脉冲式残烟处理装置的电气系统设计

Design on Electrical System of Pulsed Residual Cigarette Disposal Equipment

摘要: 针对卷烟生产过程中细支残次烟支数量多、烟丝浪费严重，以及传统人工烟丝回收方式效率低、成本高、烟丝纯净度差等问题，本文设计了一套脉冲吹气式残烟处理装置的电气控制系统。该系统以倍福TWINCAT运动控制软件为核心，协同电机、编码器、高速电磁阀、高速工业相机等元器件，实现残次烟支的连续输送、方向识别、精准定位、脉冲吹气分离、视觉检测及不合格烟支剔除等功能。通过高精度编码器叠加四倍频技术提升控制精度，解决气流传输延迟问题，并通过与机械结构的协同调试优化分离效果。试验结果表明，该系统在800支/分钟的处理速度下，烟丝吹净率稳定达到95%以上，仅需单人操作即可完成全流程作业，有效节省人力资源成本，且分离后的烟丝纯净度高、烟支杆结构完整，满足规模化烟丝回收需求。最后，针对编码器控制精度的固有局限，提出将鼓轮驱动电机替换为伺服电机的优化方向，为后续系统精度提升提供参考。

Abstract: Aiming at the problems of large quantity of defective slim cigarettes, serious tobacco waste in the cigarette production process, as well as low efficiency, high cost and poor purity of tobacco in the traditional manual tobacco recovery method, this paper designs an electrical control system for a pulse air-blowing defective cigarette processing device. Taking Beckhoff TWINCAT motion control software as the core, the system cooperates with motors, encoders, high-speed solenoid valves, high-speed industrial cameras and other components to realize the functions of continuous conveying, direction identification, precise positioning, pulse air-blowing separation, visual inspection and rejection of unqualified cigarettes for defective cigarettes. The high-precision encoder combined with quadruple frequency technology is used to improve the control accuracy, solve the problem of air flow transmission delay, and optimize the separation effect through collaborative debugging with the mechanical structure. The test results show that the system can stably achieve a tobacco blowing rate of more than 95% at a processing speed of 800 cigarettes per minute, and only one person is required to complete the whole process operation, which effectively saves human resource costs. In addition, the separated tobacco has high purity and the cigarette rod has a complete structure, which meets the demand of large-scale tobacco recovery. Finally, in view of the inherent limitation of the control accuracy of the encoder, an optimization direction of replacing the drum drive motor with a servo motor is proposed, which provides a reference for the subsequent improvement of the system accuracy.