Design And Realization Of The Online Detection Device For The Flow Of Rejects From Cigarette Makers

As key factors, slivers affect cigarette appearance quality, sensory quality, physical indicators stability, flammability and other technical indicators and materials consumption indicators. Slivers rejection is the final process of deciding whether slivers enter the cigarette or not, which has a decisive influence on the content of slivers in cigarettes. As a result, one of main measures to ensure cigarette high-quality and fine production is to strengthen detecting the flow of rejects from cigarette makers.Current methods for detecting the flow of rejects from cigarette makers belong to artificial sample and post hoc test, which has features with low inspection frequency, strong randomness, big error and being difficult to achieve real-time, on-line detection, and low guidance for controlling stem separation.This paper presents a real-time and on-line detection method of slivers based on the flow of rejects from cigarette makers, which is used to design an on-line detection device, evaluate real-time effects of slivers rejection and provide standardized and scientific data for controlling the flow of rejects from cigarette makers.This paper studies on the following aspects on detection of the flow of rejects from cigarette makers:(1) Combined with relationships between the flow of rejects from cigarette makers with numbers of cigarettes containing slivers, slivers content in cigarette and content of cut tobacco in slivers, the paper proposes an online evaluation method of slivers rejection effects based on the flow of rejects from cigarette makers.(2) According to requirements and indicators of the device, this paper analyses the principle of the slivers separation system in cigarette makers, finds the best mechanical design that the device is composed by the three-stage structure with top-down vertical distribution in the cabinet bracket. In the device, the dustpan-shape collection and weighing flap can reduce splash of slivers, a load cell is installed under the weighing flap and turn about 90 degrees, the three-way recovery structure can decrease the influence on detection accuracy from suction air in the vertical direction.(3) This paper designs the electrical control system of the device which includes the Siemens S7-200 as controller core, Siemens MS weighing module and HBM load cell as the acquisition unit, metal proximity switches as the security unit, stepper motors and drives as the coordination unit, TP277 touch screen as the interactive unit.(4) This paper analyses the mechanical construction and control requirements, studies the principle of the online detection device, designs the cycle control mode of the device, and then uses the stepper motor control method named MAP to finish the coordinated operation of the device.(5) In order to improve the detection accuracy and reduce the wind and vibration disturbance, this paper analyses the fluctuations of detection data in the wind and vibration disturbance, then studies a data acquisition and processing method based on current fluctuations of data, which uses data preprocessing, linear interpolation and offset correction. In the method, data preprocessing uses firs-order difference means to eliminate the gross-error data, and then adopts the way of combining the weighted filter with averaging filter for data filtering, and then the data is processed by the piecewise linear interpolation method, and finally the result is offset and corrected by the compensation coefficient in different segments.(6) The verification results of precision, reliability, stability and tightness shows the accuracy of the device is high, the operation is stable and reliable, and the device meets the requirements and can resist disturbances from the wind and vibration.