Automatic batching safety inspection method and equipment for emulsion explosive water-phase preparation tank

Abstract

The invention discloses an automatic batching safety inspection method and equipment for an emulsion explosive water-phase preparation tank. The method relates to the technical field of safety inspection data management, and comprises the following steps: collecting and processing automatic batching data of an emulsion explosive water phase preparation tank; and analyzing, optimizing and adjusting the data. According to the method, the automatic batching data of the emulsion explosive water-phase preparation tank are collected and processed, the automatic batching data of the emulsion explosive water-phase preparation tank are analyzed, the mixing uniformity and energy consumption efficiency evaluation value and the PI D control response timeliness evaluation value are obtained, comprehensive analysis and optimization adjustment are carried out, the stability of the safety inspection method is improved, and the safety inspection efficiency is improved. The problem that in the prior art, a safety inspection method is low in stability is solved.

Description

Technical Field

[0001] The present invention relates to the technical field of safety inspection data management, and particularly to an automatic batching safety inspection method and device for an emulsion explosive aqueous phase preparation tank. Background Art

[0002] With the urgent need for safe production in the civil explosive industry, the risks of traditional manual operations, and the rapid development of industrial automation and intelligent technologies, the proposal of the automatic batching safety inspection method for emulsion explosive aqueous phase preparation tanks is essentially an inevitable choice in the civil explosive industry driven by process safety, regulatory compliance, and technological empowerment. By deeply integrating the industrial Internet, AI algorithms, and explosion-proof robots, not only can the risk of human accidents be reduced by more than 90%, but also the transformation and upgrading of civil explosive manufacturing from "experience-driven" to "data-driven" can be promoted. In the future, with the further penetration of technologies such as digital twins and 5G private networks, the intrinsic safety level of high-risk chemical production will continue to improve.

[0003] The existing automatic batching safety inspection method for emulsion explosive aqueous phase preparation tanks monitors data in real time through sensor devices; realizes full-automatic batching through an automated control system, reduces human error, and prevents local viscosity increase caused by insufficient stirring.

[0004] For example, the safety inspection system and its scoring standard for a dangerous goods emulsion explosive production line and warehouse disclosed in the invention patent with the publication number: CN116882899A, including: water-oil phase preparation process, pharmaceutical process, steel belt cooling process, belt conveyor, charging process, packaging process, loading process, and dangerous goods warehouse, including sensing detection and automatic control systems, a density sensor, arranged on the water phase preparation tank discharge pipeline in the water-oil phase preparation process, for detecting the water phase ratio, a first vision sensor, arranged on the steel belt in the steel belt cooling process, for real-time monitoring of the steel belt operation state, and a second vision sensor, arranged in the steel belt cooling process, for detecting the personnel configuration in the steel belt cooling process.

[0005] For example, an intelligent prevention and control method and system for emulsion explosives disclosed in the invention patent announcement with the publication number: CN115619298B, including: positioning the corresponding vibration relationship period according to the vibration signal at each monitoring position; obtaining the set of monitoring positions associated with the temperature gradient of the monitoring position within the vibration relationship period as the monitoring domain; calculating the danger analysis value of each monitoring domain, and if the danger analysis value of a monitoring domain is greater than the danger threshold, sending a warning message and regulating the environment; being able to accurately locate the time period between discrete oscillations caused by intermittent falling, rolling, collision, and friction of emulsion explosives, and being able to significantly reduce false alarms and distortion phenomena in subsequent monitoring steps.

[0006] However, in the process of implementing the inventive technical solution in the embodiments of the present application, it is found that the above technologies have at least the following technical problems:

[0007] When this method is applied to the automatic batching application scenario of the aqueous phase preparation tank of emulsion explosive, the viscosity change of the emulsion explosive solution affects the uniformity of temperature distribution, and a local high-temperature area is formed in the high-viscosity area. The traditional temperature sensors are sparsely distributed in the aqueous phase preparation tank and cannot capture the local high-temperature and low-temperature areas, resulting in a large temperature difference. In a high-temperature and high-pressure environment, the metal film of the sensor is oxidized, resulting in drift error, and there is a problem of inaccurate local temperature control; when the viscosity of the emulsion explosive solution suddenly changes, accompanied by temperature changes, the PID control responds slowly to the sudden change of local temperature, resulting in a lag in the adjustment of the steam valve and inability to adjust in time, resulting in temperature runaway; in a high-viscosity solution, a fixed rotation speed leads to a stirring dead zone and an increase in the mixing uniformity; when the viscosity suddenly changes, the rotation speed is not dynamically adjusted, resulting in an increase in energy consumption; when the temperature exceeds the preset temperature, the decomposition reaction of ammonium nitrate accelerates, releasing gas, and the pressure in the tank rises suddenly. The change of liquid viscosity affects the heat distribution and conduction, and there is a problem of insufficient stability of the safety inspection method. Summary of the Invention

[0008] By providing a safety inspection method and device for automatic batching of the aqueous phase preparation tank of emulsion explosive, the embodiments of the present application solve the problem of low stability of the safety inspection method in the prior art and improve the stability of the safety inspection method.

[0009] The embodiments of the present application provide a safety inspection method for automatic batching of the aqueous phase preparation tank of emulsion explosive, including the following steps: collecting and processing the automatic batching data of the aqueous phase preparation tank of emulsion explosive; analyzing the automatic batching data of the aqueous phase preparation tank of emulsion explosive to obtain the evaluation values of mixing uniformity and energy consumption efficiency and the evaluation value of the timeliness of PID control response; comprehensively analyzing to obtain the safety inspection stability evaluation value of the automatic batching of the aqueous phase preparation tank; based on the comparison between the evaluation value and the threshold preset in the database, optimizing and adjusting the safety inspection method for automatic batching of the aqueous phase preparation tank of emulsion explosive.

[0010] Further, the specific steps of collecting and processing the automatic batching data of the aqueous phase preparation tank of emulsion explosive are as follows: through the Internet of Things technology, the sensor data is transmitted to the central control system in real time to collect the original data of the automatic batching of the aqueous phase preparation tank of emulsion explosive; cleaning and denoising the original data of the automatic batching of the aqueous phase preparation tank of emulsion explosive to obtain the automatic batching data of the aqueous phase preparation tank of emulsion explosive; the automatic batching data of the aqueous phase preparation tank of emulsion explosive includes mixing uniformity and energy consumption efficiency data, PID control response timeliness data, and temperature runaway frequency.

[0011] Further, the specific steps for obtaining the evaluation values of mixing uniformity and energy consumption efficiency are as follows: The mixing uniformity and energy consumption efficiency data include the stirring dead zone area, PID control response time, maximum temperature in the aqueous phase preparation tank, minimum temperature in the aqueous phase preparation tank, maximum amplitude of viscosity mutation of the emulsion explosive solution, minimum amplitude of viscosity mutation of the emulsion explosive solution, and mixing uniformity; Obtain the stirring dead zone area threshold, PID control response time threshold, standard value of temperature difference in the aqueous phase preparation tank, standard value of viscosity mutation amplitude difference of the emulsion explosive, mixing uniformity threshold, weight factor of the stirring dead zone area, weight factor of mixing uniformity, weight factor of PID control response time, weight factor of temperature difference coefficient, and weight factor of viscosity mutation coefficient of the emulsion explosive solution from the safety inspection database of the aqueous phase preparation tank; Conduct a ratio analysis of the stirring dead zone area and the stirring dead zone area threshold, perform an averaging process on the results of the ratio analysis, and use the weight factor of the stirring dead zone area to correct the results of the averaging process, denoted as the first component of the evaluation value of mixing uniformity and energy consumption efficiency; Conduct a ratio analysis of the PID control response time and the PID control response time threshold, and use the weight factor of the PID control response time to correct the results of the ratio analysis, denoted as the second component of the evaluation value of mixing uniformity and energy consumption efficiency; Conduct a ratio analysis of the deviation between the maximum temperature and the minimum temperature in the aqueous phase preparation tank and the standard value of temperature difference in the aqueous phase preparation tank, and use the weight factor of the temperature difference coefficient to correct the results of the ratio analysis, denoted as the temperature difference coefficient; Conduct a ratio analysis of the deviation between the maximum amplitude of viscosity mutation of the emulsion explosive solution and the minimum amplitude of viscosity mutation of the emulsion explosive solution and the standard value of viscosity mutation amplitude difference of the emulsion explosive, and use the weight factor of the viscosity mutation coefficient of the emulsion explosive solution to correct the results of the ratio analysis, denoted as the viscosity mutation coefficient of the emulsion explosive solution; Conduct a ratio analysis of the mixing uniformity and the mixing uniformity threshold, perform an averaging process on the results of the ratio analysis, and use the weight factor of mixing uniformity to correct the results of the averaging process, denoted as the third component of the evaluation value of mixing uniformity and energy consumption efficiency; Conduct a ratio analysis of the coupling result of the first component of the evaluation value of mixing uniformity and energy consumption efficiency, the second component of the evaluation value of mixing uniformity and energy consumption efficiency, the temperature difference coefficient, and the viscosity mutation coefficient of the emulsion explosive solution with the third component of the evaluation value of mixing uniformity and energy consumption efficiency to obtain the evaluation value of mixing uniformity and energy consumption efficiency; The evaluation value of mixing uniformity and energy consumption efficiency represents the quantitative data for dynamically adjusting the stirring speed.

[0012] Further, the specific steps for obtaining the PID control response timeliness evaluation value are as follows: The PID control response timeliness data includes the PID control response time, the steam valve adjustment lag time, the maximum stirring power in the aqueous phase preparation tank, the minimum stirring power in the aqueous phase preparation tank, the maximum amplitude of the viscosity mutation of the emulsion explosive solution, and the minimum amplitude of the viscosity mutation of the emulsion explosive solution; Obtain the PID control response time threshold, the steam valve adjustment lag time threshold, the standard value of the stirring power difference in the aqueous phase preparation tank, the standard value of the viscosity mutation amplitude difference of the emulsion explosive, the weight factor of the PID control response time, the weight factor of the steam valve adjustment lag time, the weight factor of the energy consumption change coefficient, and the weight factor of the viscosity mutation coefficient of the emulsion explosive solution from the safety inspection database of the aqueous phase preparation tank; Conduct a ratio analysis of the PID control response time threshold and the PID control response time, and use the weight factor of the PID control response time to correct the result of the ratio analysis, which is recorded as the first component of the PID control response timeliness evaluation value; Conduct a ratio analysis of the steam valve adjustment lag time threshold and the steam valve adjustment lag time, and use the weight factor of the steam valve adjustment lag time to correct the result of the ratio analysis, which is recorded as the second component of the PID control response timeliness evaluation value; Conduct a ratio analysis of the deviation between the maximum stirring power and the minimum stirring power in the aqueous phase preparation tank and the standard value of the stirring power difference in the aqueous phase preparation tank, and use the weight factor of the energy consumption change coefficient to correct the result of the ratio analysis, which is recorded as the energy consumption change coefficient; Conduct a ratio analysis of the deviation between the maximum amplitude of the viscosity mutation of the emulsion explosive solution and the minimum amplitude of the viscosity mutation of the emulsion explosive solution and the standard value of the viscosity mutation amplitude difference of the emulsion explosive, and use the weight factor of the viscosity mutation coefficient of the emulsion explosive solution to correct the result of the ratio analysis, which is recorded as the viscosity mutation coefficient of the emulsion explosive solution; Conduct a ratio analysis of the coupling result of the first component and the second component of the PID control response timeliness evaluation value and the coupling result of the energy consumption change coefficient and the viscosity mutation coefficient of the emulsion explosive solution to obtain the PID control response timeliness evaluation value; The PID control response timeliness evaluation value represents the response speed of the control system and reflects its ability to handle emergencies.

[0013] Further, the specific steps for comprehensively analyzing and obtaining the stability evaluation value of the automatic batching safety inspection of the aqueous phase preparation tank are as follows: Obtain the temperature runaway frequency threshold, the weight factor of the PID control response timeliness evaluation value, the weight factors of the mixing uniformity and energy consumption efficiency evaluation values, and the weight factor of the temperature runaway frequency from the safety inspection database of the aqueous phase preparation tank; Average the PID control response timeliness evaluation value, and use the weight factor of the PID control response timeliness evaluation value to correct the averaged result, denoted as the first component of the stability evaluation value of the automatic batching safety inspection of the aqueous phase preparation tank; Average the mixing uniformity and energy consumption efficiency evaluation values, and use the weight factors of the mixing uniformity and energy consumption efficiency evaluation values to correct the averaged result, denoted as the second component of the stability evaluation value of the automatic batching safety inspection of the aqueous phase preparation tank; Analyze the ratio of the temperature runaway frequency to the temperature runaway frequency threshold, average the result of the ratio analysis, and use the weight factor of the temperature runaway frequency to correct the averaged result, denoted as the third component of the stability evaluation value of the automatic batching safety inspection of the aqueous phase preparation tank; Analyze the ratio of the coupling result of the first component of the stability evaluation value of the automatic batching safety inspection of the aqueous phase preparation tank, the second component of the stability evaluation value of the automatic batching safety inspection of the aqueous phase preparation tank, and the third component of the stability evaluation value of the automatic batching safety inspection of the aqueous phase preparation tank, and comprehensively analyze to obtain the stability evaluation value of the automatic batching safety inspection of the aqueous phase preparation tank; The stability evaluation value of the automatic batching safety inspection of the aqueous phase preparation tank represents the quantitative data of the stability of the aqueous phase preparation tank during the automatic batching process.

[0014] Further, the specific steps for optimizing and adjusting the automatic batching safety inspection method for the aqueous phase preparation tank of emulsion explosives are as follows: Obtain the first threshold of the PID control response timeliness evaluation value, the second threshold of the mixing uniformity and energy consumption efficiency evaluation value, and the comprehensive threshold of the stability evaluation value of the automatic batching safety inspection of the aqueous phase preparation tank from the database; Compare and analyze the PID control response timeliness evaluation value, the mixing uniformity and energy consumption efficiency evaluation value, the stability evaluation value of the automatic batching safety inspection of the aqueous phase preparation tank with the first threshold of the PID control response timeliness evaluation value, the second threshold of the mixing uniformity and energy consumption efficiency evaluation value, and the comprehensive threshold of the stability evaluation value of the automatic batching safety inspection of the aqueous phase preparation tank to obtain the optimized and adjusted automatic batching safety inspection method for the aqueous phase preparation tank of emulsion explosives; The optimized and adjusted automatic batching safety inspection method for the aqueous phase preparation tank of emulsion explosives includes the PID control response timeliness optimization method, the mixing uniformity and energy consumption efficiency optimization method, and the stability optimization method of the automatic batching safety inspection of the aqueous phase preparation tank.

[0015] Further, the specific steps of the PID control response timeliness optimization method are as follows: If the PID control response timeliness evaluation value is greater than or equal to the first threshold of the PID control response timeliness evaluation value, there is no need to perform the PID control response timeliness optimization method; if the PID control response timeliness evaluation value is less than the first threshold of the PID control response timeliness evaluation value, adjust the PID parameters to improve the response speed to temperature and viscosity mutations; design an emergency stop logic and set the trigger conditions for the maximum and minimum thresholds of temperature, pressure, and viscosity.

[0016] Further, the specific steps of the mixing uniformity and energy consumption efficiency optimization method are as follows: If the mixing uniformity and energy consumption efficiency evaluation value is lower than or equal to the second threshold of the mixing uniformity and energy consumption efficiency evaluation value, there is no need to perform the mixing uniformity and energy consumption efficiency optimization method; if the mixing uniformity and energy consumption efficiency evaluation value is higher than the second threshold of the mixing uniformity and energy consumption efficiency evaluation value, simulate the automatic batching process of the aqueous phase preparation tank of emulsion explosive by using CFD software and set parameters according to the actual safety inspection; identify the dead zones and high-temperature points in the automatic batching process of the aqueous phase preparation tank of emulsion explosive by analyzing the fused data; adjust the output frequency of the frequency converter in real time according to the output of the PID control algorithm to control the rotation speed of the stirring equipment.

[0017] Further, the specific steps of the automatic batching safety inspection stability optimization method for the aqueous phase preparation tank are as follows: If the automatic batching safety inspection stability evaluation value of the aqueous phase preparation tank is greater than or equal to the comprehensive threshold of the automatic batching safety inspection stability evaluation value of the aqueous phase preparation tank, there is no need to perform the automatic batching safety inspection stability optimization method for the aqueous phase preparation tank; if the automatic batching safety inspection stability evaluation value of the aqueous phase preparation tank is less than the comprehensive threshold of the automatic batching safety inspection stability evaluation value of the aqueous phase preparation tank, monitor the temperature and viscosity of each area in real time for abnormal positioning; correct the automatic batching safety inspection data of the aqueous phase preparation tank through model predictive control; dynamically adjust the automatic batching safety inspection path of the aqueous phase preparation tank by correcting the automatic batching safety inspection data of the aqueous phase preparation tank.

[0018] The embodiment of the present application provides an automatic batching safety inspection device for the aqueous phase preparation tank of emulsion explosive, including: recording the time series data of temperature and control signals through a data recorder; collecting the temperature inside the aqueous phase preparation tank through a temperature sensor; measuring the viscosity of the emulsion explosive solution through a capillary viscometer; collecting the stirring power inside the aqueous phase preparation tank through a power sensor.

[0019] One or more technical solutions provided in the embodiment of the present application have at least the following technical effects or advantages:

[0020] 1. By collecting and processing the automatic batching data of the aqueous phase preparation tank for emulsion explosives, analyzing the automatic batching data of the aqueous phase preparation tank for emulsion explosives, obtaining the evaluation values of mixing uniformity, energy consumption efficiency, and the evaluation value of the timeliness of PID control response, comprehensively analyzing and optimizing the adjustment, the stability of the safety inspection method is improved, and the problem of low stability of the safety inspection method in the existing technology is solved.

[0021] 2. By analyzing the automatic batching data of the aqueous phase preparation tank for emulsion explosives, obtaining the evaluation values of mixing uniformity, energy consumption efficiency, and the evaluation value of the timeliness of PID control response, thus ensuring the uniform distribution of each component of the aqueous solution, avoiding performance instability caused by too high or too low local concentration, and further reducing energy consumption and production costs.

[0022] 3. By comprehensively analyzing to obtain the stability evaluation value of the automatic batching safety inspection of the aqueous phase preparation tank and optimizing the safety inspection method for the automatic batching of the aqueous phase preparation tank for emulsion explosives, potential safety hazards such as abnormal temperature and pressure fluctuations are discovered, and preventive measures are taken to reduce the risk of accidents. Description of the Drawings

[0023] Figure 1 It is the flowchart of the safety inspection method for the automatic batching of the aqueous phase preparation tank for emulsion explosives provided by the embodiment of the present application;

[0024] Figure 2 It is the schematic diagram of the viscosity-time change curve of the emulsion explosive solution provided by the embodiment of the present application. Detailed Embodiments

[0025] The embodiment of the present application provides a safety inspection method and equipment for the automatic batching of the aqueous phase preparation tank for emulsion explosives, solves the problem of low stability of the safety inspection method in the existing technology, collects and processes the automatic batching data of the aqueous phase preparation tank for emulsion explosives, analyzes the automatic batching data of the aqueous phase preparation tank for emulsion explosives, obtains the evaluation values of mixing uniformity, energy consumption efficiency, and the evaluation value of the timeliness of PID control response, and comprehensively analyzes and optimizes the adjustment to improve the stability of the safety inspection method.

[0026] The technical solution in the embodiment of the present application is to solve the above problem of low stability of the safety inspection method, and the general idea is as follows:

[0027] By collecting and processing the automatic batching data of the aqueous phase preparation tank for emulsion explosives, analyzing the automatic batching data of the aqueous phase preparation tank for emulsion explosives, obtaining the evaluation values of mixing uniformity, energy consumption efficiency, and the evaluation value of the timeliness of PID control response, and comprehensively analyzing and optimizing the adjustment to improve the stability of the safety inspection method.

[0028] To better understand the above technical solution, the above technical solution will be described in detail below in conjunction with the accompanying drawings of the specification and specific embodiments.

[0029] As Figure 1 shown, it is a flowchart of an automatic batching safety inspection method for the aqueous phase preparation tank of emulsion explosives provided by an embodiment of the present application. This method is applied to the automatic batching safety inspection method and equipment for the aqueous phase preparation tank of emulsion explosives. The method includes the following steps: collecting and processing the automatic batching data of the aqueous phase preparation tank of emulsion explosives; analyzing the automatic batching data of the aqueous phase preparation tank of emulsion explosives to obtain the evaluation values of mixing uniformity and energy consumption efficiency and the evaluation value of PID control response timeliness; comprehensively analyzing to obtain the stability evaluation value of the automatic batching safety inspection of the aqueous phase preparation tank; based on the comparison between the evaluation value and the preset threshold value in the database, optimizing and adjusting the automatic batching safety inspection method for the aqueous phase preparation tank of emulsion explosives.

[0030] In this embodiment, when automatically batching the aqueous phase of the emulsion explosive preparation tank, the core goal of the central control system to dynamically adjust the raw material quantity is to control the viscosity of the emulsion explosive within the preset threshold by compensating the influence of temperature and time in real time, and to avoid the stratification of the emulsion or uneven sensitization caused by abnormal viscosity of the emulsion explosive. As shown in Table 1, Figure 2 shown, the horizontal axis (X-axis) is time (minutes), ranging from 0 to 60 minutes, and is divided into three stages according to the process, namely 0-20 minutes: raw material dissolution stage; 20-40 minutes: heating stage; 40-60 minutes: emulsification stage; the vertical axis (Y-axis) is the viscosity (cP) of the emulsion explosive solution, logarithmic scale (to adapt to a large viscosity range), ranging from 0 to 10,000 cP;

[0031] Table 1 Emulsion explosive solution viscosity change status table

[0032]

[0033] Further, the specific steps of collecting and processing the automatic batching data of the aqueous phase preparation tank of emulsion explosives are as follows: through the Internet of Things technology, real-time transmit the sensor data to the central control system to collect the original data of the automatic batching of the aqueous phase preparation tank of emulsion explosives; clean and denoise the original data of the automatic batching of the aqueous phase preparation tank of emulsion explosives to obtain the automatic batching data of the aqueous phase preparation tank of emulsion explosives; the automatic batching data of the aqueous phase preparation tank of emulsion explosives includes mixing uniformity and energy consumption efficiency data, PID control response timeliness data, and temperature out-of-control frequency.

[0034] Further, the specific steps to obtain the evaluation values of mixing uniformity and energy consumption efficiency are as follows: The mixing uniformity and energy consumption efficiency data include the stirring dead zone area, PID control response time, maximum temperature in the aqueous phase preparation tank, minimum temperature in the aqueous phase preparation tank, maximum amplitude of viscosity mutation of the emulsion explosive solution, minimum amplitude of viscosity mutation of the emulsion explosive solution, and mixing uniformity; Obtain the stirring dead zone area threshold, PID control response time threshold, standard value of temperature difference in the aqueous phase preparation tank, standard value of viscosity mutation amplitude difference of the emulsion explosive, mixing uniformity threshold, weight factor of the stirring dead zone area, weight factor of mixing uniformity, weight factor of PID control response time, weight factor of temperature difference coefficient, and weight factor of viscosity mutation coefficient of the emulsion explosive solution from the safety inspection database of the aqueous phase preparation tank; Conduct a ratio analysis of the stirring dead zone area and the stirring dead zone area threshold, average the results of the ratio analysis, and correct the results of the averaging process using the weight factor of the stirring dead zone area, which is denoted as the first component of the evaluation value of mixing uniformity and energy consumption efficiency; Conduct a ratio analysis of the PID control response time and the PID control response time threshold, and correct the results of the ratio analysis using the weight factor of the PID control response time, which is denoted as the second component of the evaluation value of mixing uniformity and energy consumption efficiency; Conduct a ratio analysis of the deviation between the maximum temperature and the minimum temperature in the aqueous phase preparation tank and the standard value of temperature difference in the aqueous phase preparation tank, and correct the results of the ratio analysis using the weight factor of the temperature difference coefficient, which is denoted as the temperature difference coefficient; Conduct a ratio analysis of the deviation between the maximum amplitude of viscosity mutation and the minimum amplitude of viscosity mutation of the emulsion explosive solution and the standard value of viscosity mutation amplitude difference of the emulsion explosive, and correct the results of the ratio analysis using the weight factor of the viscosity mutation coefficient of the emulsion explosive solution, which is denoted as the viscosity mutation coefficient of the emulsion explosive solution; Conduct a ratio analysis of the mixing uniformity and the mixing uniformity threshold, average the results of the ratio analysis, and correct the results of the averaging process using the weight factor of mixing uniformity, which is denoted as the third component of the evaluation value of mixing uniformity and energy consumption efficiency; Conduct a ratio analysis of the coupling result of the first component of the evaluation value of mixing uniformity and energy consumption efficiency, the second component of the evaluation value of mixing uniformity and energy consumption efficiency, the temperature difference coefficient, and the viscosity mutation coefficient of the emulsion explosive solution and the third component of the evaluation value of mixing uniformity and energy consumption efficiency to obtain the evaluation value of mixing uniformity and energy consumption efficiency; The evaluation value of mixing uniformity and energy consumption efficiency represents the quantitative data for dynamically adjusting the stirring speed.

[0035] In this embodiment, the specific method for analyzing and obtaining the evaluation values of mixing uniformity and energy consumption efficiency is as follows:

[0036]

[0037]

[0038] The preset mixing uniformity and energy consumption efficiency detection points are numbered in sequence. S0 represents the number of the mixing uniformity and energy consumption efficiency detection point under the T0-th mixing uniformity and energy consumption efficiency detection segment, S0 = 1, 2,..., S, where S represents the total number of mixing uniformity and energy consumption efficiency detection points.

[0039] The preset mixing uniformity and energy consumption efficiency time is divided into mixing uniformity and energy consumption efficiency detection segments of the same time length. T0 represents the number of the mixing uniformity and energy consumption efficiency detection segment, T0 = 1, 2,..., T, where T represents the total number of mixing uniformity and energy consumption efficiency detection segments.

[0040] Represents the mixing uniformity and energy consumption efficiency evaluation value of the T0-th mixing uniformity and energy consumption efficiency detection segment.

[0041] Represents the area of the stirring dead zone under the S0-th mixing uniformity and energy consumption efficiency detection point. It is the area of the region that is not fully mixed during the stirring process. The fluid visualization technology is used to observe and measure the flow of the fluid in the aqueous phase preparation tank, generate a flow field image, extract the dead zone region through image processing software, calculate the number of pixels, and then convert it to the actual area according to the scale to determine the area of the stirring dead zone.

[0042] G0 represents the threshold of the stirring dead zone area, which is a preset stirring dead zone area threshold obtained from the safety inspection database of the aqueous phase preparation tank. It can be the average value of the stirring dead zone areas under the preset historical mixing uniformity and energy consumption efficiency detection points in the safety inspection database of the aqueous phase preparation tank.

[0043] Represents the PID control response time under the T0-th mixing uniformity and energy consumption efficiency detection segment, which is the time delay from the temperature mutation to the start of the PID controller response. The time series data of the temperature and control signal are recorded by a data logger.

[0044] Z0 represents the threshold of the PID control response time, which is a preset PID control response time threshold obtained from the safety inspection database of the aqueous phase preparation tank. It can be the average value of the PID control response times under the preset historical mixing uniformity and energy consumption efficiency detection segments in the safety inspection database of the aqueous phase preparation tank.

[0045] Represents the temperature difference coefficient under the T0-th mixing uniformity and energy consumption efficiency detection segment.

[0046] Represents the viscosity mutation coefficient of the emulsion explosive solution under the T0-th mixing uniformity and energy consumption efficiency detection segment.

[0047] It represents the maximum temperature in the aqueous phase preparation tank under the T0th mixing uniformity and energy consumption efficiency detection section, which is collected by a temperature sensor.

[0048] It represents the minimum temperature in the aqueous phase preparation tank under the T0th mixing uniformity and energy consumption efficiency detection section.

[0049] ΔW represents the standard value of the temperature difference in the aqueous phase preparation tank, which is a preset standard value of the temperature difference in the aqueous phase preparation tank obtained from the safety inspection database of the aqueous phase preparation tank. It can be the average value of the temperature difference in the aqueous phase preparation tank under the preset historical mixing uniformity and energy consumption efficiency detection section in the safety inspection database of the aqueous phase preparation tank.

[0050] It represents the maximum amplitude of the viscosity mutation of the emulsion explosive solution under the T0th mixing uniformity and energy consumption efficiency detection section. The viscosity of the emulsion explosive solution is measured by a capillary viscometer.

[0051] It represents the minimum amplitude of the viscosity mutation of the emulsion explosive solution under the T0th mixing uniformity and energy consumption efficiency detection section.

[0052] ΔF represents the standard value of the amplitude difference of the viscosity mutation of the emulsion explosive, which is a preset standard value of the amplitude difference of the viscosity mutation of the emulsion explosive obtained from the safety inspection database of the aqueous phase preparation tank. It can be the average value of the amplitude difference of the viscosity mutation of the emulsion explosive under the preset historical mixing uniformity and energy consumption efficiency detection section in the safety inspection database of the aqueous phase preparation tank.

[0053] It represents the mixing uniformity under the S0th mixing uniformity and energy consumption efficiency detection point, which is collected by a chemical analysis instrument such as high performance liquid chromatography.

[0054] D0 represents the mixing uniformity threshold, which is a preset mixing uniformity threshold obtained from the safety inspection database of the aqueous phase preparation tank. It can be the average value of the mixing uniformity under the preset historical mixing uniformity and energy consumption efficiency detection section in the safety inspection database of the aqueous phase preparation tank.

[0055] It is a preset stirring dead zone area weight factor obtained from the safety inspection database of the aqueous phase preparation tank.

[0056] It is a preset mixing uniformity weight factor obtained from the safety inspection database of the aqueous phase preparation tank.

[0057] It is a preset PID control response time weight factor obtained from the safety inspection database of the aqueous phase preparation tank.

[0058] is the preset temperature difference coefficient weight factor obtained from the safety inspection database of the aqueous phase preparation tank.

[0059] is the preset viscosity mutation coefficient weight factor of the emulsion explosive solution obtained from the safety inspection database of the aqueous phase preparation tank.

[0060] Obtain the mapping table of weight factors through the database, and quickly extract the corresponding weight factors according to the current stirring dead zone area, mixing uniformity, PID control response time, temperature difference coefficient, and viscosity mutation coefficient of the emulsion explosive solution, such as the weight factor of the stirring dead zone area, the weight factor of mixing uniformity, the weight factor of PID control response time, the weight factor of temperature difference coefficient, and the weight factor of viscosity mutation coefficient of the emulsion explosive solution. For example, this mapping table defines a clear set of association rules that convert the specific values of the stirring dead zone area, mixing uniformity, PID control response time, temperature difference coefficient, and viscosity mutation coefficient of the emulsion explosive solution into their corresponding weight factors. Under this mechanism, whether it is to achieve a one-to-one exact match or a many-to-one relationship where multiple parameters converge into a single weight, the dynamic acquisition of weight factors can be effectively achieved.

[0061] The larger the stirring dead zone area, the more areas that are not fully mixed during the stirring process, resulting in a decrease in mixing uniformity; the mixing uniformity is affected by the control of the stirring process. The shorter the PID control response time, the faster and more accurate the temperature control, which helps to maintain stable stirring conditions and thus improve the mixing uniformity; the greater the difference between the maximum temperature and the minimum temperature in the aqueous phase preparation tank, it causes local overheating or overcooling, affecting the dissolution and dispersion of components, thus reducing the mixing uniformity; the greater the difference between the maximum temperature and the minimum temperature in the aqueous phase preparation tank, the greater the difference between the maximum amplitude of the viscosity mutation of the emulsion explosive solution and the minimum amplitude of the viscosity mutation of the emulsion explosive solution, because temperature affects the viscosity of the solution, the viscosity decreases with increasing temperature and increases with decreasing temperature; the shorter the PID control response time, it helps to quickly adjust the temperature and maintain the stability of the temperature in the aqueous phase preparation tank.

[0062] There is a positive correlation between the stirring dead zone area and the evaluation values of mixing uniformity and energy consumption efficiency. The larger the stirring dead zone area, the lower the mixing uniformity. The larger the stirring dead zone area, the larger the evaluation values of mixing uniformity and energy consumption efficiency. There is a negative correlation between the mixing uniformity and the evaluation values of mixing uniformity and energy consumption efficiency. The larger the mixing uniformity, the more effective the stirring process. The larger the mixing uniformity, the smaller the evaluation values of mixing uniformity and energy consumption efficiency. There is a positive correlation between the PID control response time and the evaluation values of mixing uniformity and energy consumption efficiency. If the PID control response time is too long, the temperature control is inaccurate, resulting in temperature fluctuations during the mixing process. The larger the PID control response time, the larger the evaluation values of mixing uniformity and energy consumption efficiency. There is a positive correlation between the temperature difference coefficient and the evaluation values of mixing uniformity and energy consumption efficiency. The larger the temperature difference coefficient, the greater the temperature difference in the aqueous phase preparation tank. The larger the temperature difference coefficient, the larger the evaluation values of mixing uniformity and energy consumption efficiency. There is a positive correlation between the viscosity mutation coefficient of the emulsion explosive solution and the evaluation values of mixing uniformity and energy consumption efficiency. The larger the viscosity mutation coefficient of the emulsion explosive solution, the more unstable the solution properties, increasing the load of the stirring equipment and the mixing non-uniformity. The larger the viscosity mutation coefficient of the emulsion explosive solution, the larger the evaluation values of mixing uniformity and energy consumption efficiency.

[0063] Further, the specific steps to obtain the PID control response timeliness evaluation value are as follows: The PID control response timeliness data includes the PID control response time, the steam valve adjustment lag time, the maximum stirring power in the aqueous phase preparation tank, the minimum stirring power in the aqueous phase preparation tank, the maximum amplitude of the viscosity mutation of the emulsion explosive solution, and the minimum amplitude of the viscosity mutation of the emulsion explosive solution; Obtain the PID control response time threshold, the steam valve adjustment lag time threshold, the standard value of the stirring power difference in the aqueous phase preparation tank, the standard value of the viscosity mutation amplitude difference of the emulsion explosive, the weight factor of the PID control response time, the weight factor of the steam valve adjustment lag time, the weight factor of the energy consumption change coefficient, and the weight factor of the viscosity mutation coefficient of the emulsion explosive solution from the safety inspection database of the aqueous phase preparation tank; Conduct a ratio analysis of the PID control response time threshold and the PID control response time, and use the weight factor of the PID control response time to correct the result of the ratio analysis, denoted as the first component of the PID control response timeliness evaluation value; Conduct a ratio analysis of the steam valve adjustment lag time threshold and the steam valve adjustment lag time, and use the weight factor of the steam valve adjustment lag time to correct the result of the ratio analysis, denoted as the second component of the PID control response timeliness evaluation value; Conduct a ratio analysis of the deviation between the maximum stirring power and the minimum stirring power in the aqueous phase preparation tank and the standard value of the stirring power difference in the aqueous phase preparation tank, and use the weight factor of the energy consumption change coefficient to correct the result of the ratio analysis, denoted as the energy consumption change coefficient; Conduct a ratio analysis of the deviation between the maximum amplitude of the viscosity mutation of the emulsion explosive solution and the minimum amplitude of the viscosity mutation of the emulsion explosive solution and the standard value of the viscosity mutation amplitude difference of the emulsion explosive, and use the weight factor of the viscosity mutation coefficient of the emulsion explosive solution to correct the result of the ratio analysis, denoted as the viscosity mutation coefficient of the emulsion explosive solution; Conduct a ratio analysis of the coupling result of the first component of the PID control response timeliness evaluation value and the second component of the PID control response timeliness evaluation value and the coupling result of the energy consumption change coefficient and the viscosity mutation coefficient of the emulsion explosive solution to obtain the PID control response timeliness evaluation value; The PID control response timeliness evaluation value represents the response speed of the control system and reflects its ability to handle emergencies.

[0064] In this embodiment, the specific method for analyzing and obtaining the PID control response timeliness evaluation value is as follows:

[0065]

[0066] ρ1 + ρ2 + ρ3 + ρ4 = 1;

[0067] Number the preset PID control response timeliness detection segments in sequence. N0 represents the number of the PID control response timeliness detection segment, N0 = 1, 2,..., N, and N represents the total number of the numbers of the PID control response timeliness detection segments.

[0068] It represents the evaluation value of the PID control response timeliness for the N0th PID control response timeliness detection segment.

[0069] Q0 represents the PID control response time threshold, which is a preset PID control response time threshold obtained from the safety inspection database of the aqueous phase preparation tank. It can be the average value of the PID control response time under the preset historical PID control response timeliness detection segments in the safety inspection database of the aqueous phase preparation tank.

[0070] It represents the PID control response time under the N0th PID control response timeliness detection segment.

[0071] P0 represents the steam valve adjustment lag time threshold, which is a preset steam valve adjustment lag time threshold obtained from the safety inspection database of the aqueous phase preparation tank. It can be the average value of the steam valve adjustment lag time under the preset historical PID control response timeliness detection segments in the safety inspection database of the aqueous phase preparation tank.

[0072] It represents the steam valve adjustment lag time under the N0th PID control response timeliness detection segment, and the steam valve adjustment lag time is obtained through the system log.

[0073] It represents the energy consumption change coefficient under the N0th PID control response timeliness detection segment.

[0074] It represents the viscosity mutation coefficient of the emulsion explosive solution under the N0th PID control response timeliness detection segment.

[0075] It represents the maximum stirring power in the aqueous phase preparation tank under the N0th PID control response timeliness detection segment, which is obtained by real-time monitoring and collection through a power sensor.

[0076] It represents the minimum stirring power in the aqueous phase preparation tank under the N0th PID control response timeliness detection segment.

[0077] ΔR represents the standard value of the stirring power difference in the aqueous phase preparation tank, which is a preset standard value of the stirring power difference in the aqueous phase preparation tank obtained from the safety inspection database of the aqueous phase preparation tank. It can be the average value of the stirring power difference in the aqueous phase preparation tank under the preset historical PID control response timeliness detection segments in the safety inspection database of the aqueous phase preparation tank.

[0078] It represents the maximum amplitude of the viscosity mutation of the emulsion explosive solution under the N0th PID control response timeliness detection segment.

[0079] It represents the minimum amplitude of viscosity mutation of the emulsion explosive solution under the N0th PID control response timeliness detection segment.

[0080] ΔH represents the standard value of the viscosity mutation amplitude difference of the emulsion explosive, which is the preset standard value of the viscosity mutation amplitude difference of the emulsion explosive obtained from the safety inspection database of the aqueous phase preparation tank, and can be the average value of the viscosity mutation amplitude difference of the emulsion explosive under the preset historical PID control response timeliness detection segment in the safety inspection database of the aqueous phase preparation tank.

[0081] ρ1 is the preset PID control response time weight factor obtained from the safety inspection database of the aqueous phase preparation tank.

[0082] ρ2 is the preset steam valve adjustment lag time weight factor obtained from the safety inspection database of the aqueous phase preparation tank.

[0083] ρ3 is the preset energy consumption change coefficient weight factor obtained from the safety inspection database of the aqueous phase preparation tank.

[0084] ρ4 is the preset emulsion explosive solution viscosity mutation coefficient weight factor obtained from the safety inspection database of the aqueous phase preparation tank.

[0085] By obtaining the mapping table of the weight factors from the database, the corresponding weight factors can be quickly extracted according to the current PID control response time, steam valve adjustment lag time, energy consumption change coefficient, and emulsion explosive solution viscosity mutation coefficient, such as the weight factor of the PID control response time, the weight factor of the steam valve adjustment lag time, the weight factor of the energy consumption change coefficient, and the weight factor of the emulsion explosive solution viscosity mutation coefficient. For example, this mapping table defines a clear set of association rules, which converts the specific values of the PID control response time, steam valve adjustment lag time, energy consumption change coefficient, and emulsion explosive solution viscosity mutation coefficient into their corresponding weight factors. Under this mechanism, whether it is to achieve an exact one-to-one match or a one-to-many relationship where multiple parameters converge into a single weight, the dynamic acquisition of the weight factors can be effectively achieved.

[0086] The longer the steam valve adjustment lag time, it means the shorter the time interval between the valve receiving the control signal and the valve actually starting to act, then the longer the PID control response time; the energy consumption change coefficient reflects the degree of energy consumption fluctuation during the process. A short PID control response time means that the temperature control is more rapid, reducing the additional energy consumption caused by temperature fluctuations, thereby reducing the energy consumption change coefficient; the longer the steam valve adjustment lag time, it leads to untimely temperature control, resulting in too high or too low temperature, and additional energy is required to correct it, thereby increasing the energy consumption change coefficient; the larger the emulsion explosive solution viscosity mutation coefficient, it indicates that the solution viscosity fluctuates greatly, affecting the load of the stirring equipment, resulting in energy consumption fluctuations, thereby increasing the energy consumption change coefficient.

[0087] There is a negative correlation between the PID control response time and the evaluation value of the PID control response timeliness. The shorter the PID control response time, the faster the controller reacts to the change of the set value. The longer the PID control response time, the smaller the evaluation value of the PID control response timeliness. There is a negative correlation between the steam valve adjustment lag time and the evaluation value of the PID control response timeliness. The shorter the steam valve adjustment lag time, the faster the valve reacts to the control signal. The longer the steam valve adjustment lag time, the smaller the evaluation value of the PID control response timeliness. There is a negative correlation between the energy consumption change coefficient and the evaluation value of the PID control response timeliness. A small energy consumption change coefficient indicates small energy consumption fluctuations during the process, usually meaning that the control system is stable and the response is timely. The larger the energy consumption change coefficient, the smaller the evaluation value of the PID control response timeliness. There is a negative correlation between the energy consumption change coefficient and the evaluation value of the PID control response timeliness. A small viscosity mutation coefficient indicates stable solution viscosity, and the control system adjusts to the viscosity change timely and effectively. The larger the energy consumption change coefficient, the smaller the evaluation value of the PID control response timeliness.

[0088] Furthermore, the specific steps for comprehensively analyzing and obtaining the stability evaluation value of the automatic batching safety inspection of the aqueous phase preparation tank are as follows: Obtain the temperature runaway frequency threshold, the weight factor of the PID control response timeliness evaluation value, the weight factors of the mixing uniformity and energy consumption efficiency evaluation values, and the weight factor of the temperature runaway frequency from the safety inspection database of the aqueous phase preparation tank; Average the PID control response timeliness evaluation value, and use the weight factor of the PID control response timeliness evaluation value to correct the averaged result, which is denoted as the first component of the stability evaluation value of the automatic batching safety inspection of the aqueous phase preparation tank; Average the mixing uniformity and energy consumption efficiency evaluation values, and use the weight factors of the mixing uniformity and energy consumption efficiency evaluation values to correct the averaged result, which is denoted as the second component of the stability evaluation value of the automatic batching safety inspection of the aqueous phase preparation tank; Analyze the ratio of the temperature runaway frequency to the temperature runaway frequency threshold, average the result of the ratio analysis, and use the weight factor of the temperature runaway frequency to correct the averaged result, which is denoted as the third component of the stability evaluation value of the automatic batching safety inspection of the aqueous phase preparation tank; Analyze the ratio of the coupling result of the first component, the second component, and the third component of the stability evaluation value of the automatic batching safety inspection of the aqueous phase preparation tank, and comprehensively analyze to obtain the stability evaluation value of the automatic batching safety inspection of the aqueous phase preparation tank; The stability evaluation value of the automatic batching safety inspection of the aqueous phase preparation tank represents the quantitative data of the stability of the aqueous phase preparation tank during the automatic batching process.

[0089] In this embodiment, the specific method for analyzing and obtaining the mixing uniformity and energy consumption efficiency evaluation values is as follows:

[0090]

[0091] Number the automatic batching safety inspection stability detection points of the preset aqueous phase preparation tank in sequence. K0 represents the number of the automatic batching safety inspection stability detection points of the aqueous phase preparation tank, K0 = 1, 2,..., K, and K represents the total number of the automatic batching safety inspection stability detection points of the aqueous phase preparation tank.

[0092] δ represents the automatic batching safety inspection stability evaluation value of the aqueous phase preparation tank.

[0093] represents the PID control response timeliness evaluation value of the N0th PID control response timeliness detection segment.

[0094] represents the mixing uniformity and energy consumption efficiency evaluation values of the T0th mixing uniformity and energy consumption efficiency detection segment.

[0095] represents the temperature runaway frequency under the K0th automatic batching safety inspection stability detection point of the aqueous phase preparation tank, and the temperature runaway frequency is collected by an infrared temperature sensor.

[0096] φ0 represents the temperature runaway frequency threshold, which is a preset temperature runaway frequency threshold obtained from the safety inspection database of the aqueous phase preparation tank, and can be the average value of the temperature runaway frequencies under the preset historical automatic batching safety inspection stability detection points of the aqueous phase preparation tank in the safety inspection database of the aqueous phase preparation tank.

[0097] is a preset PID control response timeliness evaluation value weight factor obtained from the safety inspection database of the aqueous phase preparation tank.

[0098] is a preset mixing uniformity and energy consumption efficiency evaluation value weight factor obtained from the safety inspection database of the aqueous phase preparation tank.

[0099] is a preset temperature runaway frequency weight factor obtained from the safety inspection database of the aqueous phase preparation tank.

[0100] Obtain the mapping table of weight factors through the database, and quickly extract the corresponding weight factors according to the current PID control response timeliness evaluation value, mixing uniformity, energy consumption efficiency evaluation value, and temperature runaway frequency, such as the weight factor of the PID control response timeliness evaluation value, the weight factor of the mixing uniformity and energy consumption efficiency evaluation value, and the weight factor of the temperature runaway frequency. For example, this mapping table defines a clear set of association rules that convert the specific values of the PID control response timeliness evaluation value, mixing uniformity, energy consumption efficiency evaluation value, and temperature runaway frequency into their corresponding weight factors. Under this mechanism, whether it is to achieve an exact one-to-one match or a one-to-many relationship where multiple parameters converge into a single weight, the dynamic acquisition of weight factors can be effectively achieved.

[0101] The higher the PID control response timeliness evaluation value, the faster the parameters such as stirring speed and temperature can be adjusted to adapt to the changes in the mixing process, which helps to improve the mixing uniformity, and the smaller the mixing uniformity and energy consumption efficiency evaluation value; the lower the temperature runaway frequency indicates stable temperature control, which is conducive to maintaining a constant mixing condition, thereby improving the mixing uniformity, and the smaller the mixing uniformity and energy consumption efficiency evaluation value; the higher the PID control response timeliness evaluation value, the faster the temperature deviation can be corrected, reducing the frequency of temperature runaway, and the lower the temperature runaway frequency.

[0102] There is a positive correlation between the PID control response timeliness evaluation value and the stability evaluation value of the automatic batching safety inspection of the aqueous phase preparation tank. The larger the PID control response timeliness evaluation value, the faster the process parameters can be adjusted to maintain the stability of the batching process and reduce the safety risks caused by untimely control. The larger the PID control response timeliness evaluation value, the larger the stability evaluation value of the automatic batching safety inspection of the aqueous phase preparation tank; there is a negative correlation between the mixing uniformity and energy consumption efficiency evaluation value and the stability evaluation value of the automatic batching safety inspection of the aqueous phase preparation tank. The larger the mixing uniformity and energy consumption efficiency evaluation value, it means that the distribution is uneven during the batching process, increasing the potential safety risks caused by uneven mixing. The higher the mixing uniformity and energy consumption efficiency evaluation value, the lower the stability evaluation value of the automatic batching safety inspection of the aqueous phase preparation tank; there is a negative correlation between the temperature runaway frequency and the stability evaluation value of the automatic batching safety inspection of the aqueous phase preparation tank. The larger the temperature runaway frequency, it means that the temperature control is unstable, which may cause changes in the material properties during the batching process. The higher the temperature runaway frequency, the lower the stability evaluation value of the automatic batching safety inspection of the aqueous phase preparation tank.

[0103] Further, the specific steps for optimizing the automatic batching safety inspection method for the aqueous phase preparation tank of emulsion explosives are as follows: Obtain the first threshold of the PID control response timeliness evaluation value, the second threshold of the mixing uniformity and energy consumption efficiency evaluation value, and the comprehensive threshold of the automatic batching safety inspection stability evaluation value of the aqueous phase preparation tank from the database; Compare and analyze the PID control response timeliness evaluation value, the mixing uniformity and energy consumption efficiency evaluation value, and the automatic batching safety inspection stability evaluation value of the aqueous phase preparation tank with the first threshold of the PID control response timeliness evaluation value, the second threshold of the mixing uniformity and energy consumption efficiency evaluation value, and the comprehensive threshold of the automatic batching safety inspection stability evaluation value of the aqueous phase preparation tank to obtain the optimized automatic batching safety inspection method for the aqueous phase preparation tank of emulsion explosives; The optimized automatic batching safety inspection method for the aqueous phase preparation tank of emulsion explosives includes the PID control response timeliness optimization method, the mixing uniformity and energy consumption efficiency optimization method, and the automatic batching safety inspection stability optimization method of the aqueous phase preparation tank.

[0104] Further, the specific steps of the PID control response timeliness optimization method are as follows: If the PID control response timeliness evaluation value is greater than or equal to the first threshold of the PID control response timeliness evaluation value, there is no need to perform the PID control response timeliness optimization method; If the PID control response timeliness evaluation value is less than the first threshold of the PID control response timeliness evaluation value, adjust the PID parameters to improve the response speed to temperature and viscosity mutations; Design an emergency stop logic and set the trigger conditions for the highest and lowest threshold values of temperature, pressure, and viscosity.

[0105] In this embodiment, the PID controller is a common industrial control system used to regulate the response speed of temperature and the viscosity mutation of the emulsion explosive solution. According to the deviation between the preset threshold and the actual value, it controls the output through three links: proportional (P), integral (I), and derivative (D) to achieve the control of the process. The goal of adjusting the PID parameters is to improve the system's response speed to temperature and the viscosity mutation of the emulsion explosive solution, enabling it to quickly adjust the output so that the actual value equals the preset threshold. Gradually adjust the P, I, and D parameters of the PID controller to find the optimal PID parameter combination, enabling the system to quickly respond to temperature and the viscosity mutation of the emulsion explosive solution and maintain stable operation. Adjusting the PID parameters can improve the system's response speed to temperature and the viscosity mutation of the emulsion explosive solution, enabling the system to react before the parameters approach the threshold, thus reducing the occurrence of emergency stops. At the same time, the emergency stop logic is the last line of defense to prevent the expansion of accidents. According to the automatic batching process of the emulsion explosive aqueous phase preparation tank, determine the maximum and minimum safety thresholds of temperature, pressure, and the viscosity of the emulsion explosive solution. If any two of the temperature, pressure, and the viscosity of the emulsion explosive solution are greater than the maximum safety threshold or lower than the minimum safety threshold, directly trigger the emergency stop logic, first stop heating, then stop stirring, and finally close the valve. If any one of the temperature, pressure, and the viscosity of the emulsion explosive solution is greater than the maximum safety threshold or lower than the minimum safety threshold, trigger an alarm to alert the operator. Continuously monitor abnormal situations to ensure that once the abnormality is eliminated, the system can be safely restarted.

[0106] Furthermore, the specific steps of the mixing uniformity and energy consumption efficiency optimization method are as follows: If the evaluation values of mixing uniformity and energy consumption efficiency are lower than or equal to the second threshold of the evaluation values of mixing uniformity and energy consumption efficiency, there is no need to perform the mixing uniformity and energy consumption efficiency optimization method. If the evaluation values of mixing uniformity and energy consumption efficiency are higher than the second threshold of the evaluation values of mixing uniformity and energy consumption efficiency, then simulate the automatic batching process of the emulsion explosive aqueous phase preparation tank using CFD software and set parameters according to the actual safety inspection. Identify the dead zones and high-temperature points in the automatic batching process of the emulsion explosive aqueous phase preparation tank by analyzing the fused data. According to the output of the PID control algorithm, adjust the output frequency of the frequency converter in real time to control the rotation speed of the stirring equipment.

[0107] In this embodiment, the computational fluid dynamics (CFD) software is used to simulate the mixing process, analyze the flow state of the fluid in the container, set appropriate parameters such as fluid properties, boundary conditions, and initial conditions according to the actual working conditions, divide the mesh of the simulation area to ensure the calculation accuracy and efficiency, and collect sensor data in real time, including key parameters such as temperature, flow rate, and viscosity. Using data fusion technology, the multi-sensor data is integrated into a unified data format to provide a basis for subsequent analysis. By analyzing the fused data, the dead zones (poor flow areas) and high-temperature points in the mixing process are identified. Using the CFD simulation results and sensor data, the positions and ranges of the dead zones and high-temperature points are accurately located, a temperature prediction model of the mixing process is established, the relationship between the input variables (such as heating power, cooling rate, etc.) and the output variable (such as temperature) is considered, the goals of temperature control are set, such as maintaining a constant temperature, rapid heating, etc., and the optimal control strategy is calculated according to the real-time collected temperature data and the prediction model, and the working state of the heating or cooling equipment is adjusted; the parameters of the frequency converter are set according to the actual needs, such as the frequency range, starting method, etc., and the output frequency of the frequency converter inside the mixing equipment is adjusted in real time according to the output of the PID control algorithm to control the rotation speed of the mixing equipment.

[0108] Further, the specific steps of the stability optimization method for the automatic batching safety inspection of the aqueous phase preparation tank are as follows: if the stability evaluation value of the automatic batching safety inspection of the aqueous phase preparation tank is greater than or equal to the comprehensive threshold value of the stability evaluation value of the automatic batching safety inspection of the aqueous phase preparation tank, there is no need to perform the stability optimization method for the automatic batching safety inspection of the aqueous phase preparation tank; if the stability evaluation value of the automatic batching safety inspection of the aqueous phase preparation tank is less than the comprehensive threshold value of the stability evaluation value of the automatic batching safety inspection of the aqueous phase preparation tank, the temperature and viscosity of each area are monitored in real time for abnormal positioning; the automatic batching safety inspection data of the aqueous phase preparation tank is corrected by model predictive control; by correcting the automatic batching safety inspection data of the aqueous phase preparation tank, the automatic batching safety inspection path of the aqueous phase preparation tank is dynamically adjusted.

[0109] In this embodiment, the temperature and viscosity changes in each area are monitored in real time. When the temperature in a certain area of the aqueous phase preparation tank exceeds the preset temperature or the viscosity mutation exceeds the preset viscosity mutation, this area is automatically marked as a high-risk area; through real-time monitoring and automatic marking, the areas with problems can be quickly identified, providing clear targets for subsequent inspections and handling, and conducting priority sorting. ΔT represents the degree of temperature deviation, and Δμ represents the degree of viscosity deviation. The system will evaluate the risk level of each area according to the deviation degrees of these two parameters. Dynamically generating the inspection path Based on the risk levels of each area, the system will dynamically generate the inspection path to ensure that high-risk areas are inspected first. The purpose is to ensure the reasonable allocation of resources through priority sorting, improving the efficiency and accuracy of inspections. The real-time inspection data such as the temperature field and viscosity distribution are input as the initial state of the MPC through model predictive control (MPC). Historical inspection records, such as the local crystallization frequency, are used to correct the model parameters and improve the accuracy of prediction. The data obtained during the inspection process will be fed back to the MPC model in real time for updating the model state. Through the combination of MPC and inspection feedback, real-time and precise control is achieved to ensure the stable operation of the system. Through the above technical steps, the automatic batching safety inspection data of the aqueous phase preparation tank are corrected, and the automatic batching safety inspection path of the aqueous phase preparation tank is dynamically adjusted. The automatic batching safety inspection data of the aqueous phase preparation tank include the temperature gradient at the top of the aqueous phase preparation tank, the viscosity of the emulsion explosive solution, and the degree of temperature deviation.If the temperature gradient at the top of the aqueous phase preparation tank is greater than the preset temperature gradient threshold of the aqueous phase preparation tank, then the MPC action at this time is to automatically increase the stirring speed and the cooling water flow rate to reduce the temperature gradient at the top of the tank; the inspection path is adjusted to generate an inspection path based on real-time data (such as bottom of the tank → middle part → top), ensuring that high-risk areas are given key attention, and the residence time in high-risk areas is extended for more detailed inspection and recording of the situation; if the viscosity of the local emulsion explosive solution in the aqueous phase preparation tank is greater than the viscosity threshold of the emulsion explosive solution, the pulse flushing program is automatically started to remove local high-viscosity substances and restore normal flow, and the inspection path is adjusted to generate an inspection path based on real-time data (such as bottom of the tank → middle part → top). High-viscosity substances are likely to accumulate at the bottom of the tank and need to be monitored keyly. If the viscosity at the bottom of the tank is greater than the viscosity threshold of the emulsion explosive solution, the frequency or intensity of the pulse flushing program needs to be increased; the middle part is the key area for the flow of the emulsion explosive solution, and it is necessary to ensure that the viscosity of the emulsion explosive solution tends to the viscosity threshold of the emulsion explosive solution to ensure smooth flow; the viscosity of the emulsion explosive solution at the top is relatively low, but it still needs to be monitored to ensure that there is no local area with a high viscosity of the emulsion explosive solution; if the temperature deviation exceeds the preset temperature deviation threshold, the standby cooling system is triggered to quickly reduce the temperature and prevent further temperature rise, and at the same time, the operator is notified for manual intervention and handling. The inspection path is adjusted to generate an inspection path based on real-time data (such as high-temperature area of the aqueous phase preparation tank → medium-temperature area of the aqueous phase preparation tank → low-temperature area of the aqueous phase preparation tank), keyly monitoring the high-temperature area of the aqueous phase preparation tank and preferentially triggering the standby cooling system; the system conducts automatic inspections regularly, detects abnormal operation states and parameters of the equipment, alarms and records in time, remotely monitors the system state through a mobile terminal or a PC terminal, realizes remote maintenance and fault diagnosis, and dynamically adjusts the automatic batching safety inspection path of the aqueous phase preparation tank.

[0110] The automatic batching safety inspection equipment for the emulsion explosive aqueous phase preparation tank provided by the embodiment of the present application includes: recording the time series data of temperature and control signals through a data recorder; collecting the temperature inside the aqueous phase preparation tank through a temperature sensor; measuring the viscosity of the emulsion explosive solution through a capillary viscometer; and collecting the stirring power inside the aqueous phase preparation tank through a power sensor.

[0111] Those skilled in the art should understand that the embodiments of the present invention can be provided as a method, a system, or a computer program product. Therefore, the present invention can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Moreover, the present invention can take the form of a computer program product implemented on one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0112] The present invention is described with reference to the flowcharts and / or block diagrams of methods, apparatuses (systems), and computer program products according to embodiments of the present invention. It should be understood that each flow and / or block in the flowcharts and / or block diagrams, as well as the combination of flows and / or blocks in the flowcharts and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to the processors of general-purpose computers, special-purpose computers, embedded processors, or other programmable data processing devices to generate a machine, such that the instructions executed by the processors of the computer or other programmable data processing devices produce means for implementing the functions specified in one flow Figure 1 one flow or multiple flows and / or blocks Figure 1 or multiple blocks.

[0113] These computer program instructions can also be stored in a computer-readable memory that can direct a computer or other programmable data processing device to work in a specific manner, such that the instructions stored in the computer-readable memory produce a manufactured article including instruction means that implement the functions specified in one flow Figure 1 one flow or multiple flows and / or blocks Figure 1 or multiple blocks.

[0114] These computer program instructions can also be loaded onto a computer or other programmable data processing device, such that a series of operation steps are executed on the computer or other programmable device to generate a computer-implemented process, and thus the instructions executed on the computer or other programmable device provide steps for implementing the functions specified in one flow Figure 1 one flow or multiple flows and / or blocks Figure 1 or multiple blocks.

[0115] Although the preferred embodiments of the present invention have been described, those skilled in the art can make additional changes and modifications once they learn the basic creative concepts. Therefore, the appended claims are intended to be construed to include the preferred embodiments as well as all changes and modifications falling within the scope of the present invention.

[0116] Obviously, those skilled in the art can make various changes and deformations to the present invention without departing from the spirit and scope of the present invention. Thus, if these modifications and deformations of the present invention fall within the scope of the claims of the present invention and their equivalent technologies, the present invention is also intended to include these changes and deformations.

Claims

1. An automatic batching safety inspection method for the aqueous phase preparation tank of emulsion explosive, characterized in that, It includes the following steps: Collect and process the automatic batching data of the aqueous phase preparation tank of emulsion explosives; Analyze the automatic batching data of the aqueous phase preparation tank of emulsion explosives to obtain the evaluation values of mixing uniformity and energy consumption efficiency and the evaluation value of PID control response timeliness; Comprehensively analyze to obtain the evaluation value of the stability of the automatic batching safety inspection of the aqueous phase preparation tank; Based on the comparison between the evaluation value and the preset threshold in the database, optimize and adjust the automatic batching safety inspection method for the aqueous phase preparation tank of emulsion explosives.

2. The automatic batching safety inspection method for the aqueous phase preparation tank of emulsion explosive according to claim 1, wherein, The specific steps of collecting and processing the automatic batching data of the aqueous phase preparation tank of emulsion explosives are as follows: Through the Internet of Things technology, transmit the sensor data to the central control system in real time to collect the original data of the automatic batching of the aqueous phase preparation tank of emulsion explosives; Clean and denoise the original data of the automatic batching of the aqueous phase preparation tank of emulsion explosives to obtain the automatic batching data of the aqueous phase preparation tank of emulsion explosives; The automatic batching data of the aqueous phase preparation tank of emulsion explosives includes mixing uniformity and energy consumption efficiency data, PID control response timeliness data, and temperature runaway frequency.

3. The automatic batching safety inspection method for the aqueous phase preparation tank of emulsion explosive as described in claim 1, wherein The specific steps of obtaining the evaluation values of mixing uniformity and energy consumption efficiency are as follows: The mixing uniformity and energy consumption efficiency data include the stirring dead zone area, PID control response time, maximum temperature in the aqueous phase preparation tank, minimum temperature in the aqueous phase preparation tank, maximum amplitude of viscosity mutation of the emulsion explosive solution, minimum amplitude of viscosity mutation of the emulsion explosive solution, and mixing uniformity; Obtain the stirring dead zone area threshold, PID control response time threshold, temperature difference standard value in the aqueous phase preparation tank, standard value of viscosity mutation amplitude difference of emulsion explosives, mixing uniformity threshold, weight factor of stirring dead zone area, weight factor of mixing uniformity, weight factor of PID control response time, weight factor of temperature difference coefficient, and weight factor of viscosity mutation coefficient of emulsion explosive solution from the safety inspection database of the aqueous phase preparation tank; Conduct a ratio analysis of the stirring dead zone area and the stirring dead zone area threshold, average the results of the ratio analysis, and correct the results of the averaging process using the weight factor of the stirring dead zone area, denoted as the first component of the evaluation value of mixing uniformity and energy consumption efficiency; Conduct a ratio analysis of the PID control response time and the PID control response time threshold, and correct the results of the ratio analysis using the weight factor of the PID control response time, denoted as the second component of the evaluation value of mixing uniformity and energy consumption efficiency; Conduct a ratio analysis of the deviation between the maximum temperature and the minimum temperature in the aqueous phase preparation tank and the temperature difference standard value in the aqueous phase preparation tank, and correct the results of the ratio analysis using the weight factor of the temperature difference coefficient, denoted as the temperature difference coefficient; Conduct a ratio analysis of the deviation between the maximum amplitude of viscosity mutation of the emulsion explosive solution and the minimum amplitude of viscosity mutation of the emulsion explosive solution and the standard value of viscosity mutation amplitude difference of emulsion explosives, and correct the results of the ratio analysis using the weight factor of the viscosity mutation coefficient of the emulsion explosive solution, denoted as the viscosity mutation coefficient of the emulsion explosive solution; Perform a ratio analysis on the mixing uniformity and the mixing uniformity threshold, average the results of the ratio analysis, and correct the results of the averaging process using the weight factor of the mixing uniformity, denoted as the third component of the mixing uniformity and energy consumption efficiency evaluation value; Perform a ratio analysis on the coupling results of the first component of the mixing uniformity and energy consumption efficiency evaluation value, the second component of the mixing uniformity and energy consumption efficiency evaluation value, the temperature difference coefficient, and the viscosity mutation coefficient of the emulsion explosive solution, and the third component of the mixing uniformity and energy consumption efficiency evaluation value to obtain the mixing uniformity and energy consumption efficiency evaluation value; The mixing uniformity and energy consumption efficiency evaluation value represents the quantitative data for dynamically adjusting the stirring speed.

4. The automatic batching safety inspection method for the aqueous phase preparation tank of emulsion explosive according to claim 1, wherein, The specific steps for obtaining the PID control response timeliness evaluation value are as follows: The PID control response timeliness data includes the PID control response time, the steam valve adjustment lag time, the maximum stirring power in the aqueous phase preparation tank, the minimum stirring power in the aqueous phase preparation tank, the maximum amplitude of viscosity mutation of the emulsion explosive solution, and the minimum amplitude of viscosity mutation of the emulsion explosive solution; Obtain the PID control response time threshold, the steam valve adjustment lag time threshold, the standard value of the stirring power difference in the aqueous phase preparation tank, the standard value of the viscosity mutation amplitude difference of the emulsion explosive, the weight factor of the PID control response time, the weight factor of the steam valve adjustment lag time, the weight factor of the energy consumption change coefficient, and the weight factor of the viscosity mutation coefficient of the emulsion explosive solution from the safety inspection database of the aqueous phase preparation tank; Perform a ratio analysis on the PID control response time threshold and the PID control response time, and correct the results of the ratio analysis using the weight factor of the PID control response time, denoted as the first component of the PID control response timeliness evaluation value; Perform a ratio analysis on the steam valve adjustment lag time threshold and the steam valve adjustment lag time, and correct the results of the ratio analysis using the weight factor of the steam valve adjustment lag time, denoted as the second component of the PID control response timeliness evaluation value; Perform a ratio analysis on the deviation between the maximum stirring power and the minimum stirring power in the aqueous phase preparation tank and the standard value of the stirring power difference in the aqueous phase preparation tank, and correct the results of the ratio analysis using the weight factor of the energy consumption change coefficient, denoted as the energy consumption change coefficient; Perform a ratio analysis on the deviation between the maximum amplitude of viscosity mutation of the emulsion explosive solution and the minimum amplitude of viscosity mutation of the emulsion explosive solution and the standard value of the viscosity mutation amplitude difference of the emulsion explosive, and correct the results of the ratio analysis using the weight factor of the viscosity mutation coefficient of the emulsion explosive solution, denoted as the viscosity mutation coefficient of the emulsion explosive solution; Perform a ratio analysis on the coupling results of the first component of the PID control response timeliness evaluation value and the second component of the PID control response timeliness evaluation value and the coupling results of the energy consumption change coefficient and the viscosity mutation coefficient of the emulsion explosive solution to obtain the PID control response timeliness evaluation value; The PID control response timeliness evaluation value represents the response speed of the control system, reflecting its ability to handle emergencies.

5. The automatic batching safety inspection method for the aqueous phase preparation tank of emulsion explosive according to claim 1, wherein The specific steps for comprehensively analyzing and obtaining the safety inspection stability evaluation value of the automatic batching of the aqueous phase preparation tank are as follows: Obtain the temperature runaway frequency threshold, the weight factor of the PID control response timeliness evaluation value, the weight factors of the mixing uniformity and energy consumption efficiency evaluation values, and the weight factor of the temperature runaway frequency from the safety inspection database of the aqueous phase preparation tank; Perform mean value processing on the PID control response timeliness evaluation value, and use the weight factor of the PID control response timeliness evaluation value to correct the result of the mean value processing, denoted as the first component of the safety inspection stability evaluation value for the automatic batching of the aqueous phase preparation tank; Perform mean value processing on the mixing uniformity and energy consumption efficiency evaluation values, and use the weight factors of the mixing uniformity and energy consumption efficiency evaluation values to correct the result of the mean value processing, denoted as the second component of the safety inspection stability evaluation value for the automatic batching of the aqueous phase preparation tank; Conduct a ratio analysis of the temperature runaway frequency and the temperature runaway frequency threshold, perform mean value processing on the result of the ratio analysis, and use the weight factor of the temperature runaway frequency to correct the result of the mean value processing, denoted as the third component of the safety inspection stability evaluation value for the automatic batching of the aqueous phase preparation tank; Conduct a ratio analysis of the coupling result of the first component, the second component, and the third component of the safety inspection stability evaluation value for the automatic batching of the aqueous phase preparation tank, and comprehensively analyze to obtain the safety inspection stability evaluation value for the automatic batching of the aqueous phase preparation tank; The safety inspection stability evaluation value for the automatic batching of the aqueous phase preparation tank represents the quantitative data of the stability of the aqueous phase preparation tank during the automatic batching process.

6. The automatic batching and safety inspection method for the aqueous phase preparation tank of emulsion explosive according to claim 1, wherein, The specific steps of the optimization and adjustment method for the safety inspection of the automatic batching of the aqueous phase preparation tank for emulsion explosive are as follows: Obtain the first threshold of the PID control response timeliness evaluation value, the second threshold of the mixing uniformity and energy consumption efficiency evaluation values, and the comprehensive threshold of the safety inspection stability evaluation value for the automatic batching of the aqueous phase preparation tank from the database; Conduct a comparative analysis through the PID control response timeliness evaluation value, the mixing uniformity and energy consumption efficiency evaluation values, the safety inspection stability evaluation value for the automatic batching of the aqueous phase preparation tank, and the first threshold of the PID control response timeliness evaluation value, the second threshold of the mixing uniformity and energy consumption efficiency evaluation values, and the comprehensive threshold of the safety inspection stability evaluation value for the automatic batching of the aqueous phase preparation tank to obtain the optimization and adjustment method for the safety inspection of the automatic batching of the aqueous phase preparation tank for emulsion explosive; The optimization and adjustment method for the safety inspection of the automatic batching of the aqueous phase preparation tank for emulsion explosive includes the PID control response timeliness optimization method, the mixing uniformity and energy consumption efficiency optimization method, and the safety inspection stability optimization method for the automatic batching of the aqueous phase preparation tank.

7. The automatic batching safety inspection method for the aqueous phase preparation tank of emulsion explosive according to claim 6, characterized in that, The specific steps of the PID control response timeliness optimization method are as follows: If the PID control response timeliness evaluation value is greater than or equal to the first threshold of the PID control response timeliness evaluation value, there is no need to perform the PID control response timeliness optimization method; If the PID control response timeliness evaluation value is less than the first threshold of the PID control response timeliness evaluation value, adjust the PID parameters to improve the response speed to temperature and viscosity mutations; design an emergency stop logic and set the trigger conditions for the highest and lowest thresholds of temperature, pressure, and viscosity.

8. The automatic batching safety inspection method for the aqueous phase preparation tank of emulsion explosive according to claim 6, characterized in that, The specific steps of the mixing uniformity and energy consumption efficiency optimization method are as follows: If the evaluation values of mixing uniformity and energy consumption efficiency are lower than or equal to the second threshold of the evaluation values of mixing uniformity and energy consumption efficiency, there is no need to perform the mixing uniformity and energy consumption efficiency optimization method; If the evaluation values of mixing uniformity and energy consumption efficiency are higher than the second threshold of the evaluation values of mixing uniformity and energy consumption efficiency, the automatic batching process of the aqueous phase preparation tank for emulsion explosive is simulated by using CFD software, and parameters are set according to the actual safety inspection; by analyzing the fused data, the dead zones and high-temperature points in the automatic batching process of the aqueous phase preparation tank for emulsion explosive are identified; according to the output of the PID control algorithm, the output frequency of the frequency converter is adjusted in real time to control the rotation speed of the stirring equipment.

9. The automatic batching safety inspection method for the aqueous phase preparation tank of emulsion explosive according to claim 6, characterized in that, The specific steps of the safety inspection stability optimization method for the automatic batching of the aqueous phase preparation tank are as follows: If the evaluation value of the safety inspection stability of the automatic batching of the aqueous phase preparation tank is greater than or equal to the comprehensive threshold of the evaluation value of the safety inspection stability of the automatic batching of the aqueous phase preparation tank, there is no need to perform the safety inspection stability optimization method for the automatic batching of the aqueous phase preparation tank; If the evaluation value of the safety inspection stability of the automatic batching of the aqueous phase preparation tank is less than the comprehensive threshold of the evaluation value of the safety inspection stability of the automatic batching of the aqueous phase preparation tank, the temperature and viscosity of each area are monitored in real time for abnormal positioning; the safety inspection data of the automatic batching of the aqueous phase preparation tank are corrected by model predictive control; by correcting the safety inspection data of the automatic batching of the aqueous phase preparation tank, the safety inspection path of the automatic batching of the aqueous phase preparation tank is dynamically adjusted.

10. An automatic batching safety inspection device for the aqueous phase preparation tank of emulsion explosive, characterized in that, Including: Recording the time series data of temperature and control signals through a data logger; Collecting the temperature inside the aqueous phase preparation tank through a temperature sensor; Measuring the viscosity of the emulsion explosive solution with a capillary viscometer; collecting the stirring power inside the aqueous phase preparation tank through a power sensor.

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