Design of early warning system for cylinder conveyor units in YF615 carton reservoir system

To facilitate the maintenance work of cylinder conveyor units in YF615 carton reservoir system, an early warning system was designed based on a supervisory control and data acquisition (SCADA) platform. High-speed current acquisition of the cylinder motor was achieved via PLC cyclic interruption, and massive current data were rapidly stored in a database using C script in WinCC. The dynamic time warping (DTW) algorithm was employed to analyze the current data and cylinder conveyor units in abnormal state were identified. Trouble report form based on Java management software was provided to facilitate maintenance work. The designed system was tested on the YF615 system in Changde Cigarette Factory for one year. The results showed that compared with patrol inspection, the time for finding out all cylinder conveyor units in trouble was reduced from 328.8 minutes to 6.9 minutes, or reduced by 97.9%. The system successfully reported 29 warnings including belt entangled by foreign matters, cylinder screw loosening, belt breakage and motor wire wearing with an accuracy rate of 100%. This technology provides support for improving the efficiency of cigarette cartoning and reducing the maintenance workload.