1、1Design and Research on Online Sampling Device of New Cigarette Making MachineAbstract. The paper introduces the structure and design principles of online sampling device of a new high-speed cigarette machine. The device is an important part of C2 cigarette online sampling and measurement system, it
2、 gets samples from the high-speed cigarette maker machines conveiying line and send samples to C2 measuring instrument for testing, and it achieved the goal of automatic on-line monitoring of cigarette physical parameters. The device has compact structure and expediently installation, which makes it
3、 not only replace manual sampling of high-speed cigarette making machine, but also detect and display various physical parameters of cigarette in real time. Key words: high-speed cigarette making machine; online sampling device; C2 cigarette integrated test stand Introduction With increasing strict
4、of large-scale and high-speed industrialized cigarette production process on quality control of cigarette product, the disadvantages of traditional manual 2offline sampling methods have been prominent. And using real-time online sampling detection system is becoming the objective and direction of ci
5、garette production manufacturing enterprises 1. At present, Protos-M8 high-speed cigarette making machine manufactured by German HAUNI Company is a cigarette making machine at the speed of 20000m/min which is the fastest to produce cigarette in the world. As it is fast to produce cigarette, the orig
6、inal offline methods of detecting physical parameters such as circumference, draw resistance, weight, length and ventilation rate of cigarettes have been unable to meet the requirements of detecting M8 high-speed cigarette making machine. So the paper improves C2 cigarette integrated test stand and
7、designs a new cigarette online sampling device, which not only achieves the objective of matching with high-speed cigarette making machine, but also realizes online automatic test function 2. Complete Machine Structure and Operating Principles Complete machine structure New cigarette online sampling
8、 device consist of many core components including step motor, sensor, photoelectric switch, vacuum system, vertical guide rail, cylinder, sampling arm, adsorption tank and control system, as shown in Figure 1. 3Operating principles When the sampling device operates, the controller sends low signals,
9、 step motor 1 turns to drive driving belt on output shaft of step motor 1 to run and drive sliding seat 5 fixed on driving belt 7 to drop, which drives sampling arm 8 hinging with sliding seat 5 drop on conveyor line 11 of high-speed cigarette making machine. The sampling hand 15 at the bottom of sa
10、mpling arm 8 takes sample 14 and incline to direction A. Sampling arm 8 turns around spindle 6 and is independent of photoelectric switch 3. Vacuum system starts, samples absorption hole absorbs samples, controller sends rising signals, step motor 1 turns to drive driving belt 7 on output shaft of s
11、tep motor 1 to run, and drive sliding seat 5 fixed on driving belt 7 to rise, which drives sampling arm 8 hinging with sliding seat 5 to rise. Sensor 2 senses the position of sampling arm 8, the controller sends signals, piston lever of cylinder 4 pushes sampling arm 8, and sampling arm 8 turns arou
12、nd spindle 6. The vacuum system is closed, and samples drop on driving belt 9 and are transmitted to test board by driving belt 9, and piston rod of cylinder 4 resets, for the next cycle. Control system design Control system of new cigarette online sampling device has 4two design functions. 1) Opera
13、tion of sampling arm takes sectional speed change. In different stages of sampling arm falling and rising, different operation speeds are taken, which not only reduces negative influence of sampling arm contacting with product samples, but also improves sampling efficiency and sampling success rate.
14、 2) The sampling arms that can swing freely have light extrusion force on cigarettes of product line, and have little damage on cigarettes. Under normal circumstances, sampling arms are vertical. On sampling, sensor senses sampling arm swing, and sampling arm returns to the initial position. Design
15、principles The control system applies Siemens PLC S7-224 as CPU to realize sampling of Protos-M8 high-speed cigarette making machine. In the process of PLC programming, the total travel of step motor is set to be 15600 pulses which can be achieved according to real stroke length. In the process of s
16、ampling arm falling, the speed is set for segmentation, and the pulse is counted by counter. When step motor is 8000 steps, vacuum generator is started. And when step motor is 12600 steps, sampling plate of sampling arm is almost close to cigarettes on product line, and the speed is set to be low sp
17、eed, the purpose 5for which is to reduce the influence of sampling hand catching cigarettes and to increase the risk of successful sampling. When there is one of the following conditions, sampling arm returns immediately. 1) When cigarettes are adsorbed by sampling plate, negative-pressure switch of
18、 sampling device jumps. 2) The stroke of step motor reaches 15600 steps. 3) When sampling planet is extruded by cigarettes on product line and swings, photoelectric switch of sampling arm jumps 1. In the returning process, it leaves product line with high speed, and vacuum generator starts all the t
19、ime. After the origin-location senor senses that sampling arm reaches the origin, PLC judges if negative-pressure switch is adsorbed by samples. If there is no, sampling arm falls and resamples, which repeats for four times at most. If there is, subsequent actions are made, and sampling success sign
20、al is sent to C2. After receiving C2 feedback signal, sampling arm is propelled to high status by cylinder, and step motor stops when it falls to the location point of 300 pulses. And sampling driving belt starts, vacuum is closed, and cigarettes are placed on driving belt and transmitted to C2 weig
21、ht unit. When C2 weight unit senses the change, it feedbacks the signal to sampler, and the sampling process ends. When it reaches sampling period, the 6sampling of next sample begins 4. Control process The core control process of online sampling device for new cigarette making machine is that under
22、 the premise of starting the sampling function of C2 cigarette integrated test stand, after manufacturer is started, the startup signal is sent to C2, and sampling device begins to sample 60 seconds after delaying. And the above three conditions are used to judge if the sample is achieved. The contr
23、ol process of C2 online sampling device operation is shown in Figure 2. PLC hardware wiring diagram As shown in Figure 4 (PLC hardware wiring diagram), online sampling device has two motors, step motor and sample presentation motor. Step motor controls drop distance of sampling arm, and sample prese
24、ntation motor drives the conveyor belt of samples to run. The swing-arm cylinder controls the swing of sampling arm, which makes the achieved samples send to conveyor belt of samples.The output of the 1,2and the stepper driver is connected, to control stepper motor operation,the output3,4 are respec
25、tively connected with two electromagnetic valves, control arm cylinder and vacuum generator,output of 5and the sample motor is connected,to control the sample motor running,Number 6, 7 and 8 output terminal in the figure are 7used to communicate with C2, number 9 input terminal is the startup signal
26、 of M8 high-speed cigarette making machine, and number 10 and 11 input terminal inserts from C2, the function for which is to activate online sampling device 5,Input 12andnegative pressure switch is connected,detecting whether the samples were adsorbed. Conclusion Through researches and exploration,
27、 the paper proposes the design ideas of a new cigarette making online sampling device. The innovation is segmental speed adjustment function and swing of sampling arm. The device combines step motor and annular driving belt to drive sampling arm to move, which completely replaces cylinder-type drivi
28、ng mode applied to tobacco factory in China. The device has compact structure, easy installation and stable operation, so it has great generalization in cigarette industry and can be applied to high-speed cigarette making machine or over-speed cigarette making machine. Foundation item: Zhejiang toba
29、cco industry limited liability company science and technology project:”Research and application of on-line detection technology branch of physical parameters of smoke in M8 high speed machine“(No.ZJZY2013D012). 8References 1 Wang Yuguang, Zhang Li, Wang Jun, Si Rulin, Application of C2 cigarettes to
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31、ool and Automatic Processing Technology, 2008, 11: 44-45. 4 Wang Lihong, Zhao Yueling, Yang Zhongwen, Study on speed control methods of step motor based on PLC J, Journal of Liaoning University Of Technology (Natural Science), 2010,30(4)：215-217. 5 Lu Yunhua, Graphic appliances and PLC control technology M, Beijing: Mechanical Press, 2011:60-70.
