1 Introduction
As the mainstay of the development of China's tobacco industry, a well-known tobacco machinery company is one of the earliest enterprises engaged in the research and development and manufacturing of tobacco machinery products in China. In order to build world-class tobacco equipment, the company has always been committed to continuous technological innovation and independent research and development of new products, and the transformation of the filter rod forming machine is to ensure product quality, improve production efficiency and safety.
Since the 80s of the last century, KDF2 has been the main model of filter rod production, and has been praised for its high stability, low cost, easy operation and flexible modification. With the development of science and technology and the research of molding equipment, K2 is facing the fate of being eliminated. At present, there are three new types of filter rod forming machines K3, K4 and DF10 imported from Germany and Italy. The production speed of K3 type is 500m/min, which is high and unstable; The production speed of K4 type is 1000m/min for double guns, which is high cost and relatively stable; The production speed of DF10 is 1000m/min for two guns, which is expensive and unstable, and basically no new equipment is introduced. However, compared with these new models, the K2 has its own advantages: low cost, very stable, and can be flexibly modified, such as adding fragrance, popping beads, and so on. After the transformation, the speed can reach 500m/min, and the maximum speed is 600m/min.
2 Process introduction
The K2 filter rod forming machine consists of three parts: tow, forming and traying. The cellulose acetate tow reaches the opening roller assembly through the guide wire ring and the opener, and then turns into a loose ribbon from the tow, and then enters the molding unit after glycerin spraying and cold and hot glue treatment, and the opening width should reach 220mm.
The forming part is composed of forming paper, receiving roller, supporting roller, cutter head, cutting device, blowing device, etc., which is also the core part of K2 and the key part of this transformation. The main power of this part is provided by a main motor, in which the tiger tooth and worm gear and worm are the core part of the transmission, and its control accuracy is high, the maintenance is complex, and the quality requirements for maintenance personnel are also high. The focus of this transformation and upgrading is to turn this part of the mechanical transmission into an electrical transmission, and separate the main motor, receiving roller, acceleration roller, and cigarette gun bag roller from the original main motor to replace the mechanical transmission, which not only improves the production speed but also reduces the complexity of maintenance.
After the filter rod passes the molding process, it is a completed filter rod, one filter rod can be connected to four cigarettes, and the formed filter rod enters the loading machine through the inverted funnel for loading.
3 Lenze Control Scheme
The control of K2 filter rod forming machine is divided into three relatively independent control units: opening control, forming control and tray control. In the opening control, the longitudinal opening is controlled by adjusting the speed ratio of the three opening rollers and the main motor; The lateral opening effect is controlled by the compressed air generated by the air pump. The amount of glycerin, the amount of glue in the inner line, and the amount of sealing glue should be synchronized with the main drive; The air pressure of the high-pressure nozzle needs to be synchronized with the main drive.
In this set of schemes, the control shaft includes motion elements such as cutter head motor, cigarette gun bag wheel, receiving wheel, acceleration wheel, opening roller, glycerin motor and so on. The cutter head motor and the receiving wheel require phase synchronization, the opening roller and the cigarette gun bag wheel require speed synchronization, and the receiving wheel should follow the main motor when manually cranking, and the rest of the motors are stopped. The host computer is implemented by P500, and P500 hangs IO terminals through EPM-S130. The P500 serves as the main screen, and there is also a payscreen, which uses Schneider's low-end screen to communicate with the P500 for ModBusTcp to modify and display the speed of the opening roller. The control accuracy of hot glue and cold glue is low, and the controller of KinCo is used for control, and it is connected to the main control P500 through CAN Open communication. The electrical system structure diagram is shown below.
The cutter head of the forming machine is equipped with two knives, the cutter head rotates at a speed of 2000 rpm, cuts the filter strip, prevents the cutter head from hurting people, and is equipped with a protective cover on the cutter head, and the wall of the cover is equipped with a soundproof sponge to reduce noise; There is an interlock device inside the housing, and when the interlock is released, the housing can be opened. If the interlocking screw is loosened when the machine is running, the safety current loop will be cut off through the interlock, the machine will stop working, and the touch screen will be triggered by the PLC to display the specific operation part diagram and the relevant protective cover prompt. It is not possible to start the machine when the head housing is opened or the interlocking screw is released, and the main motor can only be started when the housing is closed and the interlocking screw is tightened. In addition, there are temperature control, emergency shutdown control, forming paper control, report generation, etc., and the control structure diagram is shown below.
4 Lenze Highlights
(1) The i700 controller launched by Lenze can realize dual-axis applications, using DC bus power supply, saving cumbersome wiring and cost-effective.
(2) The P500 all-in-one computer launched by Lenze realizes the integration of PLC and touch screen. The PLC is based on the CoDeSys platform, which is easy to learn and supports multiple forms of communication.
(3) Lenze's selection tool DSD can perform selection calculations according to the parameters provided by customers, which greatly reduces the amount of calculation and provides a basis for future debugging.
(4) Lenze has been deeply involved in the field of automation for many years and has accumulated rich experience, and the use of Lenze's Fast template can enable field engineers to do 20% of the work and complete 80% of the tasks.
(5) Lenze has a wide range of automation and drive products, from reducers, motors, servo motors, servo controllers to PLCs, touch screens, etc. From the demand level, there are high-end products, as well as low-end products. It can meet the needs of high-end and high-end customers at different levels.
5 Outlook
As the main model of the filter rod forming machine, the K2 has a very large stock in the domestic market. With more than 30 years of history and continuous improvement since the 80s, this upgrade is also based on the latest K4 on the market today. After the transformation, it can maintain the original stability and be on the same level as K3 in terms of output, while K3 and K4 basically have no place to be transformed, so this transformation has great potential in the tobacco market.
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