its grade is A. The detection location for the water-filling pneumatic diaphragm valve is the water-filling pipeline. The index characteristic is quantitative. The calibration method is as follows: the opening CV value is set to 0%, and the valve body and valve stem are at the bottom; the opening CV value is set to 100%, and the valve body and valve stem are at the top; the opening CV value is set to 50%, and the valve body and valve stem are in the middle; the opening CV value is set to 20% and 80%, and the valve body and valve stem have obvious movement. Its index grade is C.

[0064] The steam pressure gauge for the steam system controlling material temperature is located in the steam pipeline (ejector water). Its indicator characteristic is quantitative. The calibration method is: verify that the condition meets requirements and the displayed value is normal; its indicator grade is B. The steam diaphragm valve for measuring steam flow is located in the steam pipeline (ejector water). Its indicator characteristic is quantitative. The calibration method is: set the opening CV value to 0%, with the valve body and stem at the bottom; set the opening CV value to 100%, with the valve body and stem at the top; set the opening CV value to 50%, with the valve body and stem in the middle; set the opening CV value to 20% and 80%, with noticeable movement of the valve body and stem; its indicator grade is C. The steam flow meter for measuring steam flow is located in the steam pipeline (ejector water). Its indicator characteristic is quantitative. The calibration method is: refer to national standard GB / T 2624-2006; its indicator grade is C.

[0065] The temperature sensor for the hot air temperature in the hot air system for material temperature control is located in the hot air duct. Its indicator characteristic is quantitative. The calibration method is to compare it with the corresponding mechanical temperature gauge in the pipeline and observe whether it is consistent (comparison error ≤2℃ is acceptable, >2℃ is not acceptable). Its indicator grade is A. The fan frequency for hot air volume is detected in the hot air duct. Its indicator characteristic is quantitative. The calibration method is to refer to section 13.3 of the "Cigarette Process Specification" (2016 edition). Its indicator grade is C. The temperature sensor for the return air temperature is located in the hot air duct. Its indicator characteristic is quantitative. The calibration method is to compare it with the corresponding mechanical temperature gauge in the pipeline and observe whether it is consistent (comparison error ≤2℃ is acceptable, >2℃ is not acceptable). Its indicator grade is A. The manual damper for the return air damper opening is detected in the hot air duct. Its indicator characteristic is qualitative. The calibration method is to adjust the damper opening and observe whether the deviation between the displayed value and the set value meets the requirements. Its indicator grade is C.

[0066] The detection location of the dehumidification pressure gauge for the dehumidification system under material temperature control is the dehumidification pipeline. Its indicator characteristic is quantitative. The calibration method is: according to the JJG882 pressure transmitter verification procedure, and meeting process requirements, its indicator grade is B. The detection location of the dehumidification air velocity is the dehumidification pipeline. It is quantitative. The calibration method is: referring to 13.3.4 of the "Cigarette Process Specification" (2016 edition), its indicator grade is C. The detection location of the dehumidification damper for dehumidification opening is the dehumidification pipeline. Its indicator characteristic is quantitative. The calibration method is: compliance inspection, with scales set at 0%, 20%, 50%, and 90% respectively, checking the consistency of the actual opening, its indicator grade is C. The detection location of the dehumidification filter for filter cleanliness is the dehumidification pipeline. Its indicator characteristic is qualitative. The calibration method is: components are intact, sealing connections are good, operation is without abnormal noise, and mesh is not blocked, its indicator grade is B.

[0067] The detection position of the drum drive motor for the material residence time control drum drive system is below the drum. The index characteristic is quantitative. The calibration method is to measure whether the actual speed is consistent with the set value. Its index classification is C.

[0068] Step S4: According to the equipment performance evaluation items and testing methods, evaluate the equipment performance of each process.

[0069] As shown in Table 1, the equipment performance evaluation items include evaluation items and understanding items. Evaluation items include equipment reliability, non-steady-state index and comprehensive effective operating rate. Understanding items include: production capacity of each process section of the production line, production capacity of major single equipment, effective operating rate of each process section of the production line and effective operating rate of major single equipment.

[0070] Table 1 Equipment Performance Evaluation Items

[0071]

[0072] In one embodiment of the method for analyzing and evaluating the process performance of key equipment in cigarette manufacturing of the present invention, step S4 may specifically include:

[0073] Step S41, Data Acquisition and Processing: Data is acquired through central control system. Missing data is read by instruments or manually inspected. For each quality characteristic item, the start and end conditions for data acquisition are determined.

[0074] Specifically, for process operating parameters and quality indicators that are collected by the central control system (CCS), the CCS data shall prevail, and after processing according to the corresponding rules, they shall be used for testing and evaluation. For operating parameters and quality indicators that are displayed on instruments but not collected by the CCS, the data displayed on the instruments shall be randomly read three times during normal production, and the arithmetic mean shall be used for testing and evaluation. For operating parameters and quality indicators that are not displayed on instruments and not collected by the CCS, manual inspection shall be carried out, and after calculation according to the testing method, they shall be used for testing and evaluation. The data collection and transmission rules are as follows: CCS data collection should ensure the integrity of the entire batch of data, and data shall be extracted and uploaded to the CCS server at equal time intervals without any processing, with the interval not exceeding 30 seconds.

[0075] Table 2. Start and end conditions for quality characteristic items

[0076]

[0077] Specifically, the data collection start condition for material flow rate is an instantaneous flow rate greater than 100 kg / h with a 3-minute delay, and the data collection end condition is an instantaneous flow rate less than 100 kg / h with a 3-minute advance in time. For low-moisture materials with a moisture content less than or equal to 15%, the data collection start condition for outlet moisture content is an outlet moisture content greater than 8% with a 3-minute delay, and the data collection end condition is an outlet moisture content less than 8% with a 3-minute advance in time. For medium-high moisture materials with a moisture content greater than 15% and less than or equal to 23%, the data collection start condition for outlet moisture content is an outlet moisture content greater than 12% with a 3-minute delay, and the data collection end condition is an outlet moisture content less than 12% with a 3-minute advance in time. The data collection start condition for outlet temperature is synchronized with the outlet moisture content, and the data collection end condition is synchronized with the outlet moisture content. The data collection start condition for hot air temperature, cylinder wall temperature, and process gas temperature is synchronized with the starting point of the process outlet moisture content, and the data collection end condition is synchronized with the ending point of the process inlet material flow rate.

[0078] Step S42: Determine the weight of the evaluation items for the equipment performance evaluation of each process, the number of evaluation indicators corresponding to each evaluation item, the indicator weight and evaluation standard of each evaluation indicator.

[0079] Specifically, the equipment performance is evaluated using various test data and the equipment performance evaluation standard table shown in Table 3. A longitudinal comparative analysis is then conducted with historical equipment performance evaluation data, and the equipment performance evaluation conclusions are given based on the analysis results.

[0080] Table 3 Equipment Performance Evaluation Standards

[0081]

[0082] As shown in Table 3, the weight of equipment reliability for the loosening and rehydration process, the feeding process, and the drying process is 0.5, the weight of the non-steady-state index is 0.4, and the weight of the overall effective operating rate is 0.1. The evaluation indicators for equipment reliability in each process include failure rate and number of downtimes. The failure rate has a weight of 0.3, and the number of downtimes has a weight of 0.7. The evaluation criteria for failure rate are as follows: if the equipment failure rate is >1%, the failure rate score is 0 points; if the equipment failure rate is ≤1%, the failure rate score = 100 - equipment failure rate × 10000. The evaluation criteria for number of downtimes are as follows: if the number of downtimes is >0.1 times / batch, the number of downtimes has a score of 0 points; if the number of downtimes is ≤0.1 times / batch, the number of downtimes has a score of 100 - number of downtimes × 10000. If the number of downtimes is less than 0.01 times / batch, the score for downtime is 100 points. The evaluation indicators corresponding to the unsteady-state index of the loosening and rehydration process include the unsteady-state index of loosening and rehydration; the evaluation indicators corresponding to the unsteady-state index of the feeding process include the unsteady-state index of tobacco sheet feeding; and the evaluation indicators corresponding to the unsteady-state index of the drying process include the unsteady-state index of drying. The evaluation criteria for the unsteady-state index of loosening and rehydration, tobacco sheet feeding, and drying include: if the unsteady-state index is greater than 20%, the score for the unsteady-state index is 0 points; if the unsteady-state index is less than or equal to 20%, the score for the unsteady-state index is (20% - unsteady-state index) × 500. The evaluation indicator corresponding to the comprehensive effective operating rate of each process includes the comprehensive effective operating rate. The evaluation criteria corresponding to the comprehensive effective operating rate include: the score for the comprehensive effective operating rate is the comprehensive effective operating rate × 100.

[0083] Step S43, Result Analysis: Based on the evaluation criteria of the evaluation indicators of each process, score the test data, perform weighted summation on each evaluation indicator of each process to obtain the score of each evaluation item, and then perform weighted summation on each evaluation item of each process to obtain the equipment performance evaluation score of each process.

[0084] Step S5: If the equipment performance evaluation results meet the requirements, then sort and classify the indicators of each process according to the process parameters, and evaluate the process performance of each process according to the process indicator classification results.

[0085] In one embodiment of the present invention, if the equipment performance evaluation score exceeds a preset score threshold (e.g., 80 points), the equipment performance evaluation result is considered to meet the requirements; conversely, if the equipment performance evaluation score is lower than the preset score threshold (e.g., 80 points), the equipment performance evaluation result is considered to fail to meet the requirements. In one embodiment of the method for process performance analysis and evaluation of key equipment in cigarette manufacturing of the present invention, step S5 may specifically include:

[0086] Step S51: According to the degree of influence of process parameters on product quality, process performance indicators are divided into categories A, B and C. Among them, category A is key process performance indicators, category B is important process performance indicators and category C is general process performance indicators.

[0087] The results of the process performance indicators and classification for each process are shown in Tables 4-7. As shown in Table 4, among the process quality indicators for the loosening and rehydration process, the material outlet moisture content is a Class A indicator, while the material outlet temperature and reabsorption rate are Class C indicators. Among the process capacity indicators for the loosening and rehydration process, the return air temperature and material flow rate are Class A indicators, the water addition amount, compensating steam pressure, and compensating steam flow rate are Class B indicators, and the hot air temperature, hot air fan frequency, exhaust air velocity, drum speed, ejector steam pressure, and water temperature are Class C indicators. As shown in Table 5, among the process quality indicators of the feeding process, the material outlet moisture content, overall feeding accuracy, and instantaneous feeding ratio variation coefficient are Class A indicators, while the material outlet temperature is a Class C indicator. Among the process capacity indicators of the feeding process, the material flow rate and return air temperature are Class A indicators, the atomization effect is a Class B indicator, and the instantaneous flow rate of the liquid material, the exhaust opening, the drum speed, the compensating steam pressure, the ejector steam pressure, the batch liquid accumulation, the liquid temperature, the compressed air ejector pressure, and the nozzle angle are Class C indicators. As shown in Table 6, among the process quality indicators of the HT+ drum drying process, the drying outlet moisture content is a Class A indicator, while the moisture content change, the drying outlet temperature, the tobacco morphology, the leaf filling value, the whole tobacco rate, the broken tobacco rate, and the inlet moisture content are Class C indicators. Among the process capacity indicators of the HT+ drum drying process, the material flow rate, the HT steam flow rate, the hot air temperature, and the drum wall temperature are Class A indicators, the HT steam pressure, the hot air velocity, and the exhaust negative pressure are Class B indicators, and the exhaust opening, the drum wall steam pressure, and the drum speed are Class C indicators. As shown in Table 7, among the process quality indicators of CTD drying in the drying process, the moisture content at the drying outlet is a Class A indicator, while the moisture content change, drying outlet temperature, tobacco morphology, leaf filling value, whole tobacco rate, broken tobacco rate, and inlet moisture content are Class C indicators. Among the process capacity indicators of CTD drying in the drying process, the material flow rate, process gas flow rate, and process gas temperature are Class A indicators, the dehumidification process gas flow rate is a Class B indicator, and the dehumidification opening degree is a Class C indicator.

[0088] Table 4. Summarization and Classification of Technological Performance Indicators for the Loosening and Rehydration Process

[0089]

[0090] Table 5. Summarization and Classification of Process Performance Indicators for the Feeding Process

[0091]

[0092] Table 6. Summary and Classification of Process Performance Indicators for Heating and Humidifying + Drying (HT + Drum) Process

[0093]

[0094] Table 7. Summarization and Classification of Process Performance Indicators for the Drying (CTD Drying) Process

[0095]

[0096] Step S52: Based on the classification results of process indicators, evaluate the process performance of each process. For Class B and Class C indicators, only objective presentation is required during statistical analysis, without specific evaluation. For Class A indicators, first determine the weights of process quality and process capability, the indicator weights and evaluation standards of each evaluation indicator corresponding to process quality and process capability, so as to evaluate the process performance of key yarn-making equipment from the two aspects of process capability and process quality.

[0097] The evaluation indicators, weights, and evaluation criteria for each process are shown in Tables 8-11. Specifically, as shown in Table 8, in the evaluation of the process performance of key equipment in yarn making, the process quality of the loosening and rehydration process has a weight of 0.3, and the process capability has a weight of 0.7. The evaluation indicators corresponding to process quality include the material outlet moisture content cpk. The evaluation criteria for the material outlet moisture content cpk are as follows: if the material outlet moisture content cpk ≥ 1.33, the material outlet moisture content score is 100 points; if 1.33 > material outlet moisture content cpk > 0.67, the material outlet moisture content score is ((material outlet moisture content cpk - 0.67) / (1.33 - 0.67) × 100) points; if 0.67 ≥ material outlet moisture content cpk, the material outlet moisture content score is 0 points. The evaluation indicators corresponding to process capability include the return air temperature cpk and the coefficient of variation of material flow rate, wherein the weight of the return air temperature cpk is 0. 6. The evaluation criteria for return air temperature cpk include: if return air temperature cpk ≥ 1.67, the return air temperature score is 100 points; if 1.67 > return air temperature cpk ≥ 1.00, the return air temperature score is ((return air temperature cpk - 1) / (1.67 - 1.00) × 100) points; if 1.00 > return air temperature cpk, the return air temperature score is 0 points. The weight of the material flow rate variation coefficient is 0.4, and the evaluation criteria for the material flow rate variation coefficient include: if the flow rate variation coefficient ≤ 0.15, the material flow rate variation coefficient score is 100 points; if 0.15 < flow rate variation coefficient < 0.25, the material flow rate variation coefficient score is ((0.25 - flow rate variation coefficient) / (0.25 - 0.15) × 100) points; if 0.25 ≤ flow rate variation coefficient, the material flow rate variation coefficient score is 0 points.

[0098] As shown in Table 9, the weight of process quality in the feeding process is 0.6, and the weight of process capability is 0.4. The evaluation indicators corresponding to process quality include material outlet moisture content cpk, instantaneous feeding ratio variation coefficient, and overall feeding accuracy. The weight of material outlet moisture content cpk is 0.2, and the weights of instantaneous feeding ratio variation coefficient and overall feeding accuracy are 0.4. The evaluation criteria for material outlet moisture content cpk are as follows: if material outlet moisture content cpk ≥ 1.67, then the material outlet moisture content score is 100 points; if 1.67 > material outlet moisture content cpk > 1.00, then the material outlet moisture content score is ((material outlet moisture content cpk) -1.00) / (1.67-1.00)×100) points; if 1.00≥ material outlet moisture content cpk, then the material outlet moisture content score is 0 points; the evaluation criteria for the instantaneous feeding ratio variation coefficient include: if the instantaneous feeding ratio variation coefficient ≤0.5%, then the instantaneous feeding ratio variation coefficient score is 100 points; if 0.5%<instantaneous feeding ratio variation coefficient ≤1%, then the instantaneous feeding ratio variation coefficient score is ((1%-instantaneous feeding ratio variation coefficient) / (1%-0.5%)×100) points; if 1%<instantaneous feeding ratio variation coefficient, then the instantaneous feeding ratio variation coefficient score is 0 points; the overall feeding accuracy evaluation The evaluation criteria include: if the overall feeding accuracy is ≤0.02, the overall feeding accuracy score is 100 points; if 0.02 < overall feeding accuracy < 1, the overall feeding accuracy score is ((1 - overall feeding accuracy) / 0.98 × 100) points; if 1 ≤ overall feeding accuracy, the overall feeding accuracy score is 0 points. The evaluation indicators corresponding to process capability include: material flow rate variation coefficient and return air temperature cpk. The material flow rate variation coefficient has a weight of 0.4. The evaluation criteria for the material flow rate variation coefficient include: if the flow rate variation coefficient is ≤0.15, the material flow rate variation coefficient score is 100 points; if 0.15 < flow rate variation coefficient < 0.98, the overall feeding accuracy score is 0 points. If the coefficient of variation of material flow rate is 0.25, the score is ((0.25 - coefficient of variation of flow rate) / (0.25 - 0.15) × 100) points; if 0.25 ≤ coefficient of variation of flow rate, the score is 0 points. The weight of return air temperature cpk is 0.6. The evaluation criteria for return air temperature cpk include: if return air temperature cpk ≥ 1.67, the score is 100 points; if 1.67 > return air temperature cpk ≥ 1.00, the score is ((return air temperature cpk - 1) / (1.67 - 1.00) × 100) points; if 1.00 > return air temperature cpk, the score is 0 points.

[0099] As shown in Table 10, the process quality of the HT+ drum drying process has a weight of 0.3, and the process capability has a weight of 0.7. The evaluation index corresponding to the process quality includes the drying outlet moisture content (cpk). The evaluation criteria for the drying outlet moisture content (cpk) are as follows: if the drying outlet moisture content (cpk) ≥ 1.67, then the drying outlet moisture content score is 100 points; if 1.67 > drying outlet moisture content (cpk) > 1.00, then the drying outlet moisture content score is ((drying outlet moisture content (cpk) – 1.00) / (1.67 - 1.00) × 100) points; if 1.00 ≥ drying outlet moisture content (cpk), then the drying outlet moisture content score is 0 points. The process capability... The evaluation indicators corresponding to the force include: material flow rate variation coefficient, HT steam flow rate cpk, hot air temperature cpk, and cylinder wall temperature. The weights for the material flow rate variation coefficient are 0.3, HT steam flow rate cpk, hot air temperature cpk, and cylinder wall temperature are 0.2 and 0.3 respectively. The evaluation criteria for the material flow rate variation coefficient are as follows: if the material flow rate variation coefficient is ≤0.1%, the score is 100 points; if 0.1% < material flow rate variation coefficient ≤0.15%, the score is ((0.15% - flow rate variation coefficient) / (0.15% - 0.1%). The evaluation criteria for HT steam flow rate cpk include: if HT steam flow rate cpk ≥ 1.67, then HT steam flow rate scores 100 points; if 1.67 > HT steam flow rate cpk ≥ 0.67, then HT steam flow rate scores ((HT steam flow rate cpk - 0.67) / (1.67 - 0.67) × 100) points; if 0.67 > HT steam flow rate cpk, then HT steam flow rate scores 0 points; the evaluation criteria for hot air temperature cpk include: if hot air temperature cpk ≥ 1.67, then hot air temperature cpk scores 100 points; if 0.15% < HT steam flow rate cpk ≥ 0.67, then hot air temperature cpk scores 0 points; if 0.15% < HT steam flow rate ...1.67, then hot air temperature cpk scores 100 points; if 0.15% < HT steam flow rate cpk ≥ 1.67, then hot air temperature cpk scores 100 points; if 0.15% < HT steam flow rate cpk ≥ 1.67, then hot air temperature cpk scores 1 The temperature score is 100 points; if 1.67 > hot air temperature cpk ≥ 1.00, the hot air temperature score is ((hot air temperature cpk-1) / (1.67-1.00)×100) points; if 1.00 > hot air temperature cpk, the hot air temperature score is 0 points; the evaluation criteria for cylinder wall temperature cpk include: if cylinder wall temperature cpk ≥ 1.67, the cylinder wall temperature score is 100 points; if 1.67 > cylinder wall temperature cpk > 1, the cylinder wall temperature score is ((cylinder wall temperature cpk-1) / (1.67-1.00)×100) points; if 1.00 ≥ cylinder wall temperature cpk, the cylinder wall temperature score is 0 points.

[0100] As shown in Table 11, the weight of process quality in the CTD drying process is 0.3, and the weight of process capability is 0.7. The evaluation index corresponding to process quality includes the drying outlet moisture content (cpk). The evaluation criteria for drying outlet moisture content (cpk) are as follows: if drying outlet moisture content (cpk) ≥ 1.33, then the drying outlet moisture content score is 100 points; if 1.33 > drying outlet moisture content (cpk) ≥ 0.67, then the drying outlet moisture content score is ((drying outlet moisture content (cpk – 0.67) / (1.33 - 0.67) × 100) points; if... If 0.67 > the moisture content at the dryer outlet (cpk), then the moisture content at the dryer outlet receives a score of 0. The evaluation indicators for process capability include: material flow rate variation coefficient, process gas flow rate (cp), and process gas temperature (cp). The weights for the material flow rate variation coefficient and process gas temperature (cp) are 0.4, 0.3, and 0.3 respectively. The evaluation criteria for the material flow rate variation coefficient are as follows: if the material flow rate variation coefficient is ≤ 0.1%, then the score is 100; if 0.1% < the material flow rate variation coefficient... If the coefficient of variation is ≤0.15%, the score for the coefficient of variation of material flow rate is ((0.15% - coefficient of variation) / (0.15% - 0.1%) × 100) points; if 0.15% < coefficient of variation of material flow rate, the score for the coefficient of variation of material flow rate is 0 points. The evaluation criteria for process gas flow rate cp include: if process gas flow rate cp ≥ 1.67, the score for process gas flow rate is 100 points; if 1.67 > process gas flow rate cp ≥ 0.67, the score for process gas flow rate is ((process gas flow rate cp - 0.67) / (…). The process gas temperature cp is scored as follows: if the process gas temperature cp ≥ 1.67, the process gas temperature score is 100 points; if 1.67 > process gas temperature cp ≥ 1.00, the process gas temperature score is ((process gas temperature cp - 1) / (1.67 - 1.00) × 100) points; if 1.00 > process gas temperature cp, the process gas temperature score is 0 points.

[0101] Table 8. Evaluation Indicators, Weights, and Evaluation Standards for the Loosening and Rehydration Process

[0102]

[0103] Table 9. Evaluation Indicators, Weights, and Evaluation Standards for the Feeding Process

[0104]

[0105] Table 10 Evaluation Indicators, Weights, and Evaluation Standards for the Heating and Humidifying + Drying (HT + Drum) Process

[0106]

[0107] Table 11 Evaluation Indicators, Weights, and Evaluation Criteria for the Processing Performance of the Drying (CTD Drying) Process

[0108]

[0109] In practice, each indicator is scored according to the evaluation criteria in Tables 8-11. The score of each evaluation content is calculated based on the weight of each evaluation indicator set in the evaluation model. Finally, the equipment process performance score of each process is calculated according to the weight of each evaluation content of the key equipment for yarn making.

[0110] Step S6: If the equipment performance evaluation result does not meet the requirements, repair the process equipment with the lower evaluation result, and then return to the equipment performance evaluation step (i.e., return to step S4).

[0111] This invention primarily focuses on establishing a performance evaluation method for key equipment in the silk-making process. First, it clarifies the main technological tasks of each of the three key processes / equipment in the silk-making process (drying, feeding, and loosening / re-moistening). The control system structure for each process is then organized, and the overall control system is progressively broken down according to a hierarchical sequence: "Primary Functional Control System - Secondary Execution Control System - Parameters / Indicators - Actuators / Meters." This process comprehensively identifies relevant evaluation items for equipment performance. Second, based on the relevance and impact of the process on quality and the degree of quality risk, and considering the characteristics of different equipment, the relevant evaluation items are categorized, with a focus on higher-level evaluation items. Finally, the characteristics of each equipment performance evaluation item are analyzed, such as gaseous media, liquid media, and solid materials, and comprehensive and easy-to-operate testing methods are established for each item. Finally, the process performance evaluation items are comprehensively reviewed. Based on this review, the process performance evaluation items are categorized according to the degree of influence of process parameters on product quality and the importance of quality indicators. Based on this, a process performance evaluation method is established.

[0112] In one embodiment of the present invention, the performance of key equipment and the process performance of key equipment in a certain production line are evaluated, and the evaluation results are shown in Table 12 and Table 13, respectively.

[0113] Table 12 Performance Evaluation Results of Key Equipment in a Certain Production Line

[0114]

[0115] Table 13 Evaluation Results of the Process Performance of Key Equipment in a Certain Production Line

[0116]

[0117] The method for analyzing and evaluating the process performance of key equipment in cigarette manufacturing provided in this invention uses problems encountered in the evaluation of equipment process performance as input for quality improvement, aiming to improve equipment process performance, ensure the consistency of product processing quality, and enhance the level of refined processing and production. It focuses on the evaluation method of process performance of key equipment (loosening and rehydration, feeding, and drying) in the cigarette manufacturing process. Starting with the equipment's fulfillment of process tasks, process parameter design requirements, and the effectiveness of online monitoring and metering devices, it establishes evaluation standards by determining evaluation items and methods, ultimately forming a set of process performance evaluation systems for key equipment in cigarette manufacturing that "takes ensuring the intrinsic quality of the product as the main line, stabilizing process processing parameters as the element, and leveraging the performance of key equipment as the support."

[0118] The embodiments of this disclosure have now been described in detail. To avoid obscuring the concept of this disclosure, some details known in the art have not been described. Those skilled in the art can fully understand how to implement the technical solutions disclosed herein based on the above description.

[0119] While specific embodiments of this disclosure have been described in detail by way of examples, those skilled in the art should understand that the examples are for illustrative purposes only and not intended to limit the scope of this disclosure. Those skilled in the art should understand that modifications can be made to the above embodiments or equivalent substitutions can be made to some technical features without departing from the scope and spirit of this disclosure. The scope of this disclosure is defined by the appended claims.

Claims

1. A method for analyzing and evaluating the process performance of key equipment in cigarette manufacturing, characterized in that, include: Determine the technological tasks and control systems for each process in the cigarette manufacturing line; Based on the technological tasks of each process, the control system of each process is divided into hierarchical levels to determine the multi-level equipment performance evaluation items for each process. Based on the multi-level equipment performance evaluation items of each process, the equipment performance evaluation items are classified and tested. Based on the classification of equipment performance evaluation items and testing methods, the equipment performance of each process is evaluated separately. If the equipment performance evaluation results meet the requirements, then the indicators of each process are sorted and classified according to the process parameters, and the process performance is evaluated according to the process indicator classification results. If the equipment performance evaluation results do not meet the requirements, the equipment in the process with the lower evaluation results shall be repaired, and then the process shall return to the equipment performance evaluation step.

2. The method for analyzing and evaluating the process performance of key equipment in cigarette manufacturing as described in claim 1, characterized in that, The process tasks and control system for determining each step of the cigarette manufacturing line include: For the loosening and rehydration process, feeding process and drying process in the silk processing, the main process tasks and control system of each process are determined. The drying process includes HT+ drum drying and CTD drying.

3. The method for analyzing and evaluating the process performance of key equipment in cigarette manufacturing as described in claim 2, characterized in that, The process tasks corresponding to the loosening and rehydration process include: material moisture content, material temperature and material looseness. The control system corresponding to the loosening and rehydration process includes: material flow control, material moisture content control, material temperature control and material residence time control. The process tasks corresponding to the feeding process include: material moisture content, material temperature and feeding accuracy. The control system corresponding to the feeding process includes: material flow control, material moisture content control, material temperature control, feeding accuracy control and material residence time control. The process tasks corresponding to the HT+ drum drying in the drying process include: material moisture content, material temperature, tobacco filling performance and tobacco morphology. The control system corresponding to the HT+ drum drying in the drying process includes: material flow control, material moisture content control, material temperature control and material residence time control. The process tasks corresponding to CTD drying in the drying process include: material moisture content, material temperature, tobacco filling performance and tobacco morphology. The control system corresponding to CTD drying in the drying process includes: material flow control, material moisture content control, material temperature control and material residence time control.

4. The method for analyzing and evaluating the process performance of key equipment in cigarette manufacturing as described in claim 2, characterized in that, The process involves hierarchically breaking down the control system of each process according to its technological tasks, in order to determine the multi-level equipment performance evaluation items for each process, including: The control systems for each process are broken down into levels such as primary functional control system, secondary execution control system, parameters / indicators, and execution elements / meters, in order to determine the multi-level equipment performance evaluation items for each process.

5. The method for analyzing and evaluating the process performance of key equipment in cigarette manufacturing as described in claim 4, characterized in that, The primary functional control system of the loosening and rehydration process includes: material flow control, material moisture content control, material temperature control, and material residence time control. The secondary execution control system corresponding to material flow control includes a flow control system, whose parameters / indicators include instantaneous flow rate and cumulative material quantity. The actuators / meters corresponding to instantaneous flow rate and cumulative material quantity include belt scales. The secondary execution control system corresponding to material moisture content control includes a water supply system, whose parameters / indicators include water supply flow rate and water supply ratio. The actuators / meters corresponding to water supply flow rate and water supply ratio include water flow meters and water supply pneumatic diaphragm valves. The secondary execution control system corresponding to material temperature control includes a steam system, a hot air system, and a dehumidification system. The parameters / indicators corresponding to the steam system include steam pressure, steam flow rate, and steam dryness. The actuators / meters corresponding to steam pressure include steam pressure gauges, and the actuators / meters corresponding to steam flow rate include steam diaphragm valves and steam flow meters. The actuators / meters corresponding to dryness include a steam dryness meter; the parameters / indicators corresponding to the hot air system include: hot air temperature, hot air volume, return air temperature, and return air damper opening. The actuators / meters corresponding to hot air temperature include a temperature sensor; the actuators / meters corresponding to hot air volume include a fan frequency; the actuators / meters corresponding to return air temperature include a temperature sensor; and the actuators / meters corresponding to return air damper opening include a manual damper. The parameters / indicators corresponding to the dehumidification system include: dehumidification negative pressure, dehumidification air velocity, dehumidification opening, and filter cleanliness. The actuators / meters corresponding to dehumidification negative pressure include a dehumidification pressure gauge; the dehumidification air velocity is measured manually; the actuators / meters corresponding to dehumidification opening include a dehumidification damper; and the actuators / meters corresponding to filter cleanliness include a dehumidification filter. The secondary actuator control system corresponding to material residence time control includes a drum drive system. The parameters / indicators corresponding to the drum drive system include drum speed; and the actuators / meters corresponding to drum speed include a drum drive motor. The primary functional control system of the feeding process includes: material flow control, material moisture content control, material temperature control, feeding accuracy control, and material residence time control. The secondary execution control system corresponding to material flow control includes a flow control system, whose parameters / indicators include instantaneous flow rate and cumulative material quantity. The actuators / meters corresponding to instantaneous flow rate and cumulative material quantity include belt scales. The secondary execution control system corresponding to material moisture content control includes a water addition system, whose parameters / indicators include water addition flow rate and water addition ratio. The actuators / meters corresponding to water addition flow rate and water addition ratio include water flow meters and pneumatic diaphragm valves for water addition. The material temperature control... The corresponding secondary control system includes a steam system, a hot air system, a cylinder wall temperature control system, a rear chamber heating system, and a dehumidification system. The parameters / indicators of the steam system include steam pressure, steam flow rate, and steam dryness. The actuators / meters corresponding to steam pressure include a steam pressure gauge; those corresponding to steam flow rate include steam diaphragm valves and steam flow meters; and those corresponding to steam dryness include a steam dryness meter. The parameters / indicators of the hot air system include hot air temperature, hot air volume, cold air damper opening, return air temperature, and return air damper opening. The actuators / meters corresponding to hot air temperature include temperature sensors; and those corresponding to hot air volume include hot air... The actuators / meters corresponding to the anemometer, cold air damper opening (including angle actuators), return air temperature (including temperature sensors), and return air damper opening (including servo cylinders) are all included. The parameters / indicators corresponding to the cylinder wall temperature control system include: feeding cylinder wall temperature, with a temperature sensor as the corresponding actuator / meter. The parameters / indicators corresponding to the rear chamber heating system include: rear chamber temperature, with a temperature sensor as the corresponding actuator / meter. The parameters / indicators corresponding to the dehumidification system include: dehumidification negative pressure, dehumidification air velocity, dehumidification opening, and filter cleanliness. The actuator / meter corresponding to the dehumidification negative pressure includes a dehumidification pressure gauge. The wind speed is measured manually. The actuators / meters corresponding to the desiccant opening include the desiccant damper. The actuators / meters corresponding to the filter cleanliness include the desiccant filter. The secondary control system corresponding to the feeding accuracy control includes: a liquid temperature control system, a tank heating steam system, a liquid proportioning control system, and an ejector steam control system. The parameters / indicators corresponding to the liquid temperature control system include: liquid temperature and liquid stirring speed. The actuators / meters corresponding to the liquid temperature include a temperature sensor. The actuators / meters corresponding to the liquid stirring speed include the stirring motor frequency. The parameters / indicators corresponding to the tank heating steam system include steam pressure. The actuators / meters corresponding to the steam pressure include a steam pressure gauge.The parameters / indicators corresponding to the liquid feed ratio control system include: liquid feed flow rate, feed ratio, nozzle angle, nozzle atomization effect, instantaneous feed accuracy, cumulative feed accuracy, and liquid weighing system; the actuators / meters corresponding to the liquid feed flow rate include liquid flow meter and feed pump; the actuators / meters corresponding to the feed ratio include liquid flow meter and material control belt scale; the actuators / meters corresponding to the nozzle angle include visual inspection / high-speed camera; the actuators / meters corresponding to the nozzle atomization effect include visual inspection / high-speed camera; the actuators / meters corresponding to the instantaneous feed accuracy and cumulative feed accuracy include liquid flow meter and material control belt scale; the actuators / meters corresponding to the liquid weighing system include static scale; the parameters / indicators corresponding to the ejector steam control system include steam pressure, and the actuators / meters corresponding to the steam pressure include steam pressure gauge; the secondary execution control system corresponding to the material residence time control includes drum drive system, the parameters / indicators corresponding to the drum drive system include drum speed, and the actuators / meters corresponding to the drum speed include drum drive motor; The primary control system of the HT+ drum dryer in the drying process includes: material flow control, material moisture content control, material temperature control, and material residence time control. The secondary control system corresponding to material flow control includes a flow control system, whose parameters / indicators include instantaneous flow rate and cumulative material quantity. The actuators / meters corresponding to instantaneous flow rate and cumulative material quantity include belt scales. The secondary control system corresponding to material moisture content control includes: an HT heating and humidification system, a drum wall temperature control system, and a hot air system. The parameters / indicators corresponding to the HT heating and humidification system include: heating and humidification steam application rate, heating and humidification steam pressure, and steam dryness. The actuators / meters corresponding to the applied amount of heating and humidifying steam include steam flow meters; the actuators / meters corresponding to the heating and humidifying steam pressure include steam pressure gauges; and the actuators / meters corresponding to the steam dryness include steam dryness meters. The parameters / indicators corresponding to the cylinder wall temperature control system include drying cylinder wall temperature and drying cylinder wall steam pressure. The actuators / meters corresponding to the drying cylinder wall temperature include saturated steam pressure conversion, and the actuators / meters corresponding to the drying cylinder wall steam pressure include pressure sensors and pneumatic diaphragm valves. The parameters / indicators corresponding to the hot air system include hot air temperature, hot air volume, and hot air velocity. The actuators / meters corresponding to the hot air temperature include temperature sensors. The actuators and starting diaphragm valves, the actuators / meters corresponding to the hot air volume include fan frequency, and the actuators / meters corresponding to the hot air velocity include hot air anemometer and servo cylinder proportional distribution; the secondary actuator control system corresponding to the material temperature control includes a steam system and a dehumidification system, the parameters / indicators corresponding to the steam system include steam pressure and steam dryness, the actuators / meters corresponding to steam pressure include cylinder wall steam pressure gauge and heat exchanger steam pressure gauge, and the actuators / meters corresponding to steam dryness include steam dryness meter; the parameters / indicators corresponding to the dehumidification system include dehumidification negative pressure, dehumidification air velocity, dehumidification temperature, dehumidification opening degree and filter cleanliness, and the actuators / meters corresponding to dehumidification negative pressure include... The components / meters include pressure sensors; the exhaust air velocity is measured manually; the actuators / meters corresponding to the exhaust temperature include mechanical thermometers; the actuators / meters corresponding to the exhaust opening include automatic exhaust dampers; and the actuators / meters corresponding to filter cleanliness include exhaust filters. The secondary control system corresponding to material residence time control includes a heating and humidification system and a drum drive system. The parameters / indicators corresponding to the heating and humidification system include the tunnel vibration frequency, and the actuators / meters corresponding to the tunnel vibration frequency include the vibration drive motor. The parameters / indicators corresponding to the drum drive system include the drum speed, and the actuators / meters corresponding to the drum speed include the drum drive motor. The primary functional control system of the CTD drying process includes: material flow control, material moisture content control, material temperature control, and material residence time control. The secondary execution control system corresponding to material flow control includes a flow control system, whose parameters / indicators include instantaneous flow rate and cumulative material quantity. The actuators / meters corresponding to instantaneous flow rate and cumulative material quantity include belt scales. The secondary execution control system corresponding to material moisture content control includes: a process gas control system for airflow drying. The parameters / indicators corresponding to the process gas control system include: process gas flow rate, process gas temperature, expansion unit hot air volume, expansion unit hot air temperature, furnace temperature, return air temperature, oxygen content, water application rate, and sparks. The actuators / meters corresponding to process gas flow rate include gas flow meters; the actuators / meters corresponding to process gas temperature, expansion unit hot air temperature, furnace temperature, and return air temperature include temperature sensors; the actuators / meters corresponding to expansion unit hot air volume include fan frequency; the actuators / meters corresponding to oxygen content include oxygen content detectors; and the actuators corresponding to water application rate... The components / meters include water flow meters, and the corresponding actuators / meters include Mars probes; the secondary actuator control system corresponding to material temperature control includes a steam system, a dehumidification system, and inlet / outlet airlock sealing. The parameters / indicators corresponding to the steam system include steam pressure, steam flow rate, and steam dryness. The actuators / meters corresponding to steam pressure include steam pressure gauges, steam flow rate includes steam diaphragm valves and steam flow meters, and steam dryness includes a steam dryness meter; the parameters / indicators corresponding to the dehumidification system include dehumidification opening and dehumidification current. The actuators / meters corresponding to dehumidification opening include dehumidification dampers, and dehumidification current includes gas flow meters; the parameters / indicators corresponding to inlet / outlet airlock sealing include airlock gaps, and the actuators / meters corresponding to airlock gaps include feeler gauges; the secondary actuator control system corresponding to material residence time control includes a process gas flow control system for airflow drying. The parameters / indicators corresponding to the process gas flow control system include process gas flow rates, and the actuators / meters corresponding to process gas flow rates include gas flow meters.

6. The method for analyzing and evaluating the process performance of key equipment in cigarette manufacturing as described in claim 4, characterized in that, The process involves classifying and testing equipment performance evaluation items based on the multi-level equipment performance evaluation items for each process, including: Based on the hierarchy of primary functional control system, secondary execution control system, parameters / indicators, and execution elements / measuring components, the equipment performance evaluation location, index characteristics, and calibration methods for each process are determined. According to the correlation and influence of process processing quality and the degree of quality risk, and combined with the characteristics of different equipment, the performance-related evaluation items of each equipment are divided into four categories: A, B, C, and D, and tested using national standards, industry standards, or customized methods.

7. The method for analyzing and evaluating the process performance of key equipment in cigarette manufacturing as described in claim 6, characterized in that, The classification criteria for the equipment performance-related evaluation items include: Category A: key parameters that directly affect product quality; Category B: important parameters that affect process stability; Category C: minor parameters or qualitative indicators; and Category D: auxiliary parameters that have no significant impact on the process.

8. The method for analyzing and evaluating the process performance of key equipment in cigarette manufacturing as described in claim 1, characterized in that, The evaluation items for equipment performance include: equipment reliability, non-steady-state index, and overall effective operating rate. The equipment performance is evaluated for each process according to the equipment performance evaluation item classification and testing methods, including: Data acquisition and processing: Data is acquired through central control system. Missing data is read by instruments or manually inspected. For each quality characteristic item, the start and end conditions for data acquisition are determined. Determine the weight of the evaluation items for equipment performance evaluation in each process, the corresponding evaluation indicators for each evaluation item, the indicator weights and evaluation standards for each evaluation indicator; Results Analysis: The test data were scored according to the evaluation criteria of the evaluation indicators of each process. The evaluation indicators of each evaluation item in each process were weighted and summed to obtain the score of each evaluation item. Then, the evaluation indicators of each evaluation item in each process were weighted and summed to obtain the equipment performance evaluation score of each process.

9. The method for analyzing and evaluating the process performance of key equipment in cigarette manufacturing as described in claim 1, characterized in that, If the equipment performance evaluation results meet the requirements, the following steps involve sorting and classifying the indicators of each process step according to the process parameters, and evaluating the process performance of each process step according to the classification results of the process indicators: Based on the degree of influence of process parameters on product quality, process performance indicators are divided into three categories: A, B, and C. Among them, category A consists of key process performance indicators, category B consists of important process performance indicators, and category C consists of general process performance indicators. Based on the classification results of process indicators, the process performance of each process is evaluated. No specific evaluation is conducted for Category B and Category C indicators. For Category A indicators, the weights of process quality and process capability, the indicator weights of each evaluation indicator corresponding to process quality and process capability, and the evaluation criteria are determined first, so as to evaluate the process performance of key yarn-making equipment from the two aspects of process capability and process quality.

10. The method for analyzing and evaluating the process performance of key equipment in cigarette manufacturing as described in claim 9, characterized in that, In the loosening and rehydration process, the material outlet moisture content is classified as Class A, while the material outlet temperature and re-permeability are Class C. In the loosening and rehydration process capacity indicators, return air temperature and material flow rate are Class A, water addition, compensating steam pressure, and compensating steam flow rate are Class B, and hot air temperature, hot air fan frequency, exhaust velocity, drum speed, ejector steam pressure, and water temperature are Class C. In the feeding process, the material outlet moisture content, overall feeding accuracy, and instantaneous feeding ratio variation coefficient are Class A, while the material outlet temperature is Class C. In the feeding process capacity indicators, material flow rate and return air temperature are Class A, atomization effect is Class B, and instantaneous liquid flow rate, exhaust opening, drum speed, compensating steam pressure, ejector steam pressure, batch liquid accumulation, liquid temperature, compressed air ejector pressure, and nozzle angle are Class C. In the drying process, the HT... In the process quality indicators of the + drum drying process, the moisture content at the drying outlet is classified as a Class A indicator, while the moisture content change, drying outlet temperature, tobacco morphology, leaf filling value, whole tobacco rate, broken tobacco rate, and inlet moisture content are classified as Class C indicators. In the process capacity indicators of the HT+ drum drying process, the material flow rate, HT steam flow rate, hot air temperature, and drum wall temperature are classified as Class A indicators, while the HT steam pressure, hot air velocity, and exhaust negative pressure are classified as Class B indicators, and the exhaust opening, drum wall steam pressure, and drum rotation speed are classified as Class C indicators. In the process quality indicators of the CTD drying process, the moisture content at the drying outlet is classified as a Class A indicator, while the moisture content change, drying outlet temperature, tobacco morphology, leaf filling value, whole tobacco rate, broken tobacco rate, and inlet moisture content are classified as Class C indicators. In the process capacity indicators of the CTD drying process, the material flow rate, process gas flow rate, and process gas temperature are classified as Class A indicators, the exhaust process gas flow rate is classified as a Class B indicator, and the exhaust opening is classified as a Class C indicator.

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