A practical training device suitable for a simulation of a flavoring and seasoning system in the tobacco industry

Abstract

The utility model provides a kind of practical training device of analog flavoring and feeding system suitable for tobacco industry, it is related to tobacco industry practical training equipment technical field, including practical training platform, power distribution module, control module, detection module, execution module, display module, interface module and pipeline system;The practical training platform includes bearing mechanism and switchboard, the bearing mechanism bottom is provided with movable wheel, and the switchboard is used to bear electric control device;Power distribution module, control module, detection module, execution module, display module, interface module and pipeline system are all installed on the bearing plane of the bearing mechanism.Simulating is realized by hardware installation debugging to realize the simulation of each function of flavoring and feeding system, meet the teaching and practical training of flavoring and feeding system.

Description

Technical Field

[0001] This utility model belongs to the technical field of training equipment for the tobacco industry, specifically relating to a training device for a simulated flavoring and additive system suitable for the tobacco industry. Background Technology

[0002] The statements in this section are merely background information relating to this disclosure and do not necessarily constitute prior art.

[0003] The flavoring and additive process is a key step in cigarette manufacturing. It mainly involves applying blended flavorings (leaf materials) to the tobacco leaves according to a formula ratio to adjust the taste and improve the internal quality of the tobacco leaves. The equipment used to complete this process is a device equipped with a flavoring and additive system. Whether the flavoring and additive system can be applied in the correct proportion depends on its stable operation.

[0004] The flavoring and additive system requires a high level of skill from maintenance personnel. Currently, maintenance personnel primarily learn about this system on actual production equipment, which presents the following problems: (1) Insufficient training time. The existing training methods rely on actual production equipment, but due to actual production needs, the equipment is in production operation most of the time, and there is not enough time for personnel training. (2) The actual production equipment is mainly used for production and its normal condition needs to be ensured. Setting faults on the actual production equipment will interfere with normal production. (3) The input to the production equipment is the tobacco leaves and spices that are actually used in the production process, which results in a high learning cost. Utility Model Content

[0005] To address the aforementioned issues, this invention provides a training device for a simulated flavoring and additive system applicable to the tobacco industry. Through the rational layout and connection of hardware modules, it enables the simulation training of a tobacco flavoring and additive system.

[0006] This utility model provides a training device for a simulated flavoring and additive system suitable for the tobacco industry, including a training platform, a power distribution module 1, a control module 2, a detection module, an execution module, a display module, an interface module, and a piping system. The training platform serves as a support structure, with movable wheels at the bottom for easy movement. The support surface is used to install other modules, and the power distribution panel is used to support the electrical control components.

[0007] The power distribution module 1 includes an air switch, a power distribution circuit, an emergency stop switch, and a DC power supply, providing AC380V and DC24V power supplies, and featuring overload, short-circuit protection, and emergency stop functions. The air switch and power distribution circuit provide external power connection and AC380V power supply, the DC power supply provides DC24V power supply, and the emergency stop switch enables the system's emergency stop function. The control module 2 is a programmable logic controller (PLC), including a CPU, digital input / output modules, and analog input / output modules, implementing control logic.

[0008] The detection module includes an electromagnetic flow sensor 16, a liquid level sensor 14, and a valve position detection device, which collect signals of liquid flow rate, liquid level, and valve position. The execution module includes a frequency converter 7, a valve island 9, and a motor, which receives signals from the control module 2 to realize flow regulation and valve control.

[0009] The display module is a human-machine interface (HMI) 3, which connects to the control module 2 via a network to display data and input parameters. The interface module includes an aviation connector, a PROFINT network interface, an air compressor interface, and a water supply interface to enable external connections.

[0010] The pipeline system is divided into a liquid pipeline system and an air compressor pipeline system. The liquid pipeline system includes a 304 stainless steel simulated material tank (13), a float valve, a feeding pump (15), a pneumatic ball valve, a simulated feeding roller (10), and a manual shut-off valve. The air compressor pipeline system includes a pressure reducing valve, a filter, a shut-off valve, and a pneumatic ball valve to realize liquid delivery and air compressor control.

[0011] The modules form a complete system through electrical connections or signal transmission: the detection module feeds back the signal to the control module 2, the control module 2 outputs the control signal to the execution module, and the display module interacts with the control module 2 for data exchange.

[0012] Compared with the prior art, the training device for a simulated flavoring and additive system suitable for the tobacco industry provided by this utility model has the following beneficial effects: (1) This training device simulates the tobacco flavoring and feeding function by installing and debugging hardware to simulate real production equipment. It realizes the simulation of each function of the flavoring and feeding system, and can effectively imitate the precise control of the liquid flow of the flavoring and feeding system. It simulates the pre-filling, feeding, return, pipeline cleaning and pipeline blowing functions of the tobacco flavoring and feeding system, and realizes the PID control function of feeding flow according to the incoming flow, which meets the teaching and training needs of the flavoring and feeding system.

[0013] (2) The material pipeline system provided by the training device uses water and low-cost ingredients to replace the tobacco leaves and material liquid used in the actual production equipment. The process of adding flavoring and ingredients is simulated through the circulating water circuit, which reduces the training cost.

[0014] (3) The control module provided by the training device can simulate fault scenarios such as pipeline blockage and valve failure based on PLC program, which helps trainees deepen their understanding of equipment control principles. Attached Figure Description

[0015] The accompanying drawings, which form part of this disclosure, are used to provide a further understanding of this disclosure. The illustrative embodiments of this disclosure and their descriptions are used to explain this disclosure and do not constitute an undue limitation of this disclosure.

[0016] Figure 1 A plan view of the training device for the simulated flavoring and ingredient addition system provided by this utility model; Figure 2 A three-dimensional view of the training device for the simulated flavoring and ingredient addition system provided by this utility model; Figure 3 The main view of the training device for the simulated flavoring and ingredient addition system provided by this utility model; Figure 4 Left view of the training device for the simulated flavoring and ingredient addition system provided by this utility model.

[0017] In the diagram, 1. Power distribution module; 2. Control module; 3. HMI; 4. Switch; 5. Flow transmitter; 6. Level transmitter; 7. Frequency converter; 8. Button box; 9. Valve island; 10. Simulated feeding drum; 11. Air inlet; 12. Water inlet; 13. Simulated material tank; 14. Level sensor; 15. Feeding pump; 16. Flow sensor. Detailed Implementation

[0018] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present utility model. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments.

[0019] Example 1 like Figure 1-4 As shown, the training platform adopts a metal frame structure with casters installed at the bottom. The power distribution module 1, control module 2, HMI 3, etc. are installed sequentially on the bearing surface. The air switch of power distribution module 1 is connected to an external power source, and AC380V power is distributed to control module 2, frequency converter 7, etc. through the power distribution circuit. DC24V power is output to the detection module.

[0020] The PLC of control module 2 receives the start / stop signal from button box 8 through digital input module, and collects the signals from flow sensor 16 and level sensor 14 through analog input module. After internal calculation, it controls the solenoid valve of valve island 9 through digital output module and adjusts the frequency of inverter 7 through analog output module.

[0021] The flow sensor 16 of the detection module is installed in the liquid pipeline, the level sensor 14 is installed in the simulated tank 13, and the valve position detection device is integrated on the pneumatic ball valve to provide real-time feedback on the valve status. The frequency converter 7 of the execution module is connected to the motor of the feed pump 15, and the valve island 9 is connected to each pneumatic valve through air pipes.

[0022] The display module HMI3 is connected to the control module 2 via a PROFINT network interface, displaying data such as liquid level and flow rate in real time. Operators can input parameters through the HMI3. The air inlet 11 and water inlet 12 of the interface module are connected to external compressed air and water sources, respectively, to provide power to the pipeline system.

[0023] In the liquid pipeline system, the liquid in the simulated tank 13 is delivered to the simulated feeding drum 10 by the feeding pump 15. The float valve controls the liquid level, and the manual shut-off valve is used for pipeline maintenance. The air compressor pipeline system regulates the air pressure through the pressure reducing valve and removes impurities through the filter to ensure the stable operation of the pneumatic components.

[0024] This invention achieves hardware simulation of a tobacco flavoring and additive system through the structured design and connection of each module, meeting the needs of teaching and practical training, and solving the problem that training is limited by production equipment in the existing technology.

[0025] The working principle of this utility model is as follows: The training device described in this utility model works on the principle of synergy between modular hardware and control programs (implemented using existing program code). It operates outside the real tobacco production line environment, using water and low-cost ingredients to replace real tobacco leaves and liquid materials, thus simulating and reproducing the complete process flow and typical fault scenarios of a tobacco flavoring and additive system. The specific workflow is as follows: ①System startup and parameter settings Operators set training parameters through the HMI display module, such as target liquid flow rate, feeding time, feeding mode (pre-filling, feeding, return, cleaning, blowing, etc.) and the types of faults to be simulated.

[0026] ②Simulation Operation and Closed-Loop Control Based on flow sensors, level sensors, and valve position detection devices, the system collects in real time the simulated liquid flow rate in the circulating water circuit, the liquid level height in the simulated tank, and the on / off position status signals of each pneumatic valve.

[0027] The PLC receives real-time data from the detection module, as well as operation commands and parameter settings from the HMI. In feeding mode, the PLC compares the actual flow rate detected by the flow sensor with the target flow rate set by the HMI, calculates the flow deviation, and generates corresponding control signals through PID calculations.

[0028] For flow regulation signals, the PLC sends a signal to the frequency converter through its analog output module. The frequency converter then adjusts the speed of the feed pump motor accordingly, thereby precisely controlling the flow rate of the simulated liquid.

[0029] For valve switching signals, the PLC controls the valve island through its digital output module. The valve island drives the corresponding pneumatic valve (such as a pneumatic ball valve) to perform opening and closing actions, realizing the simulation switching of different process steps such as pre-filling, feeding, return, pipeline cleaning, and pipeline purging.

[0030] ③ Fault scenario simulation and diagnostic training Fault injection: When it is necessary to simulate a fault, the PLC will actively generate abnormal control signals or modify sensor feedback signals based on the preset program logic or the operator's instructions triggered by the HMI.

[0031] Simulate pipeline blockage: The PLC can control the valve island to close specific valves, or reduce the speed of the feed pump to an abnormal level through the frequency converter, simulating phenomena such as reduced flow and abnormal pressure when blockage occurs in different locations (such as circulating water circuits and return material pipelines).

[0032] Simulated valve failure: The PLC can instruct the valve island to keep specific valves in an abnormal state (such as unable to open, unable to close, or not in the correct position), and can simulate sensor detection failure by modifying the valve position detection signal sent to the PLC.

[0033] Analog sensor signal anomaly: The PLC may inject false signals into its own processing logic or directly into the HMI (for example, displaying an incorrect flow value that is seriously inconsistent with the actual flow rate, or displaying an abnormal liquid level height on the HMI), simulating faults such as drift, open circuit or short circuit of sensors such as flow meters and level gauges.

[0034] Fault symptoms: The injected fault signal affects the PLC's control logic output, causing abnormal actions in the execution modules (frequency converter, valve island), thereby altering the actual state of water flow (flow rate, pressure, flow direction) in the pipeline system. Simultaneously, abnormal operating parameters will be displayed on the HMI (regardless of whether the anomaly is real or simulated).

[0035] Diagnosis and Repair Training: Trainees need to observe abnormal data displayed on the HMI, combine this with inspection of the physical state of the device (such as listening to pump sounds and observing valve movements), and use their acquired knowledge to analyze possible causes of the fault and locate the fault point (such as a specific valve, sensor, pump, or control logic component). Trainees can attempt to modify parameters and reset operations through the HMI, or instructors can use PLC programs to resolve simulated fault states for "repair" verification.

[0036] ④ Real-time feedback and adjustment During normal simulation operation or fault simulation, the detection module continuously feeds back the updated system status signals to the PLC.

[0037] The PLC compares this feedback signal with the set value or expected state in real time.

[0038] During normal operation, the PLC continuously adjusts the control signals output to the frequency converter and valve island to achieve precise and stable control of the simulated liquid flow rate (PID closed-loop control).

[0039] For fault simulation, the PLC maintains the injected abnormal state until a reset or fault clearance command is received.

[0040] Based on the above working principle, this training device can not only realistically simulate the fully automated operation of the tobacco flavoring and additive system from startup, parameter setting, process execution to termination, but more importantly, it can safely, flexibly and repeatably simulate various key faults that are difficult to reproduce in actual equipment. This allows trainees to deeply understand the system control principle in an environment free from production constraints, and effectively improve their practical skills in operation, maintenance and fault diagnosis.

[0041] In the description of this specification, the terms "connection", "installation", "fixing", "setting", etc. are interpreted in a broad sense. For example, "connection" can be a fixed connection or an indirect connection through an intermediate component without affecting the relationship between components and the technical effect. It can also be an integral connection or a partial connection. In such cases, those skilled in the art can understand the specific meaning of the above terms in this utility model or utility model according to the specific circumstances.

[0042] The above description is only a preferred embodiment of the present utility model, but the protection scope of the present utility model is not limited thereto. Any equivalent substitutions or changes made by those skilled in the art within the technical scope disclosed in the present utility model, based on the technical solution and the inventive concept of the present utility model, should be included within the protection scope of the present utility model.

Claims

1. A training device for a simulated flavoring and additive system suitable for the tobacco industry, characterized in that, It includes a training platform, a power distribution module (1), a control module (2), a detection module, an execution module, a display module, an interface module, and a piping system; the training platform includes a support mechanism and a power distribution panel, the bottom of the support mechanism is equipped with movable wheels, and the power distribution panel is used to support electrical control devices; the power distribution module (1), control module (2), detection module, execution module, display module, interface module, and piping system are all installed on the support plane of the support mechanism.

2. The training device according to claim 1, characterized in that, The power distribution module (1) includes an air switch, a power distribution circuit, an emergency stop switch and a DC power supply; the air switch and the power distribution circuit are used to provide external power connection and AC380V power supply, the DC power supply is used to provide DC24V power supply, and the emergency stop switch is used to realize the emergency stop function of the system.

3. The training device according to claim 1, characterized in that, The control module (2) is a programmable logic controller (PLC), which includes a CPU, a digital input module, a digital output module, an analog input module, and an analog output module.

4. The training device according to claim 1, characterized in that, The detection module includes an electromagnetic flow sensor (16), a liquid level sensor (14), and a valve position detection device; the electromagnetic flow sensor (16) is used to collect the liquid flow signal, the liquid level sensor (14) is used to collect the liquid level height signal, and the valve position detection device is used to collect the valve position signal.

5. The training device according to claim 1, characterized in that, The execution module includes a frequency converter (7), a valve island (9), and a motor; the frequency converter (7) is used to adjust the frequency of the feed pump (15), the valve island (9) is used to control the opening and closing of the valve, and the motor is connected to the feed pump (15).

6. The training device according to claim 1, characterized in that, The display module is a human-computer interaction interface (HMI) (3), and the HMI (3) is connected to the control module (2) via a network.

7. The training device according to claim 1, characterized in that, The interface module includes an aviation plug, a PROFINT network interface, a compressed air interface, and a water supply interface; the aviation plug is used for external power connection, the PROFINT network interface is used for network connection, the compressed air interface is used for compressed air supply, and the water supply interface is used for water supply.

8. The training device according to claim 1, characterized in that, The pipeline system includes a liquid pipeline system and an air compressor pipeline system; the liquid pipeline system includes a 304 stainless steel simulated material tank (13), a float valve, a feeding pump (15), a pneumatic ball valve, a simulated feeding roller (10), and a manual shut-off valve; the air compressor pipeline system includes a pressure reducing valve, a filter, a shut-off valve, and a pneumatic ball valve.

9. The training device according to claim 1, characterized in that, The output of the detection module is connected to the input of the control module (2), the output of the control module (2) is connected to the input of the execution module, and the communication terminal of the display module is connected to the communication terminal of the control module (2).

10. The training apparatus according to any one of claims 1-9, characterized in that, It also includes a button box (8), which is mounted on the bearing plane of the bearing mechanism, and the signal end of the button box (8) is connected to the input end of the control module (2).

Images