A modular architecture based batch quality control system

Abstract

The utility model discloses a kind of batching quality control system based on modularization architecture, comprising: batching module includes feed tank, spice tank and be used for connecting feed tank and spice tank's batching pipeline;Weighing module includes the first weighing device being arranged in feed tank, the second weighing device being arranged in spice tank and the third weighing device being arranged in batching pipeline;Target detection module includes analog quantity acquisition device and digital logic circuit;The first weighing device, the second weighing device and the third weighing device are connected with digital logic circuit by analog quantity acquisition device;Digital logic circuit is connected with batching control module.The utility model realizes the whole-process material balance monitoring of feeding, receiving, residual by setting three weighing devices, and batching target value is corrected according to residual amount using analog quantity acquisition device and digital logic circuit, and the intelligent level and production efficiency of batching system are significantly improved.

Description

Technical Field

[0001] This utility model relates to the field of ingredient control, specifically to an ingredient quality control system based on a modular architecture. Background Technology

[0002] In the current trend of high-quality development in the tobacco industry, the degree of informatization, intelligence, and automation in the processing has become an important indicator for measuring a company's core competitiveness. As a key link in achieving refined processing and flexible production, the flavoring kitchen can precisely control the blending and addition of flavorings and fragrances according to different product needs, which is of great significance for improving the quality of tobacco products. The precision of the ratio of flavorings and fragrances in tobacco directly determines the flavor characteristics of the tobacco and the final product quality; even slight errors in the ratio can cause significant differences in product flavor and affect the consumer experience.

[0003] Traditional batching systems rely solely on tank weighing, failing to detect measurement errors (up to ±5%) caused by pipeline residue. Furthermore, offline monitoring methods cannot provide real-time production guidance, and centralized architectures present challenges for upgrades and maintenance. Pipeline residue levels are difficult to accurately detect due to factors such as material viscosity and temperature; traditional sensors cannot distinguish between liquid weight and structural stress; multi-sensor data synchronization and real-time calculation are challenging, analog signals are susceptible to interference, and computational delays are high; mechanical vibrations and electromagnetic interference in industrial environments reduce system reliability; and incompatibility between sensor interfaces from different manufacturers and difficulties in modular integration further complicate matters. These issues result in low batch-to-batch accuracy and poor consistency, failing to meet the demands of modern tobacco processing for intelligent and precise production. Utility Model Content

[0004] In view of this, the present invention provides a batching quality control system based on a modular architecture, which aims to solve the problems of low batching accuracy and poor batch-to-batch consistency in existing batching systems.

[0005] The technical solution adopted by this utility model to solve the above-mentioned technical problems is as follows:

[0006] A modular architecture-based ingredient quality control system, including

[0007] The batching module, weighing module, target detection module, and batching control module are all included.

[0008] The ingredient preparation module includes a dispensing tank, a spice tank, and an ingredient preparation pipeline for connecting the dispensing tank and the spice tank.

[0009] The weighing module includes a first weighing device installed in the dispensing tank, a second weighing device installed in the spice tank, and a third weighing device installed in the dispensing pipeline.

[0010] The target detection module includes an analog signal acquisition device and a digital logic circuit; the first weighing device, the second weighing device, and the third weighing device are all connected to the digital logic circuit through the analog signal acquisition device;

[0011] The digital logic circuit is connected to the ingredient control module.

[0012] In one possible implementation, the section between the spice pump outlet of the dispensing tank and the vertical pipe section of the spice tank is configured as an inclined pipe sloping downwards in the flow direction, and an anti-siphon elbow is provided at the end of the inclined pipe.

[0013] Pneumatic valves are installed at both the outlet of the spice pump and the starting end of the inclined pipe.

[0014] An air vent valve is installed at the lowest point of the inclined pipe.

[0015] In one possible implementation, the inclined pipe is connected to a third weighing device via a resilient support structure.

[0016] In one possible implementation, the digital logic circuit includes a target value correction circuit;

[0017] The third weighing device is connected to the target value correction circuit;

[0018] The target value correction circuit is connected to the ingredient control module.

[0019] In one possible implementation, the digital logic circuit further includes a comparison circuit connected to a third weighing device.

[0020] In one possible implementation, the control system further includes an early warning module connected to a comparison circuit.

[0021] In one possible implementation, the early warning module includes a local audible and visual alarm device and a remote communication alarm device.

[0022] In one possible implementation, the control system further includes a cleaning module connected to the batching control module.

[0023] The beneficial effects of this utility model are:

[0024] This invention achieves full-process material balance monitoring of feeding, receiving, and residue by setting up three weighing devices. It uses analog quantity acquisition devices and digital logic circuits to correct the batching target value in real time according to the residue, thereby improving the intelligence level and production efficiency of the batching system and solving the problems of low accuracy, large error and slow response of traditional batching systems. Attached Figure Description

[0025] To more clearly illustrate the technical solutions in the embodiments of this utility model, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0026] Figure 1 This is a schematic diagram of the ingredient quality control system provided in this embodiment of the utility model.

[0027] The diagram is labeled as follows: 1-Ingredient dispensing module; 2-Weighing module; 3-Target detection module; 4-Ingredient dispensing control module; 11-Dispensing tank; 12-Spice tank; 13-Ingredient dispensing pipeline; 21-First weighing device; 22-Second weighing device; 23-Third weighing device; 31-Analog signal acquisition device; 32-Digital logic circuit. Detailed Implementation

[0028] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0029] Unless otherwise defined, the technical or scientific terms used in this utility model shall have the ordinary meaning understood by one of ordinary skill in the art to which this utility model pertains. The terms "first," "second," and similar words used in this utility model do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Terms such as "comprising" or "including" mean that the element or object preceding the word encompasses the elements or objects listed following the word and their equivalents, without excluding other elements or objects. Terms such as "connected" or "linked" are not limited to physical or mechanical connections, but can include electrical connections, whether direct or indirect. Terms such as "upper," "lower," "left," and "right" are used only to indicate relative positional relationships; when the absolute position of the described object changes, the relative positional relationship may also change accordingly.

[0030] Reference Figure 1 This utility model embodiment relates to a batching quality control system based on a modular architecture, including a batching module 1, a weighing module 2, a target detection module 3, and a batching control module 4.

[0031] The ingredient dispensing module 1 includes a dispensing tank 11, a spice tank 12, and an ingredient dispensing pipe 13 for connecting the dispensing tank 11 and the spice tank 12;

[0032] The weighing module 2 includes a first weighing device 21 disposed in the dispensing tank 11, a second weighing device 22 disposed in the spice tank 12, and a third weighing device 23 disposed in the dispensing pipe 13;

[0033] The target detection module 3 includes an analog signal acquisition device 31 and a digital logic circuit 32; the first weighing device 21, the second weighing device 22 and the third weighing device 23 are all connected to the digital logic circuit 32 through the analog signal acquisition device 31.

[0034] The digital logic circuit 32 is connected to the ingredient control module 4.

[0035] In this embodiment of the invention, the target ingredient formula (such as the type of spice and the total amount of spice) and the theoretical target ingredient value M are first selected. 目标 Subsequently, the spice pump of the ingredient module 1 is started, and the corresponding spices in the dispensing tank 11 are transported to the spice tank 12 through the ingredient pipe 13. The inclined design of the ingredient pipe 13, together with the pneumatic valve and the venting valve, ensures a smooth conveying process and reduces residue.

[0036] The first weighing device 21 monitors the weight change of the dispensing tank 11 in real time and obtains the dispensing quantity M. 发料 The second weighing device 22 monitors the weight change of the spice container 12 in real time to obtain the actual received quantity M. 接收 The third weighing device 23 measures the residual amount M in the batching pipe 13 in real time through elastic support. 残留 The weighing signals of the three components are converted into digital signals by the analog acquisition device 31 (such as using an existing ADC converter) and transmitted to the digital logic circuit 32. The digital logic circuit 32 dynamically adjusts the target value of the next stage of batching according to the residual amount in the pipeline and transmits it to the batching control module 4.

[0037] Traditional batching systems calculate the amount of ingredients by weighing the tanks (the amount reduced by the dispensing tank 11 - the amount increased by the spice tank 12), but ignore the residue in the pipeline (especially high-viscosity materials, which can have a residue of 50-100g), resulting in a deviation of ±5% between the actual amount of ingredients and the target value.

[0038] M is measured and monitored in real time by the first weighing device 21 and the second weighing device 22. 发料 M 接收 Consistency is ensured by real-time measurement of pipeline residue M using the third weighing device 23. 残留The error will be compensated for in the next target value. For example, if the residual amount in the pipeline is 20g when 1000g of spices is added in the next target, the ingredient control module 4 will control the amount of material dispensed to 1020g through the discharge valve and pump body.

[0039] In some embodiments, the dispensing pipe 13 between the spice pump outlet of the dispensing tank 11 and the vertical pipe section of the spice tank 12 is configured as an inclined pipe sloping downwards along the flow direction, and an anti-siphon elbow is provided at the end of the inclined pipe. A pneumatic valve is installed at the spice pump outlet and the beginning of the inclined pipe, and an vent valve is provided at the lowest point of the inclined pipe.

[0040] In this embodiment of the invention, the inclined pipe typically adopts a downward inclination angle of 5°-8° (along the material flow direction). This angle has been verified through fluid dynamics simulation, which can both utilize gravity to accelerate material flow (increasing flow velocity by 15%-20%) and avoid excessive fluid impact that would exacerbate pipe wear. The inner wall of the pipe is mirror-polished (roughness Ra≤0.8μm), and combined with the inclined design, the residual amount of high-viscosity materials is reduced by 60%-80% compared to vertical pipes. The inclined pipe allows residual materials to naturally converge towards the lowest point, facilitating accurate measurement by the third weighing device 23 (such as a weighing sensor installed below the end of the pipe).

[0041] When the spice pump stops, the fluid in the pipeline flows back to the bottom of the anti-siphon elbow due to gravity, blocking the siphon effect and preventing the material in the dispensing tank 11 from being sucked back into the pipeline. When stopping, first close the pump outlet valve, then close the pipeline valve to avoid the formation of negative pressure in the pipeline and further reduce residual fluctuations.

[0042] In this embodiment of the invention, the target value correction circuit uses existing combinational logic gates to perform formula calculations based on the compensation coefficient k (artificially set, known range 1-1.10) corresponding to the type of flavoring raw material (e.g., high viscosity / low viscosity): M 修正 =M 目标 +kM 残留 .

[0043] The following is an example structure of the target value correction circuit, but it is not intended to be limiting.

[0044] The target value correction circuit includes the following existing hardware architecture: a memory, such as a 128×8-bit ROM memory; a multiplier to calculate the product of k and the residual amount; a 32-bit carry-lookahead adder to add the product to the batching target value to generate the corrected target value; and a 32-bit register to store the corrected target value and transmit it to the batching control module 4. It should be noted that this correction circuit is a conventional digital circuit design and does not involve any programmatic improvements to the internal functional algorithms of the aforementioned hardware architecture.

[0045] In addition, temperature changes affect the viscosity of fragrances (e.g., propylene glycol has a viscosity of 56 mPa·s at 20°C, which drops to 15 mPa·s at 50°C), resulting in residual content fluctuations of ±30%. Pump aging or pipeline wear leads to a decrease in conveying efficiency, which traditional batching systems cannot correct in real time.

[0046] In this embodiment of the invention, to address the problems of fluctuating spice viscosity due to temperature changes and decreased conveying efficiency due to pump aging or pipe wear, the invention achieves unparalleled precise control and adaptive adjustment capabilities compared to traditional batching systems through three core designs: real-time residual monitoring, compensation coefficient, and hardware structure.

[0047] This invention directly measures the residual amount M in the pipeline using a third weighing device 23. 残留 Independent of the tank weight difference calculation, it avoids the interference of viscosity changes on the "indirect calculation method". For example, when the temperature rises, the viscosity decreases and the material flowability increases, the residual amount in the pipeline decreases from 20g to 14g (fluctuation -30%). The third weighing device 23 captures this change in real time, rather than indirectly estimating it through the tank weight difference, ensuring the timeliness and accuracy of the residual amount data.

[0048] If a high-viscosity material becomes medium-viscosity due to heating, the target value correction circuit combines the compensation coefficient k corresponding to the type of fragrance raw material (e.g., adjusted from 1.10 to 1.05) and the real-time measured M. 残留 Calculate the target correction value M for the next stage of ingredient mixing. 修正 =M 目标 +kM 残留 This enables differential compensation under viscosity gradients.

[0049] If pump aging causes the residual amount per delivery to increase from 20g to 35g, the third weighing device 23 will detect M in real time. 残留 =35g, the target value correction circuit immediately adjusts the next stage feeding amount, such as from "1000+20=1020g" to "1000+35=1035g", to offset the error caused by equipment degradation in real time, without the need for manual calibration or machine shutdown maintenance.

[0050] The inclined pipe of this utility model is connected to the third weighing device 23 through a flexible hinge elastic support, which can isolate interference factors such as pump body vibration and pipe thermal expansion and contraction, and ensure M 残留 The measured values ​​only reflect the actual amount of material residue. Even if pipe wear causes changes in the roughness of the inner wall, the elastic support structure can still stably transmit the pipe weight signal, avoiding measurement deviations caused by mechanical deformation in traditional rigid connections.

[0051] In some embodiments, the digital logic circuit 32 further includes a comparison circuit; the comparison circuit is connected to the third weighing device 23.

[0052] In some embodiments, the control system further includes an early warning module connected to a comparison circuit.

[0053] In some embodiments, the early warning module includes a local audible and visual alarm device and a remote communication alarm device.

[0054] In this embodiment of the invention, the comparison circuit uses an existing digital comparator to compare the M value of the third weighing device 23. 残留 The threshold is compared with a preset threshold to determine whether an alarm is needed. Specifically, a dual threshold comparator can be used, in M... 残留 When the value exceeds the first threshold, the local audible and visual alarm device is activated. 残留 The remote communication alarm device is activated when the value exceeds the second threshold, where the second threshold is greater than the first threshold.

[0055] In some embodiments, the control system further includes a cleaning module; the cleaning module is connected to the batching control module 4.

[0056] In this embodiment of the invention, the cleaning module includes a cleaning execution device, an auxiliary purging device, and a cleanliness detection device. The auxiliary purging device is installed on the pipeline between the fragrance pump and the pneumatic valve. After the ingredients are dispensed, clean compressed air (pressure 0.3-0.5 MPa) is introduced to help remove residual droplets from the inner wall of the pipeline.

[0057] The cleanliness testing device includes:

[0058] Conductivity sensor: Installed at the cleaning water outlet, it monitors the change in the conductivity of the cleaning fluid in real time to determine whether the concentration of residual fragrance meets the standard.

[0059] Turbidity sensor: Connected in parallel with conductivity sensor, it detects the turbidity of cleaning solution through the principle of light scattering, providing dual verification of cleaning effect.

[0060] Traditional ingredient dispensing systems rely on timed cleaning (e.g., every 4 hours), but cannot detect the actual amount of residue. For example:

[0061] Low-viscosity materials (such as alcoholic fragrances) may leave only 5g of residue in inclined pipes, and regular cleaning will waste water resources.

[0062] High-viscosity materials (such as syrups and flavorings) may have a residual amount of up to 60g due to pump aging. Regular cleaning may not have been thorough enough, leading to cross-contamination.

[0063] This control system monitors M in real time via the third weighing device 23. 残留 When the residual amount is detected to be greater than 10g before material replacement (the threshold can be customized according to the material characteristics), the cleaning execution device is started, including a 30℃ warm water flushing pipeline connected to the batching pipeline 13, a compressed air passage, a cleaning fluid passage, and necessary switching valves and pumps.

[0064] The above embodiments are only used to illustrate the technical solutions of this utility model, and are not intended to limit it. Although this utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this utility model, and should all be included within the protection scope of this utility model.

Claims

1. A batching quality control system based on a modular architecture, characterized in that: include The batching module, weighing module, target detection module, and batching control module are all included. The ingredient preparation module includes a dispensing tank, a spice tank, and an ingredient preparation pipeline for connecting the dispensing tank and the spice tank. The weighing module includes a first weighing device installed in the dispensing tank, a second weighing device installed in the spice tank, and a third weighing device installed in the dispensing pipeline. The target detection module includes an analog signal acquisition device and a digital logic circuit; the first weighing device, the second weighing device, and the third weighing device are all connected to the digital logic circuit through the analog signal acquisition device; The digital logic circuit is connected to the ingredient control module.

2. The batching quality control system according to claim 1, characterized in that: The section between the spice pump outlet of the dispensing tank and the vertical pipe section of the spice tank is configured as an inclined pipe that slopes downwards along the flow direction, and an anti-siphon elbow is provided at the end of the inclined pipe. Pneumatic valves are installed at both the outlet of the spice pump and the starting end of the inclined pipe. An air vent valve is installed at the lowest point of the inclined pipe.

3. The batching quality control system according to claim 2, characterized in that: The inclined pipe is connected to the third weighing device through an elastic support structure.

4. The batching quality control system according to claim 1, characterized in that: The digital logic circuit includes a target value correction circuit; The third weighing device is connected to the target value correction circuit; The target value correction circuit is connected to the ingredient control module.

5. The batching quality control system according to claim 4, characterized in that: The digital logic circuit also includes a comparison circuit, which is connected to the third weighing device.

6. The batching quality control system according to claim 1, characterized in that: The control system also includes an early warning module, which is connected to a comparison circuit.

7. The batching quality control system according to claim 6, characterized in that: The early warning module includes a local audible and visual alarm device and a remote communication alarm device.

8. The batching quality control system according to claim 1, characterized in that: The control system also includes a cleaning module, which is connected to the ingredient control module.

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