大型连续绿茶精制加工生产线研发

Development of a large-scale continuous green tea refining and processing production line

茶叶加工技术与装备是茶叶产业发展的基础,对行业发展起着举足轻重的作用。为实现绿茶加工机械自动化生产,设计了大型连续绿茶精制加工生产线,阐述了该生产线系统结构、主要生产环节及安装调试应用。基于PLC控制的大型连续绿茶精制加工生产线,主要由鲜叶上料输送机、大型滚筒杀青机、冷却回潮机、四机协同联动式揉捻机组、并列连续预烘干机组、储料仓、计量分料装置、茶叶炒干与抛光机组、筛分装置、风选装置及配套的测控系统等组成。针对绿茶加工工艺的各个环节,采用模块化设计,根据茶叶加工企业的厂房实际情况,灵活安装组线,满足企业个性化需求。基于模糊PID温度控制的大型滚筒杀青机双模糊控制技术,解决了传统杀青温度与时间无法实现精确控制的难点问题。采用链式刮板输送智能加料装置与多机联动协同连续揉捻控制技术,实现多机协同联动式自动加料连续揉捻,边进料边揉捻,揉捻均匀度高。生产线上杀青机、理条机和烘干机各环节温度采用模糊PID控制,解决了茶叶加工温度、投叶量与杀青、理条、烘干时间实时配合的问题,输入不同等级、不同重量的鲜叶可输出相适应的杀青温度和时间,实现对茶叶生产过程的精确控制,减少人为因素的干扰,实现绿茶的智能化生产。近年来,生产线用户遍布皖、苏、浙、云、贵、川、豫、湘、鄂和陕等10多个省份200余家茶叶生产企业。该生产线的推广应用,实现了茶叶规模化生产,保证了茶叶品质,对茶产业发展具有重要意义。

Technology and equipment used in tea processing are fundamental to the development of the tea industry,playing a crucial role in its growth.To achieve the automation of green tea processing machinery production,a large-scale continuous green tea refining production line was designed,the system structure of the production line,the main production stages,and the installation,debugging,and application were described.The large-scale continuous green tea refining production line based on PLC(Programmable logic controller)control was mainly consists of fresh leaf feeding conveyors,large drum fixation machines,cooling and rehumidifying machines,a four-machine coordinated rolling unit,parallel continuous pre-drying units,storage bins,metering and distributing devices,tea frying and polishing units,screening devices,air selection devices,and accompanying monitoring and control systems.Targeting various stages of the green tea processing technique,the modular design allows flexible installation and assembly of the production line according to the actual conditions of the tea processing company’s facilities,thus meeting the personalized needs of enterprised.Dual fuzzy control technology based on fuzzy PID temperature control for the large drum fixation machine addressed the pain points and difficulties of achieving precise control over the fixation temperature and time.Chain scraper conveyor intelligent feeding device and the multi-machine coordinated rolling control technology enable automated feeding and continuous rolling,with simultaneous feeding and rolling,ensuring high uniformity in rolling.On the production line,the temperatures of the fixation machine,sorting machine,and drying machine were controlled using fuzzy PID,resolving issues related to the real-time coordination of tea processing temperature,leaf input quantity,and the timing for fixation,sorting,and drying.This system can input fresh leaves of different grades and weights,outputting corresponding fixation temperatures and times,thus achieving precise control over the tea production process,reducing human interference,and realizing intelligent green tea production.In recent years,users from over 200 tea production enterprises in more than ten provinces,including Anhui,Jiangsu,Zhejiang,Yunnan,Guizhou,Sichuan,Henan,Hunan,Hubei,and Shaanxi Province,had adopted this production line.The promotion and application of the production line developed by our team had achieved large-scale tea production,ensured tea quality,and hold significant importance for the development of the tea industry.