I. Overview Overview

With China's accession to the customs trade is approaching, the cigarette production enterprises in the focus on reducing coke and consumption at the same time, is doing everything possible to improve the intrinsic quality of cigarette products, especially the silk production line of a variety of flavored sugar liquid treatment is scientific and reasonable, directly related to the finished cigarette flavor, therefore, the flavored sugar material strict quality management, scientific preparation, accurate on-site launch, etc., is the civilization of the production of scientific management is one of the most important tools! Therefore, strict quality management of flavoring and sweeteners, scientific preparation and precise on-site launching are important means of civilized production and scientific management, which are more and more highly valued by manufacturers.

Flavors and fragrances feeding system is mainly composed of three parts: storage and measurement of raw materials; modulation, storage and delivery of finished liquid; and on-site launch of finished liquid. Its role is to be responsible for the whole factory silk line additive fragrance process of all the fragrance and sugar material modulation, storage and the site of the fixed ratio imposed, the process is: most of the raw materials through the piping system measurement sent to the modulation reaction tank modulation, modulation of the finished product fragrance and sugar material liquid through the filter into the storage reaction tank storage, according to the site of the fragrance and sugar material of the material signals, by the storage reaction tank quantitative delivery to the workshop of each According to the dosage signal of each flavored sugar, the dosage will be transported from the storage reaction tank to the operation cabinet of the dosage liquid beside the drum of flavored sugar, and then the operation cabinet will realize the fixed ratio tracking and applying to the drum.

II. Sugar dosage basic function:

The establishment of the aroma sugar feeding system can be a good solution to the past by manual inspection of the situation one by one, the use of advanced equipment and control technology to improve the automation degree of the aroma and sugar ingredients, maximize the impact of human factors to overcome the dosage precision greatly improved, thus significantly improving the quality of cigarettes, the taste obtained by the consistency of the flavor, and at the same time greatly reduce the labor intensity of workers, improve the workshop's Hygienic conditions. The normal feeding system of flavoring material is related to every work of the cigarette factory and the quality of production products. Through the company's technical personnel in the past to do the sugar ingredients batching machine has the following points must have:

1. Brand judgment function

(1) dosage output and the site to be material grade inconsistent, should alarm and stop output dosage output and the site to be material grade inconsistent, but also as normal as the material to the scene, resulting in the loss of the wrong raw materials, as well as a waste of time, resulting in serious product scrap.

(2) When there is inconsistency between the material output from the storage reaction tank and the on-site materials, the alarm should be raised and the output should be stopped. When there is inconsistency between the material output from the storage reaction tank and the on-site materials, the materials can be discharged to the site as normal, resulting in the loss of the wrong raw materials, as well as the waste of time, and in serious cases, resulting in the scrapping of the products.

3、Redundancy of the system network

Flavors and fragrances dosage monitoring system is generally composed of on-site duty room, each with a server and workstations and database management center computer, as well as other authorized network computers; database management center computer through the fiber optic and the site of the industrial LAN and the on-site duty room connected to the on-site duty room; the on-site duty room in the server as a field center control and on-site process formulas, report archiving and management; the other one as a Monitoring workstations, management computers for day-to-day site management and monitoring and control; database management center computer as the process formula parameters input and production plan issued. These computer networks must do some of the necessary redundancy design to ensure that all the way network failure, another network can seamlessly access the work. Now due to the cigarette factory 600,000 large box production line expansion project of groundbreaking, the original three workshops and part of the annex building dismantled, resulting in automatic control system part of the network equipment is damaged, lost and caused by network failure, and now the spiced sugar dosage system and technology management center has been unable to communicate.

Basic redundant components: dual database servers, dual fiber-optic network. 4. Timeliness of on-site information and control

Due to the early design is running in the WindowsNT4.0 environment of all computer hardware configuration is low, the dosage system startup, running speed is slow. Sometimes can not properly reflect the scene in real time, remote control and back to show the information is not synchronized. Therefore, the use of real-time systems in the often lagging individual data, operation flow. In order to solve these problems, we can improve the computer and configuration and installation of higher operating systems.

III. General structure

The project has carried out a scientific system design, in terms of the function of its constituent equipment, the whole batching system is divided into the following three layers:

1、Raw material layer

(1) Configuration and function of equipment in raw material layer:

Raw material reaction tank heating and heat preservation function, reaction tank liquid level signal output and display function, reaction tank quantitative water addition function, measurement reaction tank automatic measurement output function, reaction tank storage function.

2、Modulation storage layer

(1) Modulation storage layer equipment configuration

(2) Sugar storage reaction tank

(3) Spice modulation reaction tank

(4) spice storage reaction tank

(2) The function of the modulation storage layer

The modulation and storage layer mainly meets the needs of the joint workshop for the modulation, storage and transportation of sugar liquid.

① All sugar modulation reaction tank and storage reaction tank have heating and heat preservation, stirring function.

② All modulating reaction tanks and storage reaction tanks are equipped with liquid level signal output and display function, liquid level detection and processing.

③ Each modulation reaction tank has the function of adding water quantitatively.

④Function of modulating flavored sugar material liquid.

⑤ Function of storage and transportation of flavored sugar material.

⑥Automatic conveying function of flavored sugar material liquid.

3、Site launching layer

①Function of temporary storage of flavored sugar material:

②Automatic fixed-ratio fragrance/feeding function:

③Atomized launching of fragrant sugar material liquid

Fourth, the control system

1、Management principle

According to the principle of "centralized management, comprehensive monitoring and equipment control", the design of Changde Tobacco Factory's electronic control system for flavored sugar ingredient dosing can be divided into three levels according to its functions, i.e.: production management layer, centralized monitoring layer and equipment control layer.

1) The bottom layer (equipment control layer): the field bus is used to connect the I/O points, detection devices, sensors, inverters, etc. The modularized field bus-based electronic control system is used to connect the I/O points, detection devices, sensors and inverters. The equipment is controlled by the modular fieldbus-based new generation process control system SIMATICS7 series.

2) Intermediate layer (centralized monitoring layer): as the human-computer interaction interface of the control system, it realizes the combination operation, status monitoring, formula changing, parameter setting and alarm displaying, recording, etc. of the production through the monitoring computer.

3) The highest layer (production management layer): It is responsible for dealing with the comprehensive information during the operation of the whole spiced sugar ingredient batching system, including process, equipment, quality and other parameters detected and entered manually, and providing complete statistical data and all kinds of analysis charts and so on.

2、Automatic control system

The field adopts the fragrance sugar material modulation, transportation and field launching separate control, respectively constitutes the respective PLC control system.

(1) Fragrant sugar material modulation, transportation system

①, the scope of control: this system is mainly responsible for the completion of the silk production line leaf material, tobacco stalk material, expanding tobacco material, booklet material, white ribbed tobacco material, and stalk spices and mixed spices proportioning, modulation, storage and the joint workshop of the silk production line leaf material, tobacco stalk material, stalk spices and mixed spices automatically supplied and change the brand name of the residual material recycling and cleaning and blowing of the pipeline and other complete process.

②, according to the scale and function of the spice batching equipment, the process control system mainly adopts a set of S7-400 station, remote distributed I/O node (batching/site)

Valve island node (dosage / site) electronic scale node control on the dosage system with manual / automatic function selection. In manual function, some equipment can be started/stopped manually, which is convenient for fault repair and equipment maintenance; in automatic function, the functions are completed automatically according to the operation instruction.

Batching:

The operator selects the dosage grade and inputs the total amount of dosage according to the dosage list remotely issued by the database management center through the network, the system automatically calculates the quantity of each raw material through the recipe parameters of the corresponding grade in the recipe library and sends it to the central controller, which accordingly collects the pulse signals from the mass flowmeter and accumulates them so as to control the raw material reacting tank to modulate the reacting tank automatically, and the deviation caused by the pipe system, the system can automatically control the raw material reacting tank through the pipeline system and the central controller can automatically control the raw material reacting tank. For the deviation caused by the pipeline system, the system can automatically compensate through the software.

Modulation storage:

The modulated material can be transported to the storage reaction tank. By collecting the analog signal from the temperature transmitter and receiving the set temperature value from the computer, it can realize the dynamic digital display of temperature and heat preservation function. Realize "brand name tracking" for the brand name, that is, the brand name code of the modulating reaction tank is sent to the storage reaction tank of the current feed to display its material liquid brand name, and the modulating reaction tank is finished, that is, the brand name code of the modulating reaction tank is eliminated.

Conveying:

The central controller implements automatic searching for reaction tanks, first-in-first-out, according to the on-site material demand signal and the production grade number. First of all, according to the production brand number, it will automatically search for the storage material reaction tank of the brand number. If there are more than one storage tanks of the same brand number, it will realize first-in-first-out according to "order queuing".

(2) On-site launching system

①Scope of control: This dosage system is mainly responsible for completing the fixed-ratio tracking and launching of the blade material, tobacco stalk material, stalk spice and mixed spice of the silk making line in the joint workshop, as well as the recycling and cleaning of the residual material of the respective on-site pipelines.

② This dosage system is equipped with a small PLC system S7-300 and a man-machine interface for each dosage/fragrance point respectively.

③ Frequency converter and flow meter are adopted with PROFIBUS-DP interface, so as to directly enter the PROFIBUS-DP field bus to participate in the control.

3. Monitoring system

The intermediate layer of the system, namely the monitoring layer, collects the data in the PLC controller of the sugar batching and the production data coming from the network through the industrial Ethernet.

Functions: human-computer interaction interface, status monitoring, function operation, customized recipe, parameter setting, alarm (record), trend curve, report.

(1) Batching system configuration

①Hardware

The upper computer of the monitoring system consists of two IBM workstations connected to the terminal bus.

② Software

Software selection of Australia Syatt CITECT monitoring software package for system development, operating system selection of Chinese version of NT4.0 Workstation or higher WINDOWS version, configuration software selection of Australia Syatt CITECT5.4 software.

(2) Batching system description

Syatt CITECT configuration software through the object-oriented graphics provided by the way, animation links, beautiful gallery and ActiveX controls, 3DMAX three-dimensional animation and other technologies to create a beautiful process flow diagram and more detailed local process flow diagram.

(3) Batching system function

The human-computer interaction interface system organically integrates the following functional components together, constituting a set of human-computer interface system with perfect functions and easy operation.

①Functional operation

1) Functional operation of the reactor itself:

The corresponding reaction tanks in the monitoring screen are set with the reaction tank function operation buttons, and the operator clicks the button to pop up a window in which there are start/stop operations of stirring, suction, drainage, cylinder operation, etc. 2) Storage operation (feeding operation):

Operator in the monitoring screen to open the storage operation window, selected storage incense (material) reaction tank, click the storage button to start the storage operation, will be modulated incense (material) sent to the storage reaction tank storage, waiting for the delivery, and display the number of reaction tanks in the material and brand number.

3) Transportation operation (discharge operation):

The operator opens the conveying operation window on the monitoring screen, according to the production number transmitted by the production scheduling department through the network and confirm, click the conveyor button to start the conveyor operation to the incense, feeding site to send materials.

4) Scenting and dosing operation (on-site launch):

Scenting and dosing screen, the screen can dynamically display the instantaneous parameters of the field launch.

5) Cleaning and blowing operation:

Monitor the screen to set the leaf material, tobacco stalk material, stalk flavor, mixed silk flavor delivery and sugar, spice modulation of the cleaning and blowing operation.

② dosage system status display

Dynamically display the process flow diagram of the whole system, such as the liquid level of the reaction tank, temperature, valve and motor status in the pipeline and fault points, etc.

③Dosing system parameter display and input

Intelligent operation: more production plan product grade, automatically call the corresponding grade.

⑤Information prompting

⑥Error alarm, system management

Functions: comprehensive processing of information, production management, user management, report management, formula management.

This dosage management system consists of a CITECT server connected to the 100M industrial Ethernet of the wire making line via a 100M3COM network card and a 100M optical link module OSM, and the data transmission medium is fiber optic cable. the CITECT server and the two CITECT clients form a 10M standard Ethernet through the client/server mode. Since one of the CITECT clients is located far away from the CITECT server, the data transmission is also carried out using fiber-optic cables.