Visual inspection and fixed-length cutting comprehensive practical training device

Abstract

The utility model discloses a visual inspection and fixed-length cutting comprehensive practical training device, which comprises a servo controller in signal connection with a PLC (Programmable Logic Controller), and an extensible remote IO (Input / Output) module, the first servo motor and the second servo motor are in signal connection with the servo controller; the intelligent camera and the valve terminal are in signal connection with the PLC, and the three-axis air cylinder is communicated with the valve terminal through an air path; the device further comprises a rack, a partition plate synchronous belt is installed on the rack, and the first servo motor is in transmission connection with the partition plate synchronous belt. The intelligent camera photographs products conveyed on the partition plate synchronous belt, the second servo motor conducts simulation cutting on the products conveyed on the partition plate synchronous belt, and the three-axis air cylinder can remove unqualified products on the partition plate synchronous belt. The comprehensive practical training device integrates a visual inspection device, a fixed-length cutting device and a removing device, and can accurately simulate the cigarette production process, so that the device can replace electrical control of actual production equipment, and a good training platform is provided for training and skill improvement of electrical repairmen.

Description

Technical Field

[0001] This utility model relates to a training device, and more specifically, to a comprehensive training device for visual inspection and fixed-length cutting. Background Technology

[0002] The cigarette industry has a wide variety of machinery and equipment, involving a broad range of technologies. Among them are various automated, intelligent and high-precision equipment, such as cigarette making machines and packaging machines, which are key equipment in cigarette manufacturing. They all adopt fully automated control methods and intelligent detection methods to achieve high-speed manufacturing of cigarettes, cigarette packs and cigarette cartons throughout the entire process.

[0003] The cigarette rolling process involves systems such as tobacco feeding, cigarette weight adjustment, stamping and paper feeding, rolling, cigarette cutting, filter supply, transfer paper supply, and visual inspection. Qualified cigarettes are then sent to packaging machines for packaging, which includes small box packaging and carton packaging, also involving visual inspection to check packaging quality. Simultaneously, the cigarette rolling and packaging processes also involve sensor systems, servo drive control systems, and mechanical transmission systems. Due to the complexity of the equipment, modern electrical repair technicians need comprehensive electrical maintenance knowledge to diagnose malfunctions during production. This includes electrical safety knowledge, basic electrical knowledge, electrical equipment knowledge, electrical measurement and testing, fault analysis and handling, and other skills. Especially for fault analysis and handling, it is no longer sufficient to simply check circuit continuity and simple logic control signals for equipment diagnosis; the content involved is increasingly complex, requiring a higher level of familiarity with the equipment and higher individual skill levels. Therefore, for existing cigarette manufacturing equipment, in order for electrical repair workers to systematically master its control system and improve their ability to handle electrical faults, in addition to regular theoretical learning, they must also rely on on-site practical training on the equipment. This process requires the machine to be shut down or production to be stopped. Most factories cannot arrange for a long-term shutdown of a particular piece of equipment for teaching and training due to tight production tasks. Therefore, how to enable electrical maintenance personnel to conduct teaching and training without relying on on-site equipment, while achieving a high degree of simulation of the operation of electrical and mechanical equipment of cigarette manufacturing machines and packaging machines in actual production, in order to further improve the skill level of electrical maintenance personnel, has become an urgent problem to be solved. Utility Model Content

[0004] This invention overcomes the shortcomings of the prior art and provides an implementation method for a visual inspection and fixed-length cutting integrated training device, which aims to enable electrical maintenance personnel to conduct simulated practical training without on-site machine shutdown.

[0005] To solve the above-mentioned technical problems, one embodiment of this utility model adopts the following technical solution:

[0006] A comprehensive training device for visual inspection and fixed-length cutting includes a PLC controller, a servo controller, and an expandable remote I / O module. The PLC controller is signal-connected to the servo controller and the expandable remote I / O module. A first servo motor and a second servo motor are signal-connected to the servo controller. A smart camera and a valve island are signal-connected to the PLC controller, and a three-axis cylinder is connected to the air circuit of the valve island. The device also includes a frame on which a partition synchronous belt is mounted. The first servo motor is driven by the partition synchronous belt. The smart camera takes pictures of the products conveyed on the partition synchronous belt, the second servo motor performs simulated cutting of the products conveyed on the partition synchronous belt, and the three-axis cylinder can remove unqualified products from the partition synchronous belt.

[0007] Furthermore, it also includes a second photoelectric sensor that is signal-connected to the scalable remote I / O module. The second photoelectric sensor is located on one side of the feed end of the partition synchronous belt, and the smart camera is located on the side of the discharge end of the partition synchronous belt near the second photoelectric sensor.

[0008] Furthermore, it also includes a through-beam photoelectric sensor that is signal-connected to the expandable remote I / O module. A scale is mounted on the output shaft of the second servo motor, and the through-beam photoelectric sensor is located on both sides of the middle section of the synchronous belt of the partition below the scale.

[0009] Furthermore, it also includes a first photoelectric sensor that is signal-connected to the scalable remote I / O module, the three-axis cylinder is located on one side of the discharge end of the partition synchronous belt, and the first photoelectric sensor is located on the side of the partition synchronous belt near the three-axis cylinder.

[0010] Furthermore, it also includes a base, the servo controller and valve island are fixedly installed on the upper part of the base, the frame is fixedly connected to the base through a support seat, the first servo motor is fixedly connected to the base, the second photoelectric sensor is fixedly connected to the frame or base through a photoelectric sensor bracket, the smart camera is fixedly connected to the base through a camera bracket, the second servo motor is fixedly connected to the base through a motor bracket, and the three-axis cylinder is fixedly connected to the frame or base through a cylinder bracket.

[0011] Furthermore: a first synchronous pulley is rotatably mounted on one end of the frame via a bearing, and a second synchronous pulley is rotatably mounted on the other end. The partition synchronous belt is sleeved on the first and second synchronous pulleys, and the first servo motor is connected to the first synchronous pulley via a transmission belt.

[0012] Furthermore, the timing belt with partitions is assembled by uniformly fixing multiple partitions on the outer edge of the timing belt.

[0013] Furthermore: the dial is a circular disc with multiple scale markings around the center on its surface; the second servo motor must also be positioned directly above and parallel to the partition synchronous belt; the surface of the dial is perpendicular to the plane of the partition synchronous belt; and the partition of the partition synchronous belt has markings in the middle.

[0014] Furthermore, an end plate is fixedly installed at the front end of the piston rod of the three-axis cylinder, and a rejection channel is also installed on the other side of the frame, with the rejection channel directly opposite the position of the three-axis cylinder.

[0015] Compared with the prior art, this utility model has at least the following beneficial effects: This comprehensive training device integrates a dual servo motor control system, an intelligent camera, a dial, and a partition synchronous belt, etc., to construct a comprehensive training device for visual inspection and fixed-length cutting. It can accurately simulate the fixed-length cutting process of cigarette bars in the cigarette production process, as well as the online detection and control of the appearance quality of cigarette sticks and cigarette packs. It is also equipped with a rejection device, which can simulate the rejection process of unqualified products. Thus, this device can replace the electrical control of actual production equipment, providing a good training platform for the training and skills improvement of electrical repair workers. Attached Figure Description

[0016] Figure 1 This is a top view of the present invention;

[0017] Figure 2 This is a schematic diagram of the overall structure of this utility model;

[0018] Figure 3 This is a schematic diagram of the visual inspection device of this utility model;

[0019] Figure 4 This is a schematic diagram of the first servo motor transmission of this utility model;

[0020] Figure 5 This is the signal connection logic diagram of this utility model;

[0021] Reference numerals: 101, partition synchronous belt; 102, first synchronous belt pulley; 103, second synchronous belt pulley; 104, bearing cover; 105, first servo motor; 106, servo controller; 107, frame; 108, support base;

[0022] 201. Three-axis cylinder; 202. Cylinder bracket; 203. Valve island; 204. First photoelectric sensor; 205. Rejection channel;

[0023] 301. Smart camera; 302. Camera bracket; 303. Second photoelectric sensor; 304. Photoelectric sensor bracket;

[0024] 401. Second servo motor; 402. Motor bracket; 403. Scale dial; 404. Through-beam photoelectric sensor;

[0025] 501. Expandable remote I / O module; 502. Base. Detailed Implementation

[0026] To make the objectives, technical solutions, and advantages of this utility model clearer, the following detailed description is provided in conjunction with embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this utility model.

[0027] like Figure 1 As shown: A visual inspection and fixed-length cutting integrated training device includes a base 502, which is an installation platform. The upper surface of the base 502 has multiple sliding grooves to facilitate the arbitrary arrangement or adjustment of subsequent modules on the upper part. The servo controller 106, the expandable remote IO module 501, the valve island 203, the transmission device, the rejection device, the visual inspection device, and the fixed-length cutting device are fixedly connected to the base 502 through their respective brackets.

[0028] The servo controller 106 is a device that controls electrical components. It receives instruction signals from a host computer or PLC controller, which may include position, speed, or torque. It also receives feedback signals from various actuators, which may include position signals output by encoders, speed signals output by speed sensors, etc. Through internal algorithm processing, the servo controller calculates control signals and drives the servo motor to move at a predetermined speed and acceleration.

[0029] Valve island 203 is a control component composed of multiple solenoid valves. It integrates signal input / output and signal control functions. These solenoid valves share the same air intake source, but their outputs are independent. In addition to controlling the triaxial cylinder 201, valve island 203 can also be used to expand other actuators.

[0030] The expandable remote I / O module 501 communicates with the PLC controller via remote communication methods such as Ethernet, RS-485, and PROFINET, and extends input / output signals. It enables monitoring and control of remote devices, enhancing the system's flexibility and scalability.

[0031] Furthermore, combined Figure 2 , Figure 4As shown, the transmission device includes a frame 107, which is fixedly connected to the base 502 via a support 108. A first synchronous pulley 102 is rotatably mounted on one end of the frame 107 via a bearing, and a second synchronous pulley 103 is rotatably mounted on the other end. A partition synchronous belt 101 is fitted onto the first synchronous pulley 102 and the second synchronous pulley 103. The partition synchronous belt 101 is assembled by evenly fixing multiple partitions to the outer edge of the synchronous belt. A first servo motor 105 is also fixedly mounted on the base 502. The first servo motor 105 is connected via... The transmission belt is connected to the first synchronous pulley 102. When the first servo motor 105 rotates, the first synchronous pulley 102 acts as the transmission pulley, and the second synchronous pulley 103 acts as the driven pulley. Bearing covers 104 are installed on both sides of the first synchronous pulley 102 and the second synchronous pulley 103 on the frame 107. The bearing covers cover the bearings to prevent the first synchronous pulley 102 and the second synchronous pulley 103 from rotating and injuring people. A protective cover is also provided on the transmission belt between the first servo motor 105 and the first synchronous pulley 102, also to prevent the transmission belt from rotating and injuring people.

[0032] Furthermore, combined Figures 1-3 As shown, the visual inspection device includes a smart camera 301, a camera bracket 302, a second photoelectric sensor 303, and a photoelectric sensor bracket 304. The second photoelectric sensor 303 is fixed on the photoelectric sensor bracket 304, which is in turn fixedly mounted on the frame 107 or the base 502. The second photoelectric sensor 303 is located on one side of the feed end of the conveying device. The smart camera 301 is mounted on one side of the conveying device via the camera bracket 302, and is located on the side of the second photoelectric sensor 303 near the discharge end of the conveying device. The camera bracket 302 is fixedly mounted on the base 502. In addition to its camera function, the smart camera 301 also has an LED light with pulse / continuous illumination modes, enabling clear imaging of objects even in low-light conditions. Its camera height and shooting angle can be adjusted via the camera bracket 302 to accommodate different objects or working conditions. The second photoelectric sensor 303 and the smart camera 301 are installed at a certain height to avoid interfering with the imaging or monitoring of objects on the conveying device.

[0033] Furthermore, combined Figures 1-3As shown, the rejection device is located on one side of the discharge end of the conveyor device. The rejection device includes a three-axis cylinder 201, a cylinder bracket 202, a first photoelectric sensor 204, and a rejection channel 205. The three-axis cylinder 201 is located on one side of the discharge end of the conveyor device and is fixed to the frame 107 or the base 502 by the cylinder bracket 202. An end plate is fixedly installed on the front end of the piston rod of the three-axis cylinder 201. The three-axis cylinder 201 is connected to the solenoid valve on the valve island 203 through an air pipe. When the solenoid valve opens and the air path is connected, the piston rod in the three-axis cylinder 201 extends and drives the end plate to move forward, thereby removing the non-conforming material from the partition synchronous belt 101. Cigarettes or cigarette packs that do not meet the requirements are rejected. The rejection channel 205 is a sliding plate, one end of which is fixed to the frame 107 by bolts and is directly opposite the position of the three-axis cylinder 201. The first photoelectric sensor 204 is arranged at the material receiving end of the conveying device on the opposite side of the rejection channel 205. The first photoelectric sensor 204 is a certain distance away from the three-axis cylinder 201 to detect the material being conveyed from left to right on the synchronous belt and transmit the detection signal to the expandable remote IO module. The expandable remote IO module transmits the signal to the PLC controller. The PLC controller analyzes and processes the signal and sends a signal to the valve island 203 to drive the rejection device.

[0034] Furthermore, combined Figures 1-4 As shown, the fixed-length cutting device is positioned between the visual inspection device and the rejection device. The fixed-length cutting device includes a second servo motor 401, a motor bracket 402, a scale dial 403, and a through-beam photoelectric sensor 404. The second servo motor 401 is fixedly mounted on the base 502 via the motor bracket 402. The scale dial 403 is fixedly mounted on the output shaft of the second servo motor 401. The scale dial 403 is a circular disc with multiple graduation marks around its center. The second servo motor 401 is positioned between the intelligent camera 301 and the three-axis cylinder 201, both on the same side of the timing belt 101. The second servo motor 401 also needs to be positioned... The plate is directly above and parallel to the partition synchronous belt 101, and the surface of the dial 403 is perpendicular to the plane of the partition synchronous belt 101. Through-beam photoelectric sensors 404 are set on both sides of the partition synchronous belt 101 to monitor the number of partitions passing through the partition synchronous belt 101. The partitions of the partition synchronous belt 101 have markings in the middle, which correspond to the markings on the dial 403 above them. In order to avoid interference from cigarettes or cigarette packs conveyed on the partition synchronous belt 101, the installation height of the through-beam photoelectric sensors 404 is slightly higher than the height of the cigarettes or cigarette packs and lower than the height of the partitions.

[0035] Furthermore, combined Figure 5As shown, the servo controller 106 is signal-connected to the PLC controller, and the expandable remote I / O module 501 is also signal-connected to the PLC controller. Simultaneously, it can monitor the device's operating data in real time for convenient teaching and explanation. The first servo motor 105 and the second servo motor 401 are signal-connected to the servo controller 106, forming a dual servo motor control system. The first servo motor 105 drives the transmission device to simulate the operation of a cigarette production line, while the second servo motor 401 drives the dial 403 to rotate, simulating the fixed-length cutting of cigarettes. The first photoelectric sensor 204, the second photoelectric sensor 303, and the through-beam photoelectric sensor 404 are signal-connected to the expandable remote I / O module 501. The intelligent camera 301 and the valve island 203 are signal-connected to the PLC controller, and the valve island 203 controls the three-axis cylinder 201.

[0036] Specific usage method: The PLC controller sends relevant control commands to the servo controller 106 to drive the first servo motor 105 to rotate the partition synchronous belt 101.

[0037] Use of the visual inspection device and rejection device: During visual inspection, the item to be inspected, such as a cigarette stick or pack, is placed on the synchronous belt 101 of the partition. The second photoelectric sensor 303 detects the presence of the item, triggering the intelligent camera 301 to take a picture. The intelligent camera 301 transmits the image signal to the PLC controller. The PLC controller analyzes the image and determines whether the product is qualified based on the analysis information. If the product is unqualified, a rejection signal is sent to the valve island. When the first photoelectric sensor 204 detects that an unqualified product has passed through, the valve island 203... When the solenoid valve is connected, the piston rod of the three-axis cylinder 201 extends, causing the end plate to move forward. This pushes the defective products from the partition synchronous belt 101 to the rejection channel 205. The defective products slide out through the rejection channel 205. After rejection, the piston rod of the three-axis cylinder 201 retracts to avoid interfering with the subsequent conveying of products. If the product is qualified, it continues to flow backward. By rejecting defective products through the three-axis cylinder 201, the system simulation of online detection of the appearance quality of cigarettes in the cigarette making machine and the appearance quality of cigarette packs in the packaging machine is realized.

[0038] The use of the fixed-length cutting simulation device: When the through-beam photoelectric sensor 404 detects the passage of the partition on the timing belt, it transmits the signal to the PLC controller via the expandable remote I / O module. The PLC controller sends a signal command to the servo controller 106, which drives the second servo motor 401 to rotate the dial 403. By controlling the running speed of both, the distance the timing belt should move forward for each full rotation of the dial can be simulated, thus mimicking the process of fixed-length cutting of cigarette strips in a cigarette machine. After one full rotation, a certain mark on the dial 403 corresponds vertically to a mark on the partition directly below the dial, making it easy to visually determine the relationship between the distance of movement between the timing belt and the dial.

[0039] At the same time, the visual inspection device, rejection device, and fixed-length cutting device can operate synchronously to simulate the real-time status of cigarette making machines and packaging machines in tooling mode.

[0040] Although the present invention has been described herein with reference to illustrative embodiments, it should be understood that many other modifications and implementations can be devised by those skilled in the art, which will fall within the scope and spirit of the principles disclosed herein. More specifically, various variations and improvements can be made to the components and / or layout of the subject matter combination within the scope of the present application. Besides variations and improvements to the components and / or layout, other uses will be apparent to those skilled in the art.

Claims

1. A comprehensive training device for visual inspection and fixed-length cutting, characterized in that: The system includes a PLC controller, a servo controller (106), and an expandable remote I / O module (501). The PLC controller is connected to the expandable remote I / O module (501) and the servo controller (106) via signals. The first servo motor (105) and the second servo motor (401) are connected to the servo controller (106) via signals. The smart camera (301) and the valve island (203) are connected to the PLC controller via signals. The three-axis cylinder (201) is connected to the valve island (203) via air passage. The system also includes a frame (107) on which a partition synchronous belt (101) is installed. The first servo motor (105) is connected to the partition synchronous belt (101) via transmission. The smart camera (301) takes pictures of the products conveyed on the partition synchronous belt (101). The second servo motor (401) performs simulated cutting on the products conveyed on the partition synchronous belt (101). The three-axis cylinder (201) can remove unqualified products from the partition synchronous belt (101).

2. The integrated training device for visual inspection and fixed-length cutting according to claim 1, characterized in that: It also includes a second photoelectric sensor (303) that is signal-connected to the expandable remote I / O module (501). The second photoelectric sensor (303) is located on one side of the feed end of the partition synchronous belt (101), and the smart camera (301) is located on the side of the discharge end of the partition synchronous belt (101) near the second photoelectric sensor (303).

3. The integrated training device for visual inspection and fixed-length cutting according to claim 2, characterized in that: It also includes a through-beam photoelectric sensor (404) that is signal-connected to the expandable remote I / O module (501). A dial (403) is mounted on the output shaft of the second servo motor (401), and the through-beam photoelectric sensor (404) is located on both sides of the middle section of the timing belt (101) of the partition below the dial (403).

4. The integrated training device for visual inspection and fixed-length cutting according to claim 3, characterized in that: It also includes a first photoelectric sensor (204) that is signal-connected to the expandable remote I / O module (501), the three-axis cylinder (201) is located on one side of the discharge end of the partition synchronous belt (101), and the first photoelectric sensor (204) is located on the side of the partition synchronous belt (101) near the three-axis cylinder (201).

5. The integrated training device for visual inspection and fixed-length cutting according to claim 3 or 4, characterized in that: It also includes a base (502), the servo controller (106) and valve island (203) are fixedly installed on the upper part of the base (502), the frame (107) is fixedly connected to the base (502) through the support base (108), the first servo motor (105) is fixedly connected to the base (502), the second photoelectric sensor (303) is fixedly connected to the frame (107) or the base (502) through the photoelectric sensor bracket (304), the smart camera (301) is fixedly connected to the base (502) through the camera bracket (302), the second servo motor (401) is fixedly connected to the base (502) through the motor bracket (402), and the three-axis cylinder (201) is fixedly connected to the frame (107) or the base (502) through the cylinder bracket (202).

6. The integrated training device for visual inspection and fixed-length cutting according to claim 5, characterized in that: One end of the frame (107) is rotatably mounted with a first synchronous pulley (102) via a bearing, and the other end is rotatably mounted with a second synchronous pulley (103). The partition synchronous belt (101) is sleeved on the first synchronous pulley (102) and the second synchronous pulley (103). The first servo motor (105) is connected to the first synchronous pulley (102) via a transmission belt.

7. The integrated training device for visual inspection and fixed-length cutting according to claim 6, characterized in that: The diaphragm timing belt (101) is assembled by uniformly fixing multiple diaphragms on the outer edge of the timing belt.

8. The integrated training device for visual inspection and fixed-length cutting according to claim 7, characterized in that: The dial (403) is a disc with multiple scale markings around the center on its surface. The second servo motor (401) must be directly above and parallel to the partition synchronous belt (101). The surface of the dial (403) is perpendicular to the plane of the partition synchronous belt (101), and the partition of the partition synchronous belt (101) has markings in the middle.

9. The integrated training device for visual inspection and fixed-length cutting according to claim 6, characterized in that: An end plate is fixedly installed at the front end of the piston rod of the three-axis cylinder (201), and a rejection channel (205) is also installed on the other side of the frame (107), with the rejection channel (205) directly opposite the position of the three-axis cylinder (201).

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