Research on the maintenance path of tobacco and cigarette machinery and equipment

This article introduces the basic structure and principle of tobacco and cigarette machinery and equipment, studies its common faults and the impact of faults on equipment performance, explores the maintenance path of tobacco and cigarette machinery and equipment, and analyzes the diagnosis method, maintenance steps and optimization strategy of equipment faults to improve maintenance efficiency and equipment reliability.

As an indispensable key component in the production process, tobacco and cigarette machinery and equipment play an important role in ensuring the quality and production efficiency of tobacco products. With the continuous advancement of science and technology, these equipment are becoming increasingly complex, and their failures may lead to production interruptions and waste of resources. Therefore, in-depth research on the maintenance path of tobacco and cigarette machinery and equipment, improving maintenance efficiency and reducing production costs have important theoretical and practical value.

1 Overview of tobacco and cigarette machinery and equipment

1.1 Basic composition

Tobacco and cigarette machinery and equipment plays an indispensable core role in tobacco production. Its complex and precise composition structure directly affects the efficiency of the entire production process and the quality of the product.

Tobacco and cigarette machinery and equipment include key components such as feeding system, forming system, ignition system and packaging system. These systems cooperate with each other and perform their respective duties to form a complete and efficient cigarette production line.

The feeding system is responsible for accurately delivering raw materials such as tobacco and paper to the forming system, and its accuracy is directly related to the final quality of tobacco cigarettes. Through highly automated processes, the feeding system can ensure the accurate delivery of raw materials during the cigarette making process, thereby providing a stable and controllable production basis for the forming system.

The forming system is responsible for accurately and quickly forming raw materials such as tobacco and paper provided by the feeding system into cigarettes that meet the standards. This process requires a high degree of process control and mechanical coordination to ensure that the shape and quality of each cigarette meet the predetermined standards.

The ignition system is the guarantee for the normal combustion of tobacco cigarettes. This system ensures that the ignition process of cigarettes is uniform and stable through precise design and control. The quality of ignition is directly related to the taste of tobacco products and the uniformity of smoke generation. Therefore, the reliability of the ignition system plays a vital role in maintaining the consistent quality of cigarettes.

The packaging system is the last process to package finished cigarettes into commercially available tobacco products. The packaging system packages cigarettes neatly and orderly through efficient and precise operations to ensure the appearance and packaging quality of the products.

1.2 Principle

The operation of tobacco cigarette machinery and equipment depends not only on the mechanical structure, but also on the advanced electronic control system. The equipment coordinates the operation of each component through an intelligent control system to achieve automation and precision control of the entire cigarette making process. This integrated intelligent control system covers multiple fields such as mechanical engineering, automation technology and electronic control, ensuring the stable and reliable operation of the equipment in a highly complex working environment. The principles of tobacco cigarette machinery and equipment involve multiple disciplines and require maintenance personnel to have extensive professional knowledge. Mechanical engineering knowledge is used to understand and maintain the mechanical structure of the equipment, automation technology is responsible for the intelligent and automated control of the equipment operation, and electronic control knowledge is related to the maintenance and repair of the electronic components and control systems of the equipment. This complexity requires maintenance personnel to have comprehensive professional qualities, not only to be able to operate the mechanical structure proficiently, but also to flexibly use modern maintenance technology.

1.3 Necessity of maintenance

Although tobacco cigarette machinery and equipment have been carefully designed and manufactured, after a long period of operation, various failures will occur due to the aging of the components. As can be seen from Figure 1, the system architecture of tobacco cigarette machinery equipment includes industrial control computers and human-computer interaction systems, which in turn include switches, main control systems and other structures. Any problem in any of these steps will affect the operation of the system.

The feeding system may fail due to reasons such as raw material blockage and transmission system failure, which directly affects the continuity of production. Therefore, in the maintenance path, accurate and rapid diagnosis of the failure of the feeding system has become a key link to ensure production continuity.
Failures in the molding system may cause serious cigarette quality problems.
Wear and misalignment of mechanical parts are common failure conditions, which may cause irregular cigarette shapes and directly affect the appearance and quality of the product. In the maintenance path, the inspection and timely replacement of worn parts of the molding system have become necessary steps to ensure the regularity of cigarette shapes. Failures in the ignition system may cause uneven ignition, affecting the combustion performance of tobacco cigarettes. Uneven ignition may cause unstable combustion processes in cigarettes, affecting the taste and burning experience of tobacco products. Therefore, accurate diagnosis and timely repair of the ignition system in the maintenance path are necessary steps to ensure product quality and user satisfaction. Failure of the packaging system may have a direct impact on the sales and transportation of the product. Weak packaging may cause cigarettes to be damaged during transportation, or even damaged when displayed on the shelves. This directly affects the market image and sales benefits of the product. Therefore, in the maintenance path, careful inspection and repair of the packaging system is an important part of ensuring the appearance and integrity of the product.

2 Maintenance path of tobacco cigarette machinery and equipment

2.1 Accurately identify faults by combining traditional manual and advanced instruments

Traditional manual inspection is the crystallization of the experience and skills of maintenance personnel. By observing the operating status of the equipment, exploring whether the mechanical parts are normal, and listening to the sound of the machine, maintenance personnel can preliminarily determine whether there is any abnormality in the equipment. This method is particularly suitable for some surface faults or obvious mechanical problems. Maintenance personnel can identify the problem with years of practical experience.

For some minor and hidden faults, manual inspection is usually incapable, because these problems may not show obvious signs on the surface and require more sophisticated means to discover. In this context, modern instrument diagnostic tools have gradually attracted people’s attention and become an important means to improve the efficiency of fault diagnosis. For example, using sensors to detect the operating status of equipment can monitor the performance of each component in real time and provide comprehensive data information. Such real-time monitoring can help maintenance personnel discover potential problems and take measures to intervene in advance to avoid fault escalation or spread.

The fault recorder can record the historical operating data of the equipment and provide maintenance personnel with detailed key information such as the time and duration of the fault. This application also greatly simplifies the fault diagnosis process. By analyzing the historical operating data, the nature and cause of the fault can be determined more quickly and accurately, and targeted repairs can be carried out. These advanced instrument technologies provide maintenance personnel with more accurate and comprehensive fault information, making maintenance work more targeted and rapid.

2.2 Optimize the design of maintenance processes and implement maintenance steps

(1) Shut down and take safety measures. Before carrying out maintenance, it is necessary to ensure that the equipment has been shut down and appropriate safety measures have been taken to minimize accidents during the maintenance process. This link emphasizes the principle of safety first during the maintenance process to ensure the safety of maintenance personnel and the equipment itself.

(2) Disassembly and repair of faulty parts. According to the results of fault diagnosis, maintenance personnel need to dismantle the equipment in a targeted manner and conduct a detailed inspection of the faulty parts. This includes careful inspection and cleaning of mechanical parts, as well as testing of electronic components. Through in-depth inspection and maintenance work, maintenance personnel can more accurately determine the nature and scope of the fault, laying a solid foundation for subsequent repair work.

(3) Repair or replace faulty parts. According to the inspection and maintenance results, maintenance personnel need to decide whether to repair the faulty parts or directly replace the damaged parts. This step requires maintenance personnel to have high professional skills and operating experience to ensure the accuracy and effectiveness of the repair work. The technical proficiency of maintenance personnel is directly related to the quality of the maintenance results.

(4) Equipment debugging and trial operation. After the maintenance is completed, the equipment is fully debugged and tested to verify whether the repaired parts and systems can operate normally and in coordination. The quality of this step is directly related to the stability and reliability of the equipment. Through meticulous debugging work, maintenance personnel can ensure the smooth operation of the equipment in a normal production environment to the greatest extent possible and reduce the possibility of secondary failures.

2.3 Formulate optimization strategies and preventive measures

In order to further improve the maintainability of tobacco and cigarette machinery and equipment and reduce the frequency of failures, it is crucial to formulate effective optimization strategies and preventive measures. This is not only related to the stable operation of the equipment, but also directly affects production efficiency and product quality. Therefore, establishing a comprehensive maintenance plan, including regular inspections, maintenance and upgrades, has become a necessary means to ensure the long-term and efficient operation of tobacco and cigarette machinery and equipment.

(1) Through regular inspections and maintenance, potential problems can be discovered and solved in advance to prevent failures. This includes careful inspection of each component of the equipment, regular replacement of lubricants, and regular tightening of fasteners. By establishing an effective regular maintenance plan, the service life of the equipment can be maximized, the maintenance frequency can be reduced, and the continuity of the production line can be guaranteed. Such preventive maintenance measures not only reduce the possibility of equipment failure, but also improve maintenance efficiency, allowing the equipment to operate more stably and reliably during the production process.

(2) Through comprehensive maintenance of the equipment, wear and aging caused by long-term use of the equipment can be effectively prevented. This includes comprehensive inspection of the equipment, replacement of wearing parts and upgrading of key components. Through careful maintenance work, not only can the life of the equipment be extended, the natural loss of the equipment be slowed down, but also the efficiency of the equipment can be maintained.

(3) Equipment upgrades involve updating control systems, upgrading sensors, and improving mechanical structures. Through these improvements, not only can the performance level of the equipment be improved, but also the intelligence level of the entire production line can be improved. With the continuous development of science and technology, equipment upgrades have become an indispensable means to ensure that the production line keeps up with the trend and adapts to market changes. Regular equipment upgrades can not only enhance the function and flexibility of the equipment, but also better adapt to the continuous changes and innovations in the tobacco industry. Through such maintenance and upgrading measures, tobacco cigarette machinery and equipment can maintain high efficiency and stable performance during long-term operation, ensure the continuity and high quality of tobacco production to the greatest extent, and provide strong support for the sustainable development of the entire tobacco industry.

(4) The use of laser cladding technology to repair worn parts can not only greatly increase their service life, but also greatly reduce the maintenance cost of the enterprise.

3 Conclusion

The research in this article provides a systematic theoretical framework and practical operation guidelines for the maintenance of tobacco cigarette machinery and equipment. Through reasonable maintenance path analysis, it is expected to promote technological progress and improve production efficiency in the tobacco production industry. In future research and practice, this maintenance path can be further improved and expanded to adapt to the ever-evolving scientific and technological and industrial needs.