G.D型卷烟小盒包装机在线复选系统研发
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摘要
G.D型卷烟小盒包装机是G.D型卷烟机组中的一部分,原产地为意大利G.D公司。复选系统是安装在卷烟小盒包装机上的机电一体化设备。本论文研究的卷烟小盒包装机完成将20支香烟按7、6、7三排包成一包并贴上封签,该机在包装之前,须对每组20支烟进行检测,只要其中存在一支不合格烟,整组20支都被将视为废烟而剔除。绝大部分情况下,每组中只有1、2支不合格烟,因此,每次剔除造成很大程度的浪费,复选系统的功能是对包装机剔除的每组烟收集起来,进行单支检测,剔除不合格的烟支,最后将合格烟整理在烟盘里,送回卷烟包装机流水线上。
本文主要工作是完成复选系统的电气设计、整机调试和结果分析。电气部分设计分为检测和控制两部分。检测部分完成烟支点火端空松检测传感器的设计、制作与调试以及其他传感器的选型;控制部分内容有控制流程设计、PLC程序设计及调试、空头检测传感器参数优化。整机调试包括各传感器安装位置调整、机械电气联动及模拟现场。最后,对模拟现场的检测结果进行分析,确定系统的精度及改进方法。
复选系统电气设计的重点是检测,检测结果将决定复选系统的性能指标。烟支在复选系统中需要进行缺嘴、放反和空头三项检测,缺嘴和放反的检测都非常容易,难点是空头检测,即对烟支点火端烟丝填充是否饱满的检测。本设计使用LC谐振选频回路带电容探头的方法(即电容式)对烟支点火端进行的非接触式检测,传感器自制,输出信号为直流模拟信号,须接模拟量模块进行A/D转换后送入S7-200进行处理。由于传感器对湿度尤为敏感,故程序处理方法将影响传感器的最终检测结果。
复选系统性能指标为剔除率和误剔率。剔除率指不合格烟的剔除情况,误剔率为合格烟被剔除的情况。本论文所完成的系统在烟支湿度不稳定的情况下,剔除率为95%,误剔率为1.1%。由于烟厂是一个严格恒温恒湿的环境,故该系统今后在烟厂应用时性能指标将大幅度提高。
G.D Cigarette Box Packing Machine is a component of G.D Cigarette Packing Machines, G.D is the name of a Italian company. The Re-screening System (RS) is a electromechanical equipment which is made for the cigarette box packing machine. The cigarette box packing machine researching in this thesis packs every 20 cigarettes (7, 6, 7 three row inside) in a box, and pastes label. There is a measurement to every 20 cigarettes before packing them, if one of the 20 cigarettes is not qualified, they all will be eliminated from the production line. Obviously, much wasting exists in every eliminating The RS collects cigarettes, eliminated from the production line of cigarette box packing machine, and measures every cigarette, eliminates unqualified cigarette, at last, collects all the qualified cigarette into the cigarette disk for bringing them to the production line of cigarette box packing machine.
In my thesis, I have finished that electrical design of the RS, whole equipment debugging and analysis statistics of examination. Electrical design consists of measure and control.In the part of measurement I had finished design, production, debugging of the Cigarette Handing Measurement Sensor and other sensors' selection. In the part of control, I had finished design of controlling process, design and debugging of PLC program, optimization of the parameters of the Cigarette Handing Measurement Sensor. Whole equipment debugging includes adjustment locations of sensors, machinery and electrics joint running, and simulation real situation. In the end, analysis statistics of simulating real situation, decided the accuracy and upgrade way of the RS.
The importance of electrical design is measurement, which decides the performance of the RS. Cigarettes in the RS are tested for three features: 1. Cigarette is without filter; 2. Opposite collection; 3. Cigarette handing is empty. Number 1 and 2 are easy to measurement, Cigarette handing measurement is difficult. In my design, I used a un-touch measurement basic of LC resonance return circuit choosing frequency principle, connecting a capacity probe, to measure cigarette handing. It is a self-make sensor, it outputs a DC signal, and uses the simulation parameter module changing the simulating signal into digital signal, which gets to S7-200 and is processed. For sensor is sensitive to the humidity, the PLC program will effect the final result of the Cigarette Handing Measurement Sensor.
The performance of the RS are described as elimination rate and wrong elimination rate, elimination rate means the situation of elimination unqualified cigarettes, wrong elimination rate means the situation of elimination qualified cigarettes. The RS of the thesis get 95% and 1.1% of the two rates in an environment that the temperature and humidity are unstable. Because the cigarettes production factories are environments that the temperature and humidity are strictly stable, the performance of RS will be obviously better in the cigarettes production factories.
本文主要工作是完成复选系统的电气设计、整机调试和结果分析。电气部分设计分为检测和控制两部分。检测部分完成烟支点火端空松检测传感器的设计、制作与调试以及其他传感器的选型;控制部分内容有控制流程设计、PLC程序设计及调试、空头检测传感器参数优化。整机调试包括各传感器安装位置调整、机械电气联动及模拟现场。最后,对模拟现场的检测结果进行分析,确定系统的精度及改进方法。
复选系统电气设计的重点是检测,检测结果将决定复选系统的性能指标。烟支在复选系统中需要进行缺嘴、放反和空头三项检测,缺嘴和放反的检测都非常容易,难点是空头检测,即对烟支点火端烟丝填充是否饱满的检测。本设计使用LC谐振选频回路带电容探头的方法(即电容式)对烟支点火端进行的非接触式检测,传感器自制,输出信号为直流模拟信号,须接模拟量模块进行A/D转换后送入S7-200进行处理。由于传感器对湿度尤为敏感,故程序处理方法将影响传感器的最终检测结果。
复选系统性能指标为剔除率和误剔率。剔除率指不合格烟的剔除情况,误剔率为合格烟被剔除的情况。本论文所完成的系统在烟支湿度不稳定的情况下,剔除率为95%,误剔率为1.1%。由于烟厂是一个严格恒温恒湿的环境,故该系统今后在烟厂应用时性能指标将大幅度提高。
G.D Cigarette Box Packing Machine is a component of G.D Cigarette Packing Machines, G.D is the name of a Italian company. The Re-screening System (RS) is a electromechanical equipment which is made for the cigarette box packing machine. The cigarette box packing machine researching in this thesis packs every 20 cigarettes (7, 6, 7 three row inside) in a box, and pastes label. There is a measurement to every 20 cigarettes before packing them, if one of the 20 cigarettes is not qualified, they all will be eliminated from the production line. Obviously, much wasting exists in every eliminating The RS collects cigarettes, eliminated from the production line of cigarette box packing machine, and measures every cigarette, eliminates unqualified cigarette, at last, collects all the qualified cigarette into the cigarette disk for bringing them to the production line of cigarette box packing machine.
In my thesis, I have finished that electrical design of the RS, whole equipment debugging and analysis statistics of examination. Electrical design consists of measure and control.In the part of measurement I had finished design, production, debugging of the Cigarette Handing Measurement Sensor and other sensors' selection. In the part of control, I had finished design of controlling process, design and debugging of PLC program, optimization of the parameters of the Cigarette Handing Measurement Sensor. Whole equipment debugging includes adjustment locations of sensors, machinery and electrics joint running, and simulation real situation. In the end, analysis statistics of simulating real situation, decided the accuracy and upgrade way of the RS.
The importance of electrical design is measurement, which decides the performance of the RS. Cigarettes in the RS are tested for three features: 1. Cigarette is without filter; 2. Opposite collection; 3. Cigarette handing is empty. Number 1 and 2 are easy to measurement, Cigarette handing measurement is difficult. In my design, I used a un-touch measurement basic of LC resonance return circuit choosing frequency principle, connecting a capacity probe, to measure cigarette handing. It is a self-make sensor, it outputs a DC signal, and uses the simulation parameter module changing the simulating signal into digital signal, which gets to S7-200 and is processed. For sensor is sensitive to the humidity, the PLC program will effect the final result of the Cigarette Handing Measurement Sensor.
The performance of the RS are described as elimination rate and wrong elimination rate, elimination rate means the situation of elimination unqualified cigarettes, wrong elimination rate means the situation of elimination qualified cigarettes. The RS of the thesis get 95% and 1.1% of the two rates in an environment that the temperature and humidity are unstable. Because the cigarettes production factories are environments that the temperature and humidity are strictly stable, the performance of RS will be obviously better in the cigarettes production factories.
引文
1.万昭全,旦有明,柳通达.严格执行国际提高卷烟质量-对全国45种品牌卷烟的有害指标检测情况分析.《中国标准化》,2001年第2期
2.王兵,杨达辉,林平,刘朝贤.新的卷烟生产工序评价方法的建立.《烟草科技》,2002年第11期
3.赵彩虹.卷烟机组剔除不合格烟支的控制设计.《三峡职业技术学院学报》,2006年第3期
4.邓春宁.卷烟机烟支密端控制系统改造.《中国设备工程》,2006年第7期
5.苏文艺,黄启明.PLC及现场总线技术在卷烟包装机上的应用.《中国设备工程》,2005年第10期
6.Yv Hui,R Wild.Optimizing Production Control of a Maker-packer System in Cigarette Manufacture.＜The Journal of the Operational Research Society＞,1998.no.8,P.806-810
7.朱哲,马修水.卷烟包装机机械废品剔除机构控制电路的改进.《机械》2000年第2期
8.王云芳,赵航,杨进,周德成.1997-1999年度卷烟包装与卷烟质量分析.《烟草科技》,2001年第10期
9.G.D to display its latest technology at TABEXPO.＜Tobacco International＞.2003.no.8.P.72
10.毛建华.卷烟包装的价值分析的方法研究.《烟草科技》,2000年第2期
11.汪开保,韩永镜.成品卷烟质量检测数据处理系统的开发应用.《烟草科技》,2001年第7期
12.李金学,高尊华,杨帆,周明珠.烟支内烟丝分布对卷烟质量的影响.《烟草科技》,2004年第8期
13.姚光明,王文辉,尹献忠,李胜华,李强.烟丝结构对烟丝填充值和卷接质量的影响.《郑州轻工业学院学报(自然科学版)》,Journal of Zhengzhou University of Light Industry(Natural Science Edition),2003年第4期
14.Theophilus EH,Pence DH,Meckley DR,Higuchi MA,Bombick BR,Borgerding MF,Ayres PH,Swauger JE.Toxicological Evaluation of Expended Shredded Tobacco Stems.＜Food and Chemical Toxicology＞,2004.no.4,P.631-639
15.Hammond D,Collishaw,NE Callard C.Secret science:tobacco industry research on smoking behaviour and cigarette toxicity.＜The Lancet＞.2006.no.9512.P.781-787
16.包常明.并联型石英晶体正弦振荡电路的频率探讨.《内蒙古民族大学学报(自然版)》,2004年第6期
17.李树奇,陈东沛,李树立,王改娟.提高LC谐振电路品质因数的有效途径.《中周煤炭》,2005年第6期
18.JoonSeon Ahn,Ki-Chan Kim,Ju Lee.Parameter measurement of synchronous reluctance motor using LC resonance.＜Journal of Applied Physics＞.2006.no.8.p.08R317.1 - 08R317.3
19.袁聿海.“串并联”法在计算平板电容器电容中的应用.《湖南文理学院学报》,2005年第1期
20.李树奇,陈东沛,李树立.提高LC谐振电路品质因数的有效途径.《中洲煤炭》,2005,06
21.唐长文,何捷,菅洪彦,张海青,闵昊.电感电容压控振荡器调谐曲线分析.《电子学报》,Acta Electronica Sinica
22.钱金川,朱守敏.接近开关在自动化控制中的应用.《江苏电器》,2006年第5期
23.Semyon G.Rabinovich.Measuring Instruments and Their Properties.＜Measurement Errors and Uncertainties,Theory and Practice＞.2005.P.29-60
24.王梅.空气开关不能代替熔断器.《经济师》,2005年第4期
25.Jie Sun,Shanru Guo.The detecting for random motion of the spherical object center by the photoelectric method.＜ SPIE Volume 2899,Automated Optical Inspection for Industry＞.1996.P.27-30
26.陈战强.阀岛在卷烟机组中的应用.《工业控制计算机》,2006年第6期
27.宋国强.阀岛技术在自动化生产线上的应用.《上海电机技术高等专科学校学报》,2004年第3期
28.王仁人.气动阀岛的结构及控制方法.《液压与气动》,2000年第3期
29.M.Ertl.M.Kaltenbacher.R.Mock.R.Lerch.Numerical analysis of fast switching electromagnetic valves.＜ The International Journal for Computation and Mathematics in Electrical and Electrortie Engineering＞.2003.no.3.P.715-725.
30.何国金,覃海.电磁换向阀的数字化改造及PLC主控单元对其直接控制.《机床与液压》,2004年第1期
31.Moseler,O.Modal-supported fault detection in electromagnetic proportional valves with microcontrollers.＜Oelhydraulik und Pneumatik＞.2000.no.7.P.449-453
32.Zunzhong Ye,Yibin Ying.A Multifunctional rotary photoelectric encoder management system.＜Intelligent Systems in Design and Manufacturing Ⅵ＞.2005.P.59990Y.1-59990Y.10
33.杨怀栋,夏劲松,李贺桥,黄战华.光电开关在位移测控与工位定位系统种的应用.《仪器仪表学报》,2001年第z2期
34.秉时,兼礼.浅谈光电开关的工作原理及应用.《红外》,2002年第2期
35.丁方莉.一种漫反射式光电开关的实现.《黄山学院学报》,2006年第3期
36.张荣,徐鸣谦.容栅旋转编码器原理及应用.《传感器世界》,2006年第2期
37.刘文魁,石建玲.光电旋转编码器在角度测量中的应用.《现代制造工程》,2006年第11期
38.罗麦丰,彭铁牛.基于S7-200系列PLC的顺序控制编程方法的研究.《机床电器》,2006年第4期
39.Siemens Micro PLC ensures smooth firtish.＜Surface Engineering＞.2001.no.5.P.352-353
40.张桂臣.PLC寻址方式及其应用.《青岛远洋船员学院学报》,2005年第4期
41.彭魏臻,麻红昭,张华,张伟.PPI协议分析.《化工自动化仪表》,2006年第4期
42.李丽红.定位误差计算的分析研讨.《机械工程与自动化》,2006年第5期
43.B.MOHAN,M.ELANGO.PC Based Simulation and Control of Fluid Power Circuits with PLC.＜Emerging Trends in Mechatronics for Automation＞.2002.P.267-272
44.Douglas R.Adkins,C.Channy Wong.Devdopment of an electromagnetically actuated mercury microvalve.＜The 1998 ASME International Mechanical Engineering Congress and Exposition(IMECE'98)＞.1998.No.11.P.133-137
45.M.J.Traum,J.L.Smith Jr.,J,G.Brisson,J.Gerstmann,C.L.Hannon.Electromagnetic Smart Valves for Cryogenic Applications.＜Advances in cryogenic engineering＞.2004.P.428-435
2.王兵,杨达辉,林平,刘朝贤.新的卷烟生产工序评价方法的建立.《烟草科技》,2002年第11期
3.赵彩虹.卷烟机组剔除不合格烟支的控制设计.《三峡职业技术学院学报》,2006年第3期
4.邓春宁.卷烟机烟支密端控制系统改造.《中国设备工程》,2006年第7期
5.苏文艺,黄启明.PLC及现场总线技术在卷烟包装机上的应用.《中国设备工程》,2005年第10期
6.Yv Hui,R Wild.Optimizing Production Control of a Maker-packer System in Cigarette Manufacture.＜The Journal of the Operational Research Society＞,1998.no.8,P.806-810
7.朱哲,马修水.卷烟包装机机械废品剔除机构控制电路的改进.《机械》2000年第2期
8.王云芳,赵航,杨进,周德成.1997-1999年度卷烟包装与卷烟质量分析.《烟草科技》,2001年第10期
9.G.D to display its latest technology at TABEXPO.＜Tobacco International＞.2003.no.8.P.72
10.毛建华.卷烟包装的价值分析的方法研究.《烟草科技》,2000年第2期
11.汪开保,韩永镜.成品卷烟质量检测数据处理系统的开发应用.《烟草科技》,2001年第7期
12.李金学,高尊华,杨帆,周明珠.烟支内烟丝分布对卷烟质量的影响.《烟草科技》,2004年第8期
13.姚光明,王文辉,尹献忠,李胜华,李强.烟丝结构对烟丝填充值和卷接质量的影响.《郑州轻工业学院学报(自然科学版)》,Journal of Zhengzhou University of Light Industry(Natural Science Edition),2003年第4期
14.Theophilus EH,Pence DH,Meckley DR,Higuchi MA,Bombick BR,Borgerding MF,Ayres PH,Swauger JE.Toxicological Evaluation of Expended Shredded Tobacco Stems.＜Food and Chemical Toxicology＞,2004.no.4,P.631-639
15.Hammond D,Collishaw,NE Callard C.Secret science:tobacco industry research on smoking behaviour and cigarette toxicity.＜The Lancet＞.2006.no.9512.P.781-787
16.包常明.并联型石英晶体正弦振荡电路的频率探讨.《内蒙古民族大学学报(自然版)》,2004年第6期
17.李树奇,陈东沛,李树立,王改娟.提高LC谐振电路品质因数的有效途径.《中周煤炭》,2005年第6期
18.JoonSeon Ahn,Ki-Chan Kim,Ju Lee.Parameter measurement of synchronous reluctance motor using LC resonance.＜Journal of Applied Physics＞.2006.no.8.p.08R317.1 - 08R317.3
19.袁聿海.“串并联”法在计算平板电容器电容中的应用.《湖南文理学院学报》,2005年第1期
20.李树奇,陈东沛,李树立.提高LC谐振电路品质因数的有效途径.《中洲煤炭》,2005,06
21.唐长文,何捷,菅洪彦,张海青,闵昊.电感电容压控振荡器调谐曲线分析.《电子学报》,Acta Electronica Sinica
22.钱金川,朱守敏.接近开关在自动化控制中的应用.《江苏电器》,2006年第5期
23.Semyon G.Rabinovich.Measuring Instruments and Their Properties.＜Measurement Errors and Uncertainties,Theory and Practice＞.2005.P.29-60
24.王梅.空气开关不能代替熔断器.《经济师》,2005年第4期
25.Jie Sun,Shanru Guo.The detecting for random motion of the spherical object center by the photoelectric method.＜ SPIE Volume 2899,Automated Optical Inspection for Industry＞.1996.P.27-30
26.陈战强.阀岛在卷烟机组中的应用.《工业控制计算机》,2006年第6期
27.宋国强.阀岛技术在自动化生产线上的应用.《上海电机技术高等专科学校学报》,2004年第3期
28.王仁人.气动阀岛的结构及控制方法.《液压与气动》,2000年第3期
29.M.Ertl.M.Kaltenbacher.R.Mock.R.Lerch.Numerical analysis of fast switching electromagnetic valves.＜ The International Journal for Computation and Mathematics in Electrical and Electrortie Engineering＞.2003.no.3.P.715-725.
30.何国金,覃海.电磁换向阀的数字化改造及PLC主控单元对其直接控制.《机床与液压》,2004年第1期
31.Moseler,O.Modal-supported fault detection in electromagnetic proportional valves with microcontrollers.＜Oelhydraulik und Pneumatik＞.2000.no.7.P.449-453
32.Zunzhong Ye,Yibin Ying.A Multifunctional rotary photoelectric encoder management system.＜Intelligent Systems in Design and Manufacturing Ⅵ＞.2005.P.59990Y.1-59990Y.10
33.杨怀栋,夏劲松,李贺桥,黄战华.光电开关在位移测控与工位定位系统种的应用.《仪器仪表学报》,2001年第z2期
34.秉时,兼礼.浅谈光电开关的工作原理及应用.《红外》,2002年第2期
35.丁方莉.一种漫反射式光电开关的实现.《黄山学院学报》,2006年第3期
36.张荣,徐鸣谦.容栅旋转编码器原理及应用.《传感器世界》,2006年第2期
37.刘文魁,石建玲.光电旋转编码器在角度测量中的应用.《现代制造工程》,2006年第11期
38.罗麦丰,彭铁牛.基于S7-200系列PLC的顺序控制编程方法的研究.《机床电器》,2006年第4期
39.Siemens Micro PLC ensures smooth firtish.＜Surface Engineering＞.2001.no.5.P.352-353
40.张桂臣.PLC寻址方式及其应用.《青岛远洋船员学院学报》,2005年第4期
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