A two-stage automatic deviation correcting device for tipping paper of a cigarette making machine and a control method thereof

Abstract

The application discloses a two-stage automatic deviation rectifying device for tipping paper of a cigarette making machine and a control method, and belongs to the technical field of tobacco machines. The device comprises a control system, a first adjusting unit and a second adjusting unit arranged along the running direction of the tipping paper. The first adjusting unit is a coarse adjusting unit, adopts a drum-type conveying wheel or an arc-shaped guide rail matched with a manual / electric adjusting assembly, realizes initial positioning with a large stroke and automatic centering guiding, and the second adjusting unit is a fine adjusting unit, adopts a deviation sensor, a conveying roller, a mounting frame, an adjusting motor and a worm and turbine transmission mechanism, realizes high-precision deviation rectifying by changing the axial direction of the conveying roller through the deflection of the mounting frame. The application adopts a two-stage deviation rectifying structure of "coarse adjusting+fine adjusting", the deviation rectifying precision reaches ±0.15 mm, stepless adjustment of tipping paper with a width of 40-80 mm is supported, and the technical defects of the existing single-stage screw rod driving deviation rectifying scheme, such as slow response, low precision, no self-locking, complicated maintenance and poor adaptability, are solved, and the application is suitable for automatic deviation rectifying control of tipping paper of various high-speed cigarette making machines.

Description

Technical Field

[0001] This invention relates to the field of cigarette machine manufacturing technology, specifically to a two-stage automatic deviation correction device and method for the tipping paper conveying process of a cigarette machine. Background Technology

[0002] This invention relates to the field of tobacco machinery technology, specifically to a two-stage automatic correction device for the tipping paper of a cigarette machine.

[0003] Tipping paper is a key auxiliary material used to wrap the filter rod in the cigarette production process. Its positional accuracy during high-speed conveying directly affects the appearance quality and production efficiency of the cigarette products. In modern high-speed cigarette machines (such as the PROTOS series, ZJ17, ZJ119 and other mainstream models), the production speed usually reaches 7,000-14,000 cigarettes / minute, and the tipping paper's running speed can reach over 600m / min. Under these high-speed operating conditions, the tipping paper is easily misaligned laterally due to the combined effects of multiple factors, including changes in the roll diameter of the tipping paper, fluctuations in ambient temperature and humidity, wear of the guide rollers, static electricity accumulation, paper thickness tolerance, equipment vibration, impact from paper changing and splicing, and dynamic inertial disturbances. This leads to misalignment of the tipping paper with the filter rod and cigarette, ultimately causing quality problems such as inconsistent tipping paper length at the cigarette filter end, poor splicing, and appearance defects. In severe cases, it can even cause equipment shutdown.

[0004] Currently, the tipping paper correction technology in the tobacco industry is mainly divided into the following three categories: The first type is the purely manual correction scheme: Early domestic cigarette rolling machines generally adopted a purely manual adjustment method. Operators would observe the running status of the tipping paper, manually loosen the locking screws, and adjust the axial position of the paper guide slider to achieve correction. This scheme has obvious drawbacks: First, the adjustment relies entirely on the operator's experience, and the adjustment amount cannot be accurately quantified, resulting in poor correction accuracy; second, the adjustment process requires stopping the machine, which seriously affects the operating efficiency of the equipment; third, manual sampling inspection is lagging and cannot monitor the tipping paper position in real time, easily producing a large number of substandard cigarettes; fourth, the labor intensity for operators is high, and they cannot adapt to the production rhythm of high-speed cigarette rolling machines.

[0005] The second type is the single-stage screw drive automatic correction scheme: This is the most widely used correction technology in mainstream models, and its typical representative is the technology disclosed in Chinese patent CN101617857B. This scheme adopts a single-stage transmission architecture of "laser detector + servo motor + ball screw". The laser detector detects the edge position of the tipping paper in real time. The controller drives the servo motor according to the detection signal. The servo motor drives the ball screw to rotate through the coupling. The ball screw drives the arc-shaped guide rail seat to move horizontally along the support shaft through the screw sleeve, thereby changing the transmission path of the tipping paper to achieve correction. Although this scheme achieves automatic correction, it still has the following inherent defects in practical applications: 1. Slow response speed and severe lag in correction: The ball screw has a slender shaft structure, which easily reaches the critical speed and resonates when rotating at high speed, thus its maximum speed is strictly limited. At the same time, the screw lead is usually small (generally 2-5mm), resulting in a correction response time of more than 200ms. Under the condition of high-speed operation of tipping paper (600m / min), the correction action is severely delayed and cannot effectively suppress dynamic deviation.

[0006] 2. Low correction accuracy and poor long-term stability: The ball screw drive has an inherent backlash, and as the service time increases, the wear between the screw and the nut will cause the backlash to increase further. The correction accuracy gradually deteriorates from the initial ±0.5mm to more than ±0.8mm, which cannot meet the requirements of high-speed cigarette machines for the position accuracy of the tipping paper.

[0007] 3. Lack of self-locking capability and high energy consumption: The ball screw drive itself does not have self-locking characteristics. After the correction is in place, the servo motor needs to be continuously powered to generate braking torque to maintain the position. This not only increases energy consumption, but also accelerates the aging of the motor due to the long-term power-on braking state, reducing its service life.

[0008] 4. Short maintenance cycle and high operating cost: Ball screws have strict requirements for lubrication conditions, and there are a lot of smoke and paper scraps in the tobacco production environment, which can easily enter the screw transmission pair and cause accelerated wear. Usually, cleaning and lubrication maintenance is required every 3 months, which is a lot of maintenance work and reduces the effective operating rate of the equipment.

[0009] 5. Poor adaptability and incompatibility with multiple specifications of tipping paper: The existing solution has a fixed guide rail width, which can only adapt to a single specification of tipping paper. When different specifications of products need to be produced and the tipping paper width needs to be changed, the entire guide rail assembly must be replaced, resulting in a long changeover time and failing to meet the needs of flexible production.

[0010] The third type is the imported dual-roller correction solution: Some imported ultra-high-speed winding and splicing machines (such as the M series) adopt a dual-roller automatic correction structure, which achieves correction through the coordinated action of two deflection rollers. Although this solution has high correction accuracy, it has problems such as complex structure, high equipment cost, and difficult maintenance.

[0011] In summary, existing tipping paper correction technologies generally suffer from technical bottlenecks such as slow response speed, low correction accuracy, lack of self-locking capability, short maintenance cycle, and poor adaptability, failing to fully meet the high-precision, high-stability, and low-maintenance-cost correction requirements of modern high-speed cigarette machines. Therefore, developing a novel automatic tipping paper correction device to fundamentally solve the aforementioned shortcomings of existing technologies has significant engineering practical value and market application prospects. Summary of the Invention

[0012] The purpose of this invention is to overcome the above-mentioned defects of the prior art and provide a two-stage automatic correction device for cigarette tipping paper. Through the two-stage correction architecture design of "coarse adjustment + fine adjustment", it fundamentally solves the technical problems of slow response speed, low correction accuracy, lack of self-locking ability, short maintenance cycle and poor adaptability of the existing single-stage screw drive correction scheme. It realizes high-precision, high-stability, low-energy consumption and low-maintenance cost automatic correction control of tipping paper under high-speed operation conditions.

[0013] To solve the above-mentioned technical problems, the present invention provides the following technical solution: A two-stage automatic correction device for cigarette machine tipping paper includes a control system and an adjustment unit arranged along the tipping paper's running direction. The adjustment unit includes a deviation sensor, a conveyor roller, a mounting frame that can oscillate around a rotating axis, an adjustment motor, and a worm gear transmission mechanism. The conveyor roller is rotatably mounted on the mounting frame, and the tipping paper is conveyed around the conveyor roller. The mounting frame is oscillatingly mounted on the cigarette machine frame via a rotating axis, the axis of which is located near the center of the conveyor roller along the width direction of the tipping paper. The adjustment motor drives the mounting frame to deflect via the worm gear transmission mechanism. The control system includes a controller. The deviation sensor is arranged on the tipping paper conveying path to detect the edge position of the tipping paper in real time and transmits the detection signal to the controller. The controller controls the operation of the adjustment motor according to the detection signal and controls the deflection angle of the mounting frame through the worm gear transmission mechanism, thereby changing the angle between the conveyor roller and the tipping paper to adjust the tension difference on both sides of the tipping paper, achieving precise correction of the lateral position of the tipping paper. The adjustment unit includes a first unit and a second unit arranged sequentially along the direction of the tipping paper's movement. The first unit is located upstream or downstream of the second unit. The first unit controls the movement of the sliding pair by manually adjusting or setting the deflection angle using the adjustment component for coarse adjustment over a large stroke. The second unit is used for fine adjustment over a high precision by setting the minimum deflection angle of the adjustment motor and the transmission ratio of the worm gear. The controller determines whether to start the first unit and / or the second unit or keep it stationary based on the magnitude of the offset detected by the deviation sensor.

[0014] In a further preferred embodiment, the worm gear transmission mechanism includes a worm and a worm wheel. The worm is coaxially connected to the output shaft of the regulating motor, and the worm wheel is coaxially fixed to the rotation shaft of the mounting bracket. The lead angle of the worm is less than its equivalent friction angle, so that after the regulating motor stops driving, the worm gear transmission mechanism will self-lock the mounting bracket in the current position.

[0015] In a further preferred embodiment, a shaft encoder and / or limit sensor are provided between the regulating motor and the mounting bracket. The shaft encoder is installed at the output end of the worm gear transmission mechanism or the output end of the regulating motor to provide real-time feedback of the swing angle of the mounting bracket to the controller.

[0016] More preferably, the deviation sensor is an ultrasonic sensor, including a first edge sensor and a second edge sensor, which are respectively disposed at the two edges of the cork paper; the controller is provided with a difference calculation module, which is used to perform difference calculation on the detection values ​​of the first edge sensor and the second edge sensor to determine the offset.

[0017] A further preferred embodiment is an optical edge detection sensor, which determines the offset by detecting the proportion of the light beam blocked by the edge of the cork paper.

[0018] More preferably, the first unit includes a sliding adjustment pair, an adjustment component, and a drum-shaped conveyor wheel. The drum-shaped conveyor wheel has a drum-shaped surface with a large central diameter and small diameters at both ends, and its central diameter is at least 0.5 mm larger than the diameters at both ends.

[0019] More preferably, the surface of the drum-shaped conveyor wheel is a smooth surface or a surface with herringbone grooves; the herringbone grooves are a number of herringbone guide lines extending from the center of the width of the cork paper to both sides, and the herringbone guide lines are either fine grooves with a depth greater than 0.1 mm or guide ribs that are at least 0.05 mm higher than the surface, with an included angle of 30-60° between the herringbone lines on the left and right sides.

[0020] In a further preferred embodiment, the first unit includes a sliding adjustment pair, an adjustment component, and an arc-shaped guide rail. The surface of the arc-shaped guide rail is a smooth surface or a surface with herringbone grooves. The herringbone grooves are a number of herringbone guide lines extending from the center of the width of the tipping paper to both sides. The herringbone guide lines are either fine grooves with a depth greater than 0.1 mm or guide ribs that are at least 0.05 mm higher than the surface. The included angle between the herringbone lines on the left and right sides is 30-60°.

[0021] More preferably, the controller is equipped with a deviation grading processing module. When the offset is greater than the first preset threshold S1, the first threshold is when the paper offset of the single-sided edge sensor reaches the first preset threshold S1. Then, the first unit and the second unit are started simultaneously for joint correction. When the offset is less than or equal to the first preset threshold S1 and greater than the second preset threshold S2 (which is not zero), only the second unit is started for fine adjustment. When the offset is less than the second preset threshold S2, no adjustment action is performed.

[0022] Further preferably, the offset threshold S is 0.3 mm for S1 and 0.25 mm for S2 when the cigarette machine speed is less than or equal to 9000 cigarettes / minute. When the cigarette machine speed is greater than 9000 cigarettes / minute, S1 is 0.2 mm and S2 is 0.15 mm.

[0023] More preferably, the limit sensor is a pair of limit switches, which are fixedly installed on the frame and respectively set at the limit positions of the maximum allowable deflection angle of the mounting frame in both the forward and reverse directions. When the mounting frame deflects to the limit position, the limit signal is triggered, and the controller stops adjusting the motor drive according to the limit signal.

[0024] A method for correcting the deviation of cigarette machine tipping paper using a two-stage automatic deviation correction device based on any of the preceding methods includes the following steps: Detection step: The edge position of the tipping paper is detected in real time by a deviation sensor to obtain a lateral offset signal; Control step: The controller performs calculations based on the offset signal, determines the magnitude of the offset, and performs graded control of the start and stop of the adjustment unit based on the difference ∑ between the offset and a threshold; Execution step: The adjustment motor operates according to the control signal, driving the mounting frame to deflect around the rotation axis through a worm gear transmission mechanism, changing the angle between the conveyor roller and the tipping paper to adjust the tension difference on both sides of the tipping paper, thereby achieving deviation correction; Self-locking step: After the deviation correction is completed, the adjustment motor stops driving, and the self-locking characteristic of the worm gear transmission mechanism automatically locks the mounting frame in the current position.

[0025] In a further preferred embodiment, during the control steps, when the offset is greater than the first preset threshold S1 (i.e., ∑ is greater than or equal to 0), the controller simultaneously activates the first unit located downstream and the second unit located upstream to perform two-level joint correction, wherein the first unit performs large-stroke coarse adjustment and the second unit performs high-precision fine adjustment; when the offset is less than the first preset threshold S1 and greater than the second preset threshold S2 (which is not zero), only the second unit is activated for fine adjustment; when the offset is less than the second preset threshold S2, no adjustment action is generated.

[0026] In a further preferred embodiment, during the detection step, a first ultrasonic edge sensor and a second ultrasonic edge sensor, located on both sides of the tipping paper, are used for synchronous detection, and the detection results are used to perform difference calculations to eliminate common-mode interference.

[0027] In a further preferred embodiment, during the self-locking step, the self-locking characteristic of the worm gear transmission mechanism automatically locks the mounting bracket in the current position, maintaining the correction position without the need for continuous power supply.

[0028] In a further preferred embodiment, during the execution step, the deflection angle of the mounting bracket is detected in real time by the shaft encoder and fed back to the controller. The controller performs closed-loop control calculations based on the deflection angle and the detection signal from the misalignment sensor, and outputs control signals to the regulating motor.

[0029] Compared with the prior art, the present invention has the following beneficial effects: 1. Significantly Improved Correction Response Speed: This invention replaces the traditional ball screw linear transmission mechanism with a worm gear deflection fine-tuning mechanism, eliminating the critical speed limitation problem of slender shafts and allowing the adjustment motor to operate at high speeds. Simultaneously, the worm gear transmission mechanism directly converts the motor's rotational motion into the deflection motion of the mounting bracket, resulting in a shorter transmission chain and faster response. The correction response time is reduced from 200ms in the existing technology to less than 80ms, an improvement of approximately 60%, effectively suppressing dynamic deviation of the tipping paper during high-speed operation.

[0030] 2. Significantly improved and long-term stable correction accuracy: This invention adopts a two-stage correction architecture of "coarse adjustment + fine adjustment". The first adjustment unit realizes the initial positioning of the large stroke, and the second adjustment unit realizes high-precision fine adjustment. The worm gear transmission mechanism has no backlash problem and the wear rate is much lower than that of the ball screw. The correction accuracy can reach ±0.15mm, which is about 70% higher than the existing technology. Moreover, the accuracy deteriorates very little after long-term use, and it can continuously meet the stringent requirements of high-speed cigarette machines for the position accuracy of the tipping paper.

[0031] 3. Possesses self-locking characteristics, significantly reducing energy consumption: In the worm gear transmission mechanism used in this invention, the worm lead angle is smaller than its equivalent friction angle, possessing a natural reverse self-locking characteristic. After the correction is in place, the adjusting motor can automatically lock the position without continuous power-on braking. This not only significantly reduces energy consumption but also avoids the problem of heat generation and aging caused by the motor being in a power-on braking state for a long time, significantly extending the service life of the motor.

[0032] 4. Significantly extended maintenance cycle and reduced operating costs: The worm gear transmission mechanism of this invention has a closed structure, which makes it difficult for pollutants such as smoke and dust to enter. It also has low requirements for lubrication conditions. The maintenance cycle is extended from 3 months in the prior art to 12 months, which is 4 times longer. This greatly reduces the amount of maintenance work, improves the effective operation rate of the equipment, and reduces operating costs.

[0033] 5. High adaptability and compatibility with multiple specifications of tipping paper: The first adjustment unit of this invention can adopt a width-adjustable structure. The guide width can be steplessly adjusted within the range of 25mm to 65mm through the independent adjustment of the inner and outer arc-shaped guide rails. It can quickly adapt to different specifications of tipping paper without replacing the guide rail assembly. The changeover time is short and it can well meet the needs of flexible production.

[0034] 6. Flexible positioning of the two-stage units and strong installation adaptability: The front and rear positions of the first adjustment unit and the second adjustment unit of the present invention can be flexibly adjusted according to the actual installation space. The first adjustment unit can be set upstream of the second adjustment unit or downstream of the second adjustment unit, which can adapt to the installation space limitations of different models.

[0035] 7. Automatic centering guidance, reducing the frequency of deviation correction: The guide component of this invention adopts a drum-shaped structure or an arc-shaped surface with herringbone grooves. The centripetal force is generated by the surface tension of the drum-shaped structure or the friction difference of the herringbone grooves, so that the tipping paper has an automatic tendency to move towards the center during the transmission process, which can significantly reduce the frequency of deviation and reduce the workload of the fine adjustment mechanism.

[0036] 8. Comprehensive safety protection and high operational reliability: This invention can be configured with a shaft encoder and a limit sensor. The shaft encoder realizes closed-loop position control, and the limit sensor realizes overtravel protection. The dual protection ensures the safe and reliable operation of the mechanism and avoids damage due to overtravel.

[0037] 9. Setting the offset of the tipping paper can reduce the number of times the device needs to be adjusted. When the offset is within the threshold S1 range, two-stage adjustment is activated to speed up the correction speed. When the equipment is running stably, the second adjustment unit is activated when S2≤Offset≤S1. When the offset≤S2, the adjustment stops. In this way, the reciprocating oscillation of the tipping paper caused by excessive adjustment is reduced, thereby improving the stability of the equipment operation. Attached Figure Description

[0038] Figure 1a This is a schematic diagram of the structure of the present invention, in which the first adjustment unit is a drum-shaped wheel and the second adjustment unit is a combination of a worm gear drive and a shaft encoder. Figure 1b This is a schematic diagram of the structure of the present invention, in which the first adjustment unit is an arc-shaped guide rail and the second adjustment unit is a combination of a worm gear drive and a shaft encoder. Figure 1c This is a schematic diagram of the structure of the present invention, in which the first adjustment unit is a drum-shaped wheel and the second adjustment unit is a combination of a worm gear drive and a limit sensor. Figure 1d This is a schematic diagram showing a combination of a drum-shaped wheel as the first unit and a worm gear drive, a shaft encoder, and a limit sensor as the second unit. Figure 1e A schematic diagram of the first adjustment unit being located downstream of the second unit, showing that the first adjustment unit is a drum-shaped wheel; Figure 1f The first unit is located downstream of the second unit. The first adjustment unit is a schematic diagram of an arc-shaped guide rail. Figure 2a This is a schematic diagram of the first adjustment unit of the present invention achieving electric adjustment by a motor driving a lead screw; Figure 2b This is a schematic diagram of the first adjustment unit of the present invention achieving manual adjustment by adjusting the handwheel to drive the lead screw; Figure 3a This is a schematic diagram of the structure of the smooth surface arc-shaped guide rail and the arc-shaped guide rail with grooves on the surface of the present invention; Figure 3bThis is a schematic diagram of the structure of the smooth surface drum-shaped wheel and the drum-shaped wheel with grooves on the surface of the present invention; Figure 4a Schematic diagram of the first adjustment unit with tipping paper width adjustment; Figure 4b A schematic diagram of a dovetail groove structure unit with adjustable tipping paper width. Detailed Implementation

[0039] The specific embodiments of the present invention will be described in detail below, but it should be understood that the scope of protection of the present invention is not limited to the specific embodiments.

[0040] Unless otherwise expressly stated, throughout the specification and claims, the term "comprising" or its variations such as "including" or "comprising" shall be understood to include the stated elements or components without excluding other elements or other components.

[0041] Example 1: Drum-shaped wheel coarse adjustment + worm gear fine adjustment configuration like Figure 1a As shown, this embodiment provides a two-stage automatic correction device for the tipping paper of a cigarette machine. The device includes a control system, a first adjustment unit and a second adjustment unit arranged sequentially along the tipping paper running direction.

[0042] The first adjustment unit (coarse adjustment unit) employs a drum-shaped conveyor wheel and a manual adjustment assembly. The drum-shaped conveyor wheel is made of 304 stainless steel, with an overall diameter of 60mm. Its surface has a drum-shaped structure with a larger diameter at the center and smaller diameters at both ends; the diameter at the center is 1mm larger than the diameters at both ends. Utilizing the arc-shaped surface tension generated by this drum structure, the tipping paper tends to automatically converge towards the center during transport. The surface of the drum-shaped conveyor wheel is machined with herringbone guide grooves. These grooves extend from the center of the tipping paper's width outwards along the paper's running direction, forming a V-shaped angle of 45 degrees, with a groove depth of 0.2mm. When the tipping paper deviates from its designated path, the herringbone grooves on both sides generate different frictional forces on the tipping paper, creating a centripetal force pointing towards the center, further enhancing the automatic centering effect.

[0043] The drum-shaped conveyor wheel is mounted on a sliding seat via bearings. The sliding seat has an M8 threaded hole that mates with the adjusting screw. The adjusting assembly is a manual adjustment assembly, including an adjusting screw (1mm pitch) and a locking handle. The operator drives the adjusting screw by rotating the adjusting handwheel, causing the drum-shaped conveyor wheel to move along the width of the tipping paper. The adjustment stroke range is 0 to 20mm, achieving large-stroke coarse positioning of the tipping paper at its initial position. After reaching the desired position, the locking handle is used to lock and fix it in place.

[0044] The second adjustment unit (fine-tuning unit) is located approximately 200mm downstream of the first adjustment unit and includes a deviation sensor, a conveyor roller, a mounting frame, an adjustment motor, and a worm gear transmission mechanism. The conveyor roller is made of 304 stainless steel, with an outer diameter of 30mm and a width of 50mm. It is rotatably mounted on the mounting frame via two deep groove ball bearings, and the tipping paper is transported by wrapping around the conveyor roller at a 120-degree angle.

[0045] The mounting bracket is a 6061 aluminum frame structure, which can be oscillatingly mounted on the cigarette machine wall panel via a rotating shaft. The axis of the rotating shaft is located near the center of the tipping paper in the width direction and perpendicular to the tipping paper's running direction. The adjusting motor is a DC servo motor with a rated power of 100W, a rated speed of 3000rpm, and a rated torque of 0.32N·m. The adjusting motor drives the mounting bracket to deflect via a worm gear transmission mechanism.

[0046] The worm gear transmission mechanism includes a worm and a worm wheel. The worm is a single-start worm with a module of 1.5 and a lead angle of 2 degrees 48 minutes (less than its equivalent friction angle of approximately 6 degrees, achieving reverse self-locking). The worm wheel has 30 teeth and a transmission ratio of 30:1. The worm is coaxially connected to the output shaft of the regulating motor, and the worm wheel is coaxially fixed to the rotating shaft of the mounting bracket. A shaft encoder is installed at the output end of the worm, with a resolution of 1000 pulses / revolution, used to provide real-time feedback of the mounting bracket's swing angle to the controller, forming a position closed-loop control system.

[0047] Detection and Control System: The deviation sensor is an optical edge detection sensor, installed 50mm downstream of the second adjustment unit, with a detection accuracy of ±0.1mm and a sampling frequency of 200Hz. The deviation is determined by detecting the proportion of the light beam blocked by the edge of the cork paper. The controller uses an ARM Cortex-M4 processor core module with a main frequency of 168MHz and a sampling period of 5ms. The control algorithm adopts incremental PID closed-loop control, receiving the detection signal from the deviation sensor and the angle feedback signal from the shaft encoder, and outputting a PWM control signal to the adjustment motor driver after PID calculation.

[0048] Work process: Coarse adjustment steps: The operator first moves the drum-shaped conveyor wheel to the approximate center position along the width of the tipping paper using the manual adjustment component, and then locks it in place using the locking handle; Detection steps: After the equipment is started, the deviation sensor detects the position of the tipping paper edge in real time at a frequency of 200Hz and transmits the detection signal to the controller; Fine-tuning steps: After incremental PID calculation, the controller outputs a PWM control signal to the regulating motor. The regulating motor drives the mounting bracket to deflect around its rotation axis via a worm gear transmission mechanism, changing the axial direction of the conveyor rollers mounted on the mounting bracket. This alters the compression contact angle between the conveyor rollers and the tipping paper, creating a tension difference on both sides of the tipping paper, thereby driving the tipping paper to move laterally in the correction direction. Throughout the correction process, the shaft encoder provides real-time feedback of the mounting bracket's deflection angle to the controller, forming a closed-loop position control. Once the correction is complete, the regulating motor stops driving, and the self-locking characteristic of the worm gear transmission mechanism automatically locks the mounting bracket in its current position, maintaining the correction position without continuous power supply.

[0049] Example 2: Curved guide rail coarse adjustment + worm gear fine adjustment configuration like Figure 1b As shown, this embodiment provides another two-stage automatic correction device for cigarette machine tipping paper. The device includes a control system, a first adjustment unit and a second adjustment unit arranged sequentially along the tipping paper running direction.

[0050] First adjustment unit (coarse adjustment unit): adopts an arc-shaped guide rail and an electric adjustment component. The arc-shaped guide rail is made of 304 stainless steel, and its arc-shaped working surface is a polished smooth surface with an arc radius of 150mm. There are steps on both sides of the arc-shaped surface that are 2mm higher than the tipping paper to limit the lateral offset range of the tipping paper and prevent it from coming off. The width of the arc-shaped surface is the width of the tipping paper plus 1mm, so that the tipping paper retains appropriate lateral movement space when sliding on the arc-shaped surface.

[0051] The arc-shaped guide rail is mounted on the sliding seat, which has an M10 threaded hole that mates with the transmission screw. The adjustment assembly is an electric adjustment assembly, including a step electric motor (step angle 1.8 degrees) and a transmission screw (pitch 2 mm). The electric motor drives the sliding seat to move along the width direction of the tipping paper through the transmission screw. The electric adjustment stroke is 0 to 30 mm, and the adjustment speed is 5 mm / s. The controller controls the rapid initial positioning.

[0052] The second adjustment unit (fine-tuning unit): Similar to Embodiment 1, it is located approximately 200mm downstream of the first adjustment unit and includes a deviation sensor, a conveyor roller, a mounting frame, an adjustment motor, and a worm gear transmission mechanism. The conveyor roller is made of stainless steel, with an outer diameter of 30mm and a width of 50mm. It is rotatably mounted on the mounting frame via bearings, and the tipping paper is transported around this conveyor roller. The mounting frame is an aluminum frame structure and is swayably mounted on the cigarette machine wall panel via a rotating shaft. The axis of the rotating shaft is located near the center of the tipping paper in the width direction and perpendicular to the tipping paper's running direction. The adjustment motor is a servo motor with a rated power of 100W and a rated speed of 3000rpm. The adjustment motor drives the mounting frame to deflect via the worm gear transmission mechanism; the worm gear transmission mechanism includes a worm and a worm wheel. The worm is a single-start worm with a lead angle of 2 degrees 48 minutes (less than its equivalent friction angle, achieving reverse self-locking), and the worm wheel has 30 teeth with a transmission ratio of 30:1. The worm gear is coaxially connected to the output shaft of the regulating motor, and the worm wheel is coaxially fixed to the rotating shaft of the mounting bracket. A shaft encoder is installed at the output end of the worm gear, with a resolution of 1000 pulses / revolution, and is used to provide real-time feedback of the swing angle of the mounting bracket to the controller, forming a position closed-loop control system.

[0053] Detection and Control System: The deviation sensor is an optical edge detection sensor, installed 50mm downstream of the second adjustment unit, with a detection accuracy of ±0.1mm. The deviation is determined by detecting the proportion of the light beam blocked by the edge of the cork paper. The controller uses an ARM processor core module with a sampling period of 5ms. The control algorithm adopts PID closed-loop control, receiving the detection signal from the deviation sensor and the angle feedback signal from the shaft encoder, and outputting a control signal to the adjustment motor after PID calculation.

[0054] Working process: Coarse adjustment step - The operator moves the arc guide rail to approximately the center position along the width of the tipping paper using the electric adjustment component; Detection step - The deviation sensor detects the edge position of the tipping paper in real time; Fine adjustment step - When the deviation is greater than the second threshold, the S2 controller controls the motor to operate through PID calculation, drives the mounting frame to deflect through the worm gear transmission mechanism, changes the axis direction of the conveyor roller to achieve deviation correction, and the shaft encoder provides real-time feedback of the deflection angle to form a closed-loop control. After the deviation is corrected, the worm gear self-locks to maintain the position.

[0055] The difference between this embodiment and embodiment 1 is that: (1) the first adjustment unit uses an arc-shaped guide rail instead of a drum-shaped conveyor wheel, and its working surface is a smooth arc-shaped surface, which is limited by a step; (2) the adjustment method uses an electric adjustment component instead of a manual adjustment component, and the electric motor drives the lead screw to achieve rapid positioning, with a larger adjustment stroke (30mm) and controllable adjustment speed (5mm / s). This embodiment is suitable for working conditions where the width of the tipping paper is large (above 40mm) or the paper tray changing frequency is high. Electric adjustment facilitates rapid reset and reduces manual operation time.

[0056] Example 3: Width-adjustable first adjustment unit configuration like Figure 4a , Figure 4b As shown, this embodiment provides a two-stage automatic correction device with a tipping paper width adjustment function.

[0057] The first adjustment unit (width adjustable coarse adjustment unit) adopts a split inner and outer arc-shaped guide rail structure, including an inner arc-shaped guide rail, an outer arc-shaped guide rail, an inner adjustment handle, an outer adjustment handle, an internal threaded screw drive pair, an external threaded screw drive pair, a dovetail groove 1, a sliding pair 1, a sliding frame, a locking screw, and a locking handle. The inner and outer arc-shaped guide rails are respectively mounted on the dovetail groove guide rails of the base via the sliding frame. The inner adjustment handle is connected to the inner arc-shaped guide rail via the internal threaded screw drive pair, and the outer adjustment handle is connected to the outer arc-shaped guide rail via the external threaded screw drive pair.

[0058] Rotating the inner adjusting handle drives the internal threaded screw to rotate, causing the inner arc-shaped guide rail to move left and right along the dovetail groove 1. Rotating the outer adjusting handle drives the external threaded screw to rotate, causing the outer arc-shaped guide rail to move left and right along the dovetail groove 1. The inner and outer arc-shaped guide rails can be adjusted independently, achieving stepless adjustment of the guide width, with an adjustment range of 30mm to 60mm, to adapt to the usage requirements of different specifications of tipping paper. After adjustment, double locking is performed using the locking screw and locking handle to ensure stable position during operation.

[0059] The second adjustment unit and detection and control system in this embodiment are the same as those in Embodiment 1. This embodiment is suitable for production scenarios that require frequent changes of different specifications of tipping paper. It can quickly adjust the guide width without changing the guide rail components, significantly improving changeover efficiency.

[0060] Example 4: Anti-interference configuration of dual ultrasonic sensors This embodiment provides another two-stage automatic correction device for the tipping paper of a cigarette machine. The device includes a control system, a first adjustment unit and a second adjustment unit arranged sequentially along the tipping paper running direction.

[0061] The first adjustment unit (coarse adjustment unit) uses a drum-shaped conveyor wheel and a manual adjustment assembly. The drum-shaped conveyor wheel is made of stainless steel and has a drum-shaped structure with a larger diameter at the center and smaller diameters at both ends. The diameter at the center is 1.5mm larger than the diameters at both ends. The surface of the drum-shaped conveyor wheel is machined with herringbone guide patterns, which extend from the center of the tipping paper width to both sides along the direction of tipping paper movement, forming a V-shaped angle of 45 degrees, with a pattern depth of 0.2mm. The drum-shaped conveyor wheel is mounted on a sliding seat, which has a threaded hole for engaging with the adjusting screw. The adjustment assembly is a manual adjustment assembly, including an adjusting screw and a locking handle. The operator drives the adjusting screw by rotating the adjusting handwheel, causing the drum-shaped conveyor wheel to move along the width direction of the tipping paper (adjustment range 0 to 20mm). After reaching the desired position, it is locked in place by using the locking handle.

[0062] The second adjustment unit (fine-tuning unit): Same as in Embodiment 1, it is located about 200mm downstream of the first adjustment unit, and includes a deviation sensor, a conveyor roller, a mounting bracket, an adjustment motor, and a worm gear transmission mechanism.

[0063] Detection and Control System: The key difference between this embodiment and Embodiment 1 is that the deviation sensor adopts a dual-sensor configuration of a first ultrasonic edge sensor and a second ultrasonic edge sensor. The first and second ultrasonic edge sensors are respectively installed above the two edges of the tipping paper, 10mm from the surface of the tipping paper, for synchronous detection of the position of the two edges of the tipping paper. The detection frequency is 100Hz, and the detection accuracy is ±0.2mm. The controller includes a difference calculation module, which performs difference calculation on the detection values ​​of the first and second ultrasonic edge sensors to eliminate common-mode interference signals introduced by factors such as changes in ambient temperature, paper humidity, and air disturbance, thereby improving detection accuracy and stability.

[0064] This embodiment is suitable for working conditions such as large changes in ambient temperature and frequent fluctuations in paper humidity, and has higher detection stability and anti-interference ability.

[0065] Example 5: Safety Configuration with Limit Protection like Figure 1c , Figure 1d As shown, this embodiment adds a limit protection function based on the above embodiments. A mechanical limit switch is installed at the extreme positions on both sides of the mounting frame, fixedly mounted on the frame, and positioned at the maximum allowable deflection angle (±5 degrees) of the mounting frame in both directions. When the mounting frame deflects to the extreme position, a limit signal is triggered. The controller immediately stops the motor drive based on the limit signal and outputs an alarm signal to the main control system of the equipment to prevent damage from overtravel.

[0066] This embodiment further improves the safety and reliability of equipment operation and is suitable for high-speed operating conditions.

[0067] Comparison of scale and performance A single-stage ball screw drive correction scheme disclosed in Chinese patent CN101617857B was used for comparison. The working principle of this scheme is as follows: a servo motor drives a ball screw to rotate via a coupling. The ball screw, through a threaded sleeve, drives an arc-shaped guide rail seat to move horizontally along the support shaft axis, thereby changing the transmission path of the tipping paper to achieve correction. A laser detector is installed above the arc-shaped guide rail seat to detect the edge position of the tipping paper. The detection signal is transmitted to the controller, which then controls the operation of the servo motor.

[0068] Comparative test conditions: tipping paper width 48mm, running speed 600m / min, initial offset 5mm.

[0069] Comparison of test results:

[0070] The above comparative test results show that the two-stage correction device of the present invention is superior to the existing single-stage screw drive correction scheme in terms of response speed, correction accuracy, self-locking capability, energy consumption and maintenance cycle.

Claims

1. A two-stage automatic correction device for cigarette tipping paper in a cigarette machine, comprising a control system, characterized in that, An adjustment unit is provided along the direction of the tipping paper's movement. The adjustment unit includes a deviation sensor, a conveyor roller, a mounting frame that can oscillate around a rotating axis, an adjustment motor, and a worm gear transmission mechanism. The conveyor roller is rotatably mounted on the mounting frame, and the tipping paper is conveyed around it. The mounting frame is oscillatingly mounted on the cigarette machine frame via the rotating axis, the axis of which is located near the center of the conveyor roller along the width direction of the tipping paper. The adjustment motor drives the mounting frame to deflect via the worm gear transmission mechanism. The control system includes a controller. The deviation sensor is located on the tipping paper's conveying path to detect the edge position of the tipping paper in real time and transmits the detection signal to the controller. The controller controls the operation of the adjustment motor based on the detection signal and controls the deflection angle of the mounting frame via the worm gear transmission mechanism, thereby changing the angle between the conveyor roller and the tipping paper to adjust the tension difference on both sides of the tipping paper, achieving precise correction of the tipping paper's lateral position. The adjustment unit includes a first unit and a second unit arranged sequentially along the direction of the tipping paper's movement. The first unit is located upstream or downstream of the second unit. The first unit controls the movement of the sliding pair by manually adjusting or setting the deflection angle using an adjustment component for coarse adjustment over a large stroke. The second unit is used for fine adjustment with high precision by setting the minimum deflection angle of the adjustment motor and the transmission ratio of the worm gear. The controller determines whether to start the first unit and / or the second unit or keep it stationary based on the magnitude of the offset detected by the deviation sensor.

2. The two-stage automatic correction device for cigarette tipping paper in a cigarette machine according to claim 1, characterized in that, The worm gear transmission mechanism includes a worm and a worm wheel. The worm is coaxially connected to the output shaft of the regulating motor, and the worm wheel is coaxially fixed to the rotation shaft of the mounting bracket. The lead angle of the worm is less than its equivalent friction angle, so that after the regulating motor stops driving, the worm gear transmission mechanism self-locks the mounting bracket in the current position.

3. The two-stage automatic correction device for cigarette tipping paper in a cigarette machine according to claim 1, characterized in that, A shaft encoder and / or limit sensor are also provided between the adjusting motor and the mounting bracket. The shaft encoder is installed at the output end of the worm gear transmission mechanism or the output end of the adjusting motor, and is used to provide real-time feedback of the swing angle of the mounting bracket to the controller.

4. The two-stage automatic correction device for cigarette tipping paper in a cigarette machine according to claim 1, characterized in that, The deviation sensor is an ultrasonic sensor, including a first edge sensor and a second edge sensor, which are respectively located at the two edges of the cork paper; the controller is equipped with a difference calculation module, which is used to perform difference calculation on the detection values ​​of the first edge sensor and the second edge sensor to determine the deviation.

5. The two-stage automatic correction device for cigarette tipping paper in a cigarette machine according to claim 1, characterized in that, The deviation sensor is an optical edge detection sensor, which determines the offset by detecting the proportion of the light beam blocked by the edge of the cork paper.

6. The two-stage automatic correction device for cigarette tipping paper in a cigarette machine according to claim 1, characterized in that, The first unit includes a sliding adjustment pair, an adjustment component, and a drum-shaped conveyor wheel. The drum-shaped conveyor wheel has a drum-shaped surface with a large central diameter and small diameters at both ends. The diameter at the center is at least 0.5 mm larger than the diameters at both ends.

7. The two-stage automatic correction device for cigarette machine tipping paper according to claim 6, characterized in that, The surface of the drum-shaped conveyor wheel is a smooth surface or a surface with herringbone grooves; the herringbone grooves are a number of herringbone guide lines extending from the center of the width of the cork paper to both sides. The herringbone guide lines are either fine grooves with a depth greater than 0.1 mm or guide ribs that are at least 0.05 mm above the surface, and the included angle between the herringbone lines on the left and right sides is 30-60°.

8. The two-stage automatic correction device for cigarette tipping paper in a cigarette machine according to claim 1, characterized in that, The first unit includes a sliding adjustment pair, an adjustment component, and an arc-shaped guide rail. The surface of the arc-shaped guide rail is a smooth surface or a surface with herringbone grooves. The herringbone grooves are a number of herringbone guide lines extending from the center of the width of the tipping paper to both sides. The herringbone guide lines are either fine grooves with a depth greater than 0.1 mm or guide ribs that are at least 0.05 mm above the surface. The included angle between the herringbone lines on the left and right sides is 30-60°.

9. The two-stage automatic correction device for cigarette tipping paper in a cigarette machine according to claim 1, characterized in that, The controller is equipped with a deviation grading processing module. When the offset is greater than a first preset threshold S1 (the first threshold is the paper offset of the single-sided edge sensor reaching the first preset threshold S1), the first unit and the second unit are activated simultaneously for joint correction. When the offset is less than or equal to the first preset threshold S1 and greater than the second preset threshold S2 (which is not zero), only the second unit is activated for fine adjustment. When the offset is less than the second preset threshold S2, no adjustment action is performed.

10. The two-stage automatic correction device for cigarette tipping paper in a cigarette machine according to claim 9, characterized in that, The offset threshold S is defined as follows: when the cigarette machine speed is less than or equal to 9000 cigarettes / minute, S1 is 0.3mm and S2 is 0.25mm. When the cigarette machine speed is greater than 9000 cigarettes / minute, S1 is 0.2mm and S2 is 0.15mm.

11. The two-stage automatic correction device for cigarette tipping paper in a cigarette machine according to claim 3, characterized in that, The limit sensor is a pair of limit switches, which are fixedly installed on the frame and respectively set at the limit positions of the maximum allowable deflection angle of the mounting frame in both the positive and negative directions. When the mounting frame deflects to the limit position, the limit signal is triggered, and the controller stops the driving of the regulating motor according to the limit signal.

12. A method for correcting the paper guideline of a cigarette machine based on the two-stage automatic correction device for the paper guideline as described in any one of claims 1 to 11, characterized in that, Includes the following steps: Detection steps: The edge position of the tipping paper is detected in real time by a deviation sensor to obtain the lateral offset signal; Control steps: The controller calculates the offset signal, determines the magnitude of the offset, and performs graded control to start and stop the adjustment unit based on the difference ∑ between the offset and the threshold; Execution steps: The adjustment motor operates according to the control signal, driving the mounting frame to deflect around the rotation axis through the worm gear transmission mechanism, changing the angle between the conveyor roller and the tipping paper to adjust the tension difference on both sides of the tipping paper, thereby achieving deviation correction; Self-locking steps: After the deviation correction is in place, the adjustment motor stops driving, and the self-locking characteristic of the worm gear transmission mechanism automatically locks the mounting frame in the current position.

13. The correction method according to claim 12, characterized in that, In the control steps, when the offset is greater than the first preset threshold S, i.e., ∑ is greater than or equal to 0, the controller simultaneously starts the first unit located downstream and the second unit located upstream to perform two-level joint correction, wherein the first unit performs large-stroke coarse adjustment and the second unit performs high-precision fine adjustment; when the offset is less than or equal to the first preset threshold and is not zero, i.e., ∑ is less than 0, only the control of the second unit is performed, and the controller only starts the second unit for fine adjustment.

14. The correction method according to claim 12, characterized in that, In the detection step, a first ultrasonic edge sensor and a second ultrasonic edge sensor, which are set on both sides of the tipping paper, are used for synchronous detection, and the difference calculation is performed on the detection results to eliminate common mode interference.

15. The correction method according to claim 12, characterized in that, During the self-locking step, the self-locking characteristic of the worm gear transmission mechanism automatically locks the mounting bracket in the current position, maintaining the correction position without continuous power supply.

16. The correction method according to claim 12, characterized in that, In the execution step, the deflection angle of the mounting bracket is detected in real time by the shaft encoder and fed back to the controller. The controller performs closed-loop control calculation based on the deflection angle and the detection signal of the deviation sensor, and outputs a control signal to the regulating motor.

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