Intelligent high-temperature hot air fixing machine for tea leaves
By combining the unsaturated steam generation module, recognition camera, and near-infrared online moisture detector in the intelligent high-temperature hot air fixation machine, the problem of the difference in fixation requirements between old and tender leaves is solved, achieving a highly efficient and energy-saving tea fixation effect.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- HUBEI WUFENG HUASHENG TEA MACHINERY
- Filing Date
- 2025-06-19
- Publication Date
- 2026-07-03
AI Technical Summary
Existing blanching machines cannot simultaneously meet the different blanching needs of old and young leaves, and their poor automation results in high costs and low efficiency.
It adopts an intelligent high-temperature hot air blanching machine, combined with an unsaturated steam generation module, a recognition camera and a near-infrared online moisture detector. Through the PLC control system, it realizes intelligent identification of old leaves and young leaves and automatic adjustment of steam flow, providing suitable steam type and temperature.
It enables intelligent fixation of both old and young leaves, improving fixation efficiency and automation, saving energy, preventing tea leaves from turning yellow, and ensuring the fixation effect.
Smart Images
Figure CN224440274U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the technical field of tea processing equipment, and in particular to an intelligent high-temperature hot air fixation machine for tea. Background Technology
[0002] Existing blanching machines are usually connected to a steam supply mechanism, but the steam supply mechanism generally only supplies saturated steam. Tender leaves are prone to yellowing under saturated steam blanching, resulting in poor blanching effect.
[0003] Secondly, the device needs to process both old and tender leaves, so it needs to provide different types of steam according to the shape of the tea leaves to meet different fixing requirements. Existing fixing machines cannot switch intelligently, nor can they meet both requirements at the same time. Usually, two machines are used to process the two types of tea leaves separately, which increases costs, reduces efficiency, and makes the automation poor. Utility Model Content
[0004] This invention provides an intelligent high-temperature hot air fixation machine for tea, aiming to solve the problems of existing fixation machines being unable to simultaneously meet the different fixation needs of old and tender leaves, and having poor automatic controllability.
[0005] To solve the above-mentioned technical problems, the technical solution adopted by this utility model is: an intelligent high-temperature hot air fixation machine for tea, including a fixation machine and an unsaturated steam generation module. The fixation machine is provided with a feed inlet and a discharge outlet. The air inlet of the fixation machine is connected to the air outlet of the unsaturated steam generation module through an air outlet pipe. An electrically controlled flow valve is provided on the air outlet pipe.
[0006] The feed inlet of the blanching machine is equipped with a feed conveyor belt, and a recognition camera for identifying old leaves and young leaves is installed directly above the feed conveyor belt via a first mounting frame.
[0007] The blanching machine is equipped with a discharge conveyor belt at its discharge port, and a near-infrared online moisture detector is mounted directly above the discharge conveyor belt via a second mounting frame.
[0008] Preferably, the unsaturated steam generation module, the identification camera, the electrically controlled flow valve, and the near-infrared online moisture detector are all connected to the factory's PLC control system, and the identification camera and the near-infrared online moisture detector are linked with the unsaturated steam generation module and the electrically controlled flow valve through the factory's PLC control system.
[0009] More preferably, both the first mounting bracket and the second mounting bracket are "gate" shaped mounting brackets.
[0010] Furthermore, the bottom of both sides of the first mounting frame is provided with a fixed seat and is installed on both sides of the feeding conveyor belt by fasteners. The identification camera is installed at the bottom of the middle position of the first mounting frame, and the camera end of the identification camera is facing the feeding conveyor belt.
[0011] Furthermore, the bottom of both sides of the second mounting frame is provided with fixed seats and is installed on both sides of the discharge conveyor belt by fasteners. The sensing probe of the near-infrared online moisture detector is installed at the bottom of the middle position of the second mounting frame, and the sensing end of the sensing probe is facing the discharge conveyor belt.
[0012] More preferably, the unsaturated steam generation module includes a steam boiler. The flue gas outlet of the steam boiler is connected to the feed end of one side of the heat exchanger through a flue gas outlet pipe. Outside air is introduced into the other feed end of the heat exchanger through an air inlet fan. The flue gas and the outside air form a heat exchange combination in the heat exchanger. The heated outside air enters the steam boiler through a return pipe and mixes with the steam to form unsaturated steam. The unsaturated steam enters the outlet pipe through the steam outlet of the steam boiler.
[0013] Furthermore, both the flue gas outlet pipe and the return pipe are equipped with electrically controlled valves, which are connected to the plant's PLC control system and linked with the identification camera and near-infrared online moisture detector through the plant's PLC control system.
[0014] Furthermore, the air inlet of the air inlet is equipped with an ultrasonic atomizer.
[0015] The beneficial effects of this utility model are:
[0016] 1. This utility model can provide saturated steam and unsaturated steam through an unsaturated steam generation module, which can simultaneously meet the needs of old leaves and young leaves, and can switch between them;
[0017] 2. The device uses a camera to identify whether it is a batch of old leaves or a batch of young leaves and automatically switches between saturated and unsaturated steam, operating intelligently to ensure the efficiency and self-control of the blanching process.
[0018] 3. The device monitors the moisture content of the discharged tea leaves in real time using a near-infrared online moisture detector and adjusts the steam temperature accordingly to keep the discharged tea leaves within the set moisture content range, ensuring the fixation effect and self-control.
[0019] 4. The device recovers waste heat from flue gas to preheat air, preventing air from directly entering the steam and significantly affecting the steam temperature, thus affecting the blanching effect. At the same time, it recovers and utilizes waste heat from flue gas to avoid heat waste. Attached Figure Description
[0020] Figure 1 This is a connection diagram of the present invention;
[0021] Figure 2 This is a schematic diagram showing the arrangement of the feed inlet of the blanching machine according to this utility model;
[0022] Figure 3This is a schematic diagram showing the arrangement of the material outlet of the blanching machine according to this utility model;
[0023] In the picture: 1. Clothing machine;
[0024] 2. Unsaturated steam generation module; 201. Steam boiler; 202. Flue gas outlet pipe; 203. Heat exchanger; 204. Inlet fan; 205. Return pipe;
[0025] 3. Air outlet duct; 4. Feed inlet; 5. Discharge outlet; 6. Feed conveyor belt; 7. Discharge conveyor belt; 8. First mounting frame; 9. Identification camera; 10. Second mounting frame; 11. Near-infrared online moisture detector; 12. Electrically controlled flow valve. Detailed Implementation
[0026] The embodiments will be further described below with reference to the accompanying drawings.
[0027] like Figures 1-3 As shown in the preferred embodiment 1, an intelligent high-temperature hot air fixation machine for tea includes a fixation machine 1 and an unsaturated steam generation module 2. The fixation machine 1 is provided with a feed inlet 4 and a discharge outlet 5. The air inlet of the fixation machine 1 is connected to the air outlet of the unsaturated steam generation module 2 through an air outlet pipe 3. An electrically controlled flow valve 12 is provided on the air outlet pipe 3.
[0028] The feed inlet 4 of the blanching machine 1 is provided with a feed conveyor belt 6, and a recognition camera 9 for identifying old leaves and young leaves is installed directly above the feed conveyor belt 6 via a first mounting frame 8.
[0029] The discharge port 5 of the blanching machine 1 is provided with a discharge conveyor belt 7, and a near-infrared online moisture detector 11 is installed directly above the discharge conveyor belt 7 via a second mounting frame 10.
[0030] The device identifies whether the tea leaves are tender or old leaves through the recognition camera 9. When it is a batch of tender leaves, unsaturated steam can be introduced for fixation, while when it is a batch of old leaves, no steam or a small amount of saturated steam can be introduced for fixation to avoid excessive steam causing the tea leaves to turn yellow.
[0031] The moisture content of the tea leaves after fixation is monitored in real time by a near-infrared online moisture detector 11. The moisture content is controlled between 55% and 60%. When the moisture content exceeds this range, the power of the unsaturated steam generation module 2 is increased to raise the temperature of the supplied steam. When the moisture content is below this range, the power of the unsaturated steam generation module 2 is reduced to lower the temperature of the supplied steam, thereby ensuring the moisture content after fixation.
[0032] As a preferred embodiment 2, the method for identifying tea leaves using the camera 9 can use existing methods or procedures, such as the "A method for identifying and classifying the grade of tea buds based on computer vision" published in CN112633212B.
[0033] Young leaves are usually single, plump, and light in color; older leaves are multi-leaved, large or long, and dark in color.
[0034] In a preferred embodiment 3, the unsaturated steam generation module 2, the identification camera 9, the electrically controlled flow valve 12, and the near-infrared online moisture detector 11 are all connected to the factory's PLC control system. Furthermore, the identification camera 9 and the near-infrared online moisture detector 11 are linked with the unsaturated steam generation module 2 and the electrically controlled flow valve 12 through the factory's PLC control system, forming an automatic control system. The logic for subsequent specific devices is as follows:
[0035] 1. When the recognition camera 9 identifies tender leaves, the PLC control system in the factory opens the steam boiler 201, the air inlet fan 204, the electrically controlled flow valve 12, and the electrically controlled valves on the flue gas outlet pipe 202 and the return pipe 205. The electrically controlled flow valve 12 is adjusted to the set position A to provide unsaturated steam with a set flow rate to the blanching machine 1. Position A is a larger flow rate, and tender buds require more unsaturated steam.
[0036] 2. When the identification camera 9 identifies an old leaf, the steam boiler 201 is turned on through the factory's PLC control system, the electric control valves on the inlet fan 204 and flue gas outlet pipe 202 and return pipe 205 are closed, the electric control flow valve 12 is turned on and adjusted to the set position B, and saturated steam with a set flow rate is provided to the blanching machine 1. Position B is a small flow rate, and old leaves need very little saturated steam. Some old leaves do not even need steam for blanching, as the steam generated in the blanching process itself is sufficient.
[0037] For special batches of old leaves that do not require steam, when the identification camera 9 identifies them as old leaves, the factory's PLC control system shuts down the steam boiler 201, the air intake fan 204, the electrically controlled flow valve 12, and the electrically controlled valves on the flue gas outlet pipe 202 and the return pipe 205, directly stopping the supply of steam to meet the blanching requirements. The control process is set according to the state of the old leaves before blanching and which one to select.
[0038] 3. When the near-infrared online moisture detector 11 detects that the moisture content of the tea leaves after fixation exceeds the maximum value of the set range, the power of the steam boiler 201 is increased through the factory's PLC control system to increase the steam temperature until the moisture content returns to the set range and the steam temperature is maintained.
[0039] 4. When the near-infrared online moisture detector 11 detects that the moisture content of the tea leaves after fixation is lower than the minimum value of the set range, the power of the steam boiler 201 is reduced and the steam temperature is lowered through the factory's PLC control system until the moisture content returns to the set range and the steam temperature is maintained.
[0040] Preferably, an existing industrial PLC control system can be selected as the PLC control system.
[0041] In a preferred embodiment 4, both the first mounting bracket 8 and the second mounting bracket 10 are "door" shaped mounting brackets, facilitating installation.
[0042] The first mounting bracket 8 has fixed seats on both sides of its bottom end and is installed on both sides of the feeding conveyor belt 6 by fasteners. The identification camera 9 is installed at the bottom of the middle position of the first mounting bracket 8, and the camera end of the identification camera 9 faces the feeding conveyor belt 6. This ensures the identification camera 9 can identify tea leaves and maintain stable fixation.
[0043] The second mounting bracket 10 has fixed seats on both sides of its bottom end, which are fastened to both sides of the discharge conveyor belt 7. The sensing probe of the near-infrared online moisture detector 11 is installed at the bottom of the middle position of the second mounting bracket 10, with the sensing end of the sensing probe facing the discharge conveyor belt 7. This ensures the monitoring and stability of the moisture content of the tea leaves by the sensing probe of the near-infrared online moisture detector 11.
[0044] In a preferred embodiment 5, the unsaturated steam generation module 2 includes a steam boiler 201. The flue gas outlet of the steam boiler 201 is connected to one side of the feed end of the heat exchanger 203 via a flue gas outlet pipe 202. The other feed end of the heat exchanger 203 introduces outside air through an inlet fan 204. The flue gas and outside air form a heat exchange combination within the heat exchanger 203. The heated outside air enters the steam boiler 201 through a return pipe 205 and mixes with the steam to form unsaturated steam. The unsaturated steam enters the outlet pipe 3 through the steam outlet of the steam boiler 201. The flue gas in the high-temperature steam boiler 201 still has a temperature of over 200°C. This flue gas is used to heat fresh air. The fresh air can be heated to 50 to 60°C through the heat exchanger 203, which is equivalent to saving energy. The waste heat of the flue gas is recovered and utilized. Then, it enters the steam boiler 201, where it mixes with the air and steam to form unsaturated steam, which is then further heated to 450°C, meeting the blanching requirements of both old and young leaves.
[0045] Both the flue gas outlet duct 202 and the return duct 205 are equipped with electrically controlled valves. These valves are connected to the plant's PLC control system, which in turn links with the identification camera 9 and the near-infrared online moisture detector 11. This facilitates process control and allows switching between unsaturated and saturated steam processes.
[0046] The air inlet of the blower 204 is equipped with an ultrasonic atomizer to facilitate the uniform mixing of water vapor and air.
[0047] The working principle of this utility model:
[0048] 1. When the recognition camera 9 identifies tender leaves, the PLC control system in the factory opens the steam boiler 201, the air inlet fan 204, the electrically controlled flow valve 12, and the electrically controlled valves on the flue gas outlet pipe 202 and the return pipe 205. The electrically controlled flow valve 12 is adjusted to the set position A to provide unsaturated steam with a set flow rate to the blanching machine 1. Position A is a larger flow rate, and tender buds require more unsaturated steam.
[0049] 2. When the identification camera 9 identifies an old leaf, the steam boiler 201 is turned on through the factory's PLC control system, the electric control valves on the inlet fan 204 and flue gas outlet pipe 202 and return pipe 205 are closed, the electric control flow valve 12 is turned on and adjusted to the set position B, and saturated steam with a set flow rate is provided to the blanching machine 1. Position B is a small flow rate, and old leaves need very little saturated steam. Some old leaves do not even need steam for blanching, as the steam generated in the blanching process itself is sufficient.
[0050] For special batches of old leaves that do not require steam, when the identification camera 9 identifies them as old leaves, the factory's PLC control system shuts down the steam boiler 201, the air intake fan 204, the electrically controlled flow valve 12, and the electrically controlled valves on the flue gas outlet pipe 202 and the return pipe 205, directly stopping the supply of steam to meet the blanching requirements. The control process is set according to the state of the old leaves before blanching and which one to select.
[0051] 3. When the near-infrared online moisture detector 11 detects that the moisture content of the tea leaves after fixation exceeds the maximum value of the set range, the power of the steam boiler 201 is increased through the factory's PLC control system to increase the steam temperature until the moisture content returns to the set range and the steam temperature is maintained.
[0052] 4. When the near-infrared online moisture detector 11 detects that the moisture content of the tea leaves after fixation is lower than the minimum value of the set range, the power of the steam boiler 201 is reduced and the steam temperature is lowered through the factory's PLC control system until the moisture content returns to the set range and the steam temperature is maintained.
Claims
1. A smart high-temperature hot air fixing machine for tea leaves, comprising a fixing machine (1) and an unsaturated steam generating module (2), the fixing machine (1) is provided with a feeding port (4) and a discharging port (5), characterized in that, The air inlet of the blanching machine (1) is connected to the air outlet of the unsaturated steam generation module (2) through the air outlet pipe (3), and an electrically controlled flow valve (12) is provided on the air outlet pipe (3). The feed inlet (4) of the blanching machine (1) is provided with a feed conveyor belt (6), and a recognition camera (9) for identifying old leaves and tender leaves is installed directly above the feed conveyor belt (6) via a first mounting frame (8). The discharge port (5) of the blanching machine (1) is provided with a discharge conveyor belt (7), and a near-infrared online moisture detector (11) is installed directly above the discharge conveyor belt (7) via a second mounting frame (10).
2. The intelligent high-temperature hot air fixing machine for tea leaves according to claim 1, characterized in that, The unsaturated steam generation module (2), the identification camera (9), the electric flow valve (12), and the near-infrared online moisture detector (11) are all connected to the plant's PLC control system. The identification camera (9) and the near-infrared online moisture detector (11) are linked with the unsaturated steam generation module (2) and the electric flow valve (12) through the plant's PLC control system.
3. The intelligent high-temperature hot air fixing machine for tea leaves according to claim 2, characterized in that, Both the first mounting bracket (8) and the second mounting bracket (10) are "door" shaped mounting brackets.
4. The intelligent high-temperature hot air fixing machine for tea leaves according to claim 3, characterized in that, The first mounting frame (8) has fixed seats on both sides of the bottom and is installed on both sides of the feeding conveyor belt (6) by fasteners. The identification camera (9) is installed at the bottom of the middle position of the first mounting frame (8), and the camera end of the identification camera (9) is facing the feeding conveyor belt (6).
5. The intelligent high-temperature hot air fixation machine for tea as described in claim 3, characterized in that, The bottom of the second mounting frame (10) is provided with fixed seats on both sides and is installed on both sides of the discharge conveyor belt (7) by fasteners. The sensing probe of the near-infrared online moisture detector (11) is installed at the bottom of the middle position of the second mounting frame (10), and the sensing end of the sensing probe is facing the discharge conveyor belt (7).
6. The intelligent high-temperature hot air fixation machine for tea according to claim 2, characterized in that, The unsaturated steam generation module (2) includes a steam boiler (201). The flue gas outlet of the steam boiler (201) is connected to the feed end of one side of the heat exchanger (203) through the flue gas outlet pipe (202). The other feed end of the heat exchanger (203) introduces outside air through the air inlet fan (204). The flue gas and the outside air form a heat exchange combination in the heat exchanger (203). The heated outside air enters the steam boiler (201) through the return pipe (205) and mixes with the steam to form unsaturated steam. The unsaturated steam enters the outlet pipe (3) through the steam outlet of the steam boiler (201).
7. The intelligent high-temperature hot air fixing machine for tea leaves according to claim 6, characterized in that, Both the flue gas outlet pipe (202) and the return pipe (205) are equipped with electrically controlled valves. The electrically controlled valves are connected to the plant's PLC control system and are linked with the identification camera (9) and the near-infrared online moisture detector (11) through the plant's PLC control system.
8. The intelligent high-temperature hot air fixing machine for tea leaves according to claim 6, characterized in that, The air inlet of the air inlet fan (204) is equipped with an ultrasonic atomizer.