A jammed joint recognition and shutdown system for a ZB45 packaging machine

Abstract

The utility model discloses a kind of paper jam joint identification and shutdown system for ZB45 packing machine, belong to tobacco packaging equipment technical field.The system includes rack, paper jam cutting mechanism and mark detection sensor set by original machine, and paper jam conveying passage formed by conveying roller.It is characterized in that, the system is additionally provided with: joint detection sensor installed at 350-400mm upstream of paper jam cutting mechanism, cutting position detection sensor set at cutting mechanism, controller electrically connected with the two sensors respectively, and the output end of coil connection controller, normally closed contact point series connection into the execution relay of original machine shutdown loop.The utility model realizes the accurate identification and automatic shutdown of black joint in cutting position by the signal cooperation of two sensors and the judgment of controller to synchronous signal, reduces from 15-25 packs to about 5 packs due to black joint, effectively reduces material consumption, improves production efficiency.

Description

Technical Field

[0001] This utility model relates to the field of tobacco packaging equipment technology, specifically to a paper jam connector identification and shutdown system for a ZB45 packaging machine. Background Technology

[0002] During the packaging process of the ZB45 hard-pack packaging machine, cardboard (i.e., the outer paper of the hard-pack cigarette pack) is needed to wrap the cigarette pack. The roll of cardboard has evenly spaced black markings (hereinafter referred to as "black dots") printed along its length. These black dots serve as reference marks to achieve fixed-length cutting of the cardboard.

[0003] In existing technology, a paper jam cutting and correction system is set up for this purpose. The core of the system is a marker detection sensor that is fixedly installed at a fixed position upstream of the paper jam cutting mechanism. The installation position of the sensor has been carefully preset and calibrated. Its core design goal is to enable the system to predict and ensure that when a black dot on the paper jam is detected by the sensor, the system can predict and ensure that after the paper jam continues to travel a fixed distance, the physical position corresponding to the black dot can accurately reach the blade of the cutting mechanism to complete the cut.

[0004] This control logic relies on a stable paper feed speed. The system triggers an internal timer or position counter the moment the sensor detects a black dot, calculating the precise delay the cutting mechanism should take based on a preset fixed distance from the sensor to the blade. Simultaneously, the system also presets a reference time interval (e.g., 5 seconds) corresponding to a fixed paper length (e.g., 10cm spacing between adjacent black dots). This means that under stable operation, the marker detection sensor should detect a black dot every 5 seconds. If the actual detection time interval between two consecutive black dots is less than 5 seconds (e.g., only 4 seconds), the system determines that the paper feed is too fast, and its position is "ahead" of the cutting reference; conversely, if the detection time interval is longer than 5 seconds (e.g., 6 seconds), the system determines that the paper feed is too slow, and its position is "lagging". Once a deviation is detected, the system drives a correction motor, which slightly rotates the paper feed rollers via a transmission mechanism, actively changing the tension and effective path length of the paper in the feed path, thereby precisely correcting the longitudinal position of the paper and ensuring a constant length for each cutting segment.

[0005] However, in actual production, the length of a single roll of cardboard is limited, requiring splicing (i.e., joining) to form a longer roll. This splicing creates a darker area much wider than the normal positioning black dot, known as a "black joint." Because existing marking detection sensors (photoelectric sensors) can only identify color marks based on reflectivity differences and cannot distinguish between normal black dots and black joints based on physical width, when a large black joint passes through, the sensor continuously outputs a valid detection signal much longer than the normal black dot signal. Unable to distinguish this abnormal signal, the system misinterprets it as a continuous and severe positive or negative offset of the cardboard. This misinterpretation triggers the correction motor to run continuously in one direction, attempting to correct this non-existent offset. The direct consequence is a severe deviation in the actual cutting length of the cardboard, ultimately requiring the equipment to continuously reject 15 to 25 defective cigarette packs, resulting in significant material waste.

[0006] This application is submitted to address the above issues. Utility Model Content

[0007] To address the shortcomings of existing technologies, the purpose of this invention is to provide a paper jam splice identification and shutdown system for the ZB45 packaging machine. This system accurately identifies black splices on the paper jam and automatically triggers a shutdown the instant the black splice reaches the precise cutting position. This allows the paper jam, along with the black splice, to remain stably stationary at the preset cutting position, creating optimal conditions for operators to manually cut off the black splice and reassemble the paper jam. Ultimately, this effectively avoids the problems of continuous correction and significant material waste caused by misjudging black splices.

[0008] The technical solution adopted in this utility model is:

[0009] A paper jam splice identification and shutdown system for a ZB45 packaging machine is provided, including a frame, a paper jam cutting mechanism 5 and a marking detection sensor originally installed on the machine. The marking detection sensor is located at the paper jam cutting mechanism 5 for positioning the paper jam during cutting. The frame is provided with a paper jam conveying channel composed of multiple conveying rollers. The system also includes: The connector detection sensor 3 is fixedly installed above the paper conveying channel via a bracket 2 and is located upstream of the paper cutting mechanism 5; A cutting position detection sensor 6 is installed on the frame of the paper cutting mechanism 5 and is used to detect whether the paper cutting mechanism 5 has moved to the cutting position; The controller 4 has its signal input terminals electrically connected to the joint detection sensor 3 and the cutting position detection sensor 6, respectively. The relay is activated, and its coil is electrically connected to the signal output terminal of the controller 4. The normally closed contact of the execution relay is connected in series to any stop control circuit of the original packaging machine.

[0010] Preferably, the installation position of the connector detection sensor 3 is 350-400mm upstream of the vertical cutting line of the paper cutting mechanism 5.

[0011] Preferably, the connector detection sensor 3 is a diffuse reflection photoelectric sensor.

[0012] Preferably, the cutting position detection sensor 6 is a proximity switch; correspondingly, a metal sensing plate is fixedly provided on the moving part of the paper cutting mechanism 5, and when the paper cutting mechanism 5 moves to the cutting position, the metal sensing plate triggers the proximity switch.

[0013] Preferably, the controller 4 is a programmable logic controller.

[0014] Preferably, the normally closed contact of the execution relay is connected in series to the original packaging machine's paper shortage stop signal circuit.

[0015] The beneficial effects of this utility model are:

[0016] 1. This utility model utilizes the signal coordination of an upstream joint detection sensor and a cutting position detection sensor at the cutting mechanism. A controller judges the synchronization status of the two signals, achieving precise positioning and automatic shutdown of the black joint at the cutting station, thus eliminating continuous corrections caused by misjudgments at the source. As a result, the number of defective cigarette packs generated from processing each black joint is steadily reduced from the original 15-25 packs to approximately 5 packs, resulting in a material consumption reduction of over 70% and significant direct economic benefits.

[0017] 2. The fully automated detection and shutdown process replaces the highly stressful emergency shutdown operations that rely on manual experience, and also eliminates the tedious and time-consuming manual alignment steps. This significantly reduces downtime for processing a single black connector, effectively improving the overall operating efficiency of the equipment.

[0018] 3. Operators no longer need to perform complex emergency interventions. They only need to perform the predetermined manual cutting, joint removal, and pasting operations after the system automatically stops, which reduces the dependence on operator skills and the labor intensity of on-site operations.

[0019] 4. Based on hard-wired connection and control of programmable logic controllers, precise action judgment is achieved, avoiding uncertainties caused by delays or operational errors due to human reaction. The consistent shutdown position ensures the repeatability and stability of the processing results.

[0020] 5. This utility model, as an add-on system built with independent hardware, does not require modification to the core control system of the original packaging machine. By connecting the normally closed contacts of the actuator relay in series to the original machine's stop circuit, signal interaction and safety control are achieved. It is simple to implement, has low modification costs, and is easy to manage in later equipment maintenance, thus possessing good promotional value. Attached Figure Description

[0021] To more clearly illustrate the specific embodiments of this utility model or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this utility model. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0022] Figure 1 This is a schematic diagram of the overall structure of a paper jam connector identification and stop system for a ZB45 packaging machine according to the present invention.

[0023] Attached reference numerals: 1. Paper jam; 2. Joint detection bracket; 3. Joint detection; 4. Controller; 5. Paper jam cutting mechanism; 6. Cutting mechanism positioning detection; 7. Paper jam after cutting; 8. Manual cutter. Detailed Implementation

[0024] The present invention will be further described in detail below with reference to embodiments, but this is not intended to limit the present invention. Any modifications or improvements made based on the teachings of the present invention shall fall within the protection scope of the present invention. Where specific techniques or conditions are not specified in the embodiments, they shall be performed in accordance with the techniques or conditions described in the literature in the field or in accordance with the product manual.

[0025] Example 1

[0026] like Figure 1 As shown, the paper jam connector recognition and shutdown system for a ZB45 packaging machine provided in this embodiment is a technical solution formed by adding an independent hardware detection and control loop to the original ZB45 packaging machine. While retaining the original paper jam conveying channel composed of the frame and conveyor rollers, the paper jam cutting mechanism 5, and the original machine marking detection sensor, this system innovatively adds the following components:

[0027] A joint detection assembly is installed above the paper conveying channel. This assembly includes a joint detection bracket 2 bolted to the frame and a joint detection sensor 3 mounted on the front end of the bracket. The sensor is preferably a BOSCH BOS 40M diffuse reflection photoelectric sensor, with its detection head vertically facing the surface of the paper 1, and a detection distance set at 30mm. The sensor's installation position is precisely designed, located 350-400mm upstream of the vertical cutting line of the paper cutting mechanism 5. This specific distance provides the necessary space for the system to achieve precise stopping.

[0028] A cutting position detection component is provided at the paper cutting mechanism 5. This component includes an inductive proximity switch fixed to the frame as a cutting position detection sensor 6, and a metal sensing plate mounted on the moving parts of the cutting mechanism. When the paper cutting mechanism 5 moves to the cutting position, the metal sensing plate enters the sensing range of the proximity switch and triggers a detection signal.

[0029] The equipment's electrical control cabinet houses a control and execution component, which includes a Siemens S7-200 series programmable logic controller (PLC) as controller 4 and a standard industrial relay as execution relay. Controller 4's input terminal I0.0 is connected to connector detection sensor 3, and its input terminal I0.1 is connected to cutting position detection sensor 6. The coil of execution relay K1 is connected to controller 4's output terminal Q0.0, and its normally closed contact is connected in series to the DC24V positive line of the original machine's paper jam stop signal circuit.

[0030] In addition, a manual cutter (8) is provided next to the cutting station of the paper cutting mechanism (5) for the operator to manually cut the paper section containing the black connector that has been positioned after the system is triggered to stop.

[0031] Through the coordinated operation of the above components, this system achieves accurate identification and positioning of black joints in paper jams, effectively solving the production waste problem caused by misjudging black joints in existing technologies.

[0032] The system's operation is based on the coordinated operation of the newly added hardware components and the original machine, as detailed below:

[0033] 1. After the equipment is started, the paper jam (1) is continuously conveyed under the drive of the conveyor roller. The original machine's marking detection sensor works normally, detecting and correcting normal black spots on the paper jam in real time. At this time, the upstream joint detection sensor (3) is not triggered, the controller (4) has no output signal, the coil of the execution relay (K1) is de-energized, its normally closed contact remains closed, the original machine's shutdown control circuit remains unobstructed, and the equipment and paper jam cutting mechanism (5) operate normally according to the set cycle.

[0034] 2. When the black connector on the paper is conveyed to the connector detection sensor (3), due to its significant width characteristics, the sensor (3) continuously outputs a high-level signal (first detection signal) to the I0.0 input terminal of the controller (4). The controller (4) receives and latches the signal, using it as a necessary condition for stopping the machine, but does not act immediately at this time.

[0035] 3. After latching the first detection signal, the controller (4) waits for the second necessary condition to be met. During this time, the paper cutting mechanism (5) continues its inherent reciprocating motion. When the mechanism moves to the preset cutting position, the metal induction plate installed on its moving part triggers the cutting position detection sensor (6), and the sensor (6) then outputs a high-level signal (second detection signal) to the I0.1 input terminal of the controller (4). When the internal logic of the controller (4) detects that the two input signals I0.0 (first detection signal) and I0.1 (second detection signal) are both high, it immediately determines that the system meets the shutdown condition and sends a drive command to the coil of the execution relay (K1) through the output terminal Q0.0.

[0036] 4. When the coil of the relay (K1) is energized, it will be energized and the normally closed contact connected in series in the original packaging machine stop control circuit will be opened momentarily, thereby triggering the original machine emergency stop procedure.

[0037] The execution of the entire set of actions results in the paper jam (1) and its black connector being stationary at the cutting station. This positioning effect relies on the following coordination mechanism: when the upstream connector detection sensor (3) detects the black connector, the controller (4) does not stop immediately, but enters a waiting state until it receives the next positioning signal from the cutting position detection sensor (6), indicating that the cutting mechanism (5) has moved to the cutting position. The connector detection sensor (3) is preset at a specific distance (350-400mm) upstream of the cutting mechanism (5), which is the key to achieving synchronization in this scheme. This distance is not estimated, but calculated based on the stable conveying speed of the paper jam in the ZB45 packaging machine and the fixed motion cycle of the paper jam cutting mechanism (5).

[0038] Its core principle is that the distance ensures that the conveying time required from "the connector detection sensor detects the black connector" to "the black connector is conveyed to the cutting station along with the cardboard" is approximately equal to the waiting time required for the controller (4) to wait for "the cutting mechanism to complete the current cycle and move to the cutting position again" after receiving the first signal.

[0039] Therefore, when the cutting position detection sensor (6) is triggered, it not only means that the cutting mechanism is in place, but also that the black connector has just completed the conveying process from the detection point to the cutting point and is now located at the cutting station. At this time, the machine is stopped, thus realizing the spatial overlap between the black connector and the cutting station.

[0040] 5. The operator uses the added manual cutter (8) to cut the cardboard at the cutting station and remove the waste section containing the black joint. Then, the operator manually rotates the equipment to move the nearest normal black spot on the downstream cardboard section to the cutting position and aligns and splices the upstream new cardboard section with it at the cutting station. After splicing, the equipment is restarted. Because there are slight changes in the thickness, strength, or flatness of the cardboard at the splice, this physical anomaly will be identified as a defect by the original machine's inherent quality inspection system when it enters the downstream packaging process. Accordingly, the equipment automatically rejects about 5 packs of cigarettes, including the splice, according to its established program to completely eliminate potential defective products. After this isolated defect point passes, the equipment resumes normal production.

[0041] Finally, it should be noted that the above preferred embodiments are only used to illustrate the technical solutions of this application and are not intended to limit it. Although this application has been described in detail through the above preferred embodiments, those skilled in the art should understand that various changes can be made to it in form and detail without departing from the scope defined by the claims of this application; the dimensions described in the drawings and embodiments are not related to the specific physical object and are not used to limit the protection scope of this application. The physical dimensions can be selected and changed according to actual needs.

Claims

1. A paper jam connector identification and shutdown system for a ZB45 packaging machine, comprising a frame, a paper jam cutting mechanism (5) and a marking detection sensor originally installed on the machine, wherein the marking detection sensor is located at the paper jam cutting mechanism (5) for positioning the paper jam during cutting, and the frame is provided with a paper jam conveying channel composed of multiple conveying rollers, characterized in that, The system also includes: The connector detection sensor (3) is fixedly installed above the paper conveying channel by a bracket (2) and is located upstream of the paper cutting mechanism (5); A cutting position detection sensor (6) is installed on the frame of the paper cutting mechanism (5) to detect whether the paper cutting mechanism (5) has moved to the cutting position; The controller (4) has its signal input terminals electrically connected to the joint detection sensor (3) and the cutting position detection sensor (6), respectively. The relay is activated, and its coil is electrically connected to the signal output terminal of the controller (4); The normally closed contact of the execution relay is connected in series to any stop control circuit of the original packaging machine.

2. The paper jam connector identification and shutdown system for a ZB45 packaging machine according to claim 1, characterized in that, The installation position of the connector detection sensor (3) is 350-400mm upstream of the vertical cutting line of the paper cutting mechanism (5).

3. The paper jam connector identification and shutdown system for a ZB45 packaging machine according to claim 1, characterized in that, The connector detection sensor (3) is a diffuse reflection photoelectric sensor.

4. The paper jam connector identification and shutdown system for a ZB45 packaging machine according to claim 1, characterized in that, The cutting position detection sensor (6) is a proximity switch; correspondingly, a metal sensing sheet is fixedly provided on the moving part of the paper cutting mechanism (5). When the paper cutting mechanism (5) moves to the cutting position, the metal sensing sheet triggers the proximity switch.

5. A paper jam connector identification and shutdown system for a ZB45 packaging machine according to claim 1, characterized in that, The controller (4) is a programmable logic controller.

6. A paper jam splice identification and shutdown system for a ZB45 packaging machine according to claim 1, characterized in that, The normally closed contact of the execution relay is connected in series to the original packaging machine's paper shortage stop signal circuit.

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