A method of sterilizing a bag planting inoculator

Abstract

The application discloses a kind of bag cultivation inoculator sterilization method, including sequentially closed loop interface's before sterilization positioning verification preparation, collaborative steam sterilization negative feedback control, gradient pressure reduction pollution prevention time interlocking, strain pipeline preflushing and residual, terminal double sterilization, standardization reset and automatic inoculation trigger six steps, between each step through cross-post operation authority separation, state verification interlocking and negative feedback control mechanism Form one-way irreversible whole-process anti-bacterial closed loop system;Wherein, the state verification of previous step does not pass, inoculator control system is automatically locked and prohibited to enter next step.The application has the advantages of whole-process anti-bacterial, high degree of automation, safe and reliable operation, stable sterilization effect and traceability.

Description

Technical Field

[0001] This invention relates to the field of disinfection technology for edible mushroom bag cultivation inoculation equipment, specifically a disinfection method for a bag cultivation inoculation machine. Background Technology

[0002] In the production of edible mushroom bag cultivation, the inoculation process is the core of aseptic operation, and its cleanliness and sterilization effect directly affect the mycelial germination rate and the yield of finished products. Currently, the sterilization of bag cultivation inoculation machines mainly relies on manual segmented operation and simple equipment control. The routine process usually includes: the operator manually positioning the sterilization rack, opening the steam valve for spatial sterilization, natural cooling or manual depressurization after sterilization, then wiping or flaming the pipelines and inoculation components with alcohol for disinfection, and finally performing the inoculation operation.

[0003] However, the entire disinfection process in existing technologies relies heavily on the experience and responsibility of operators. The lack of effective status verification and interlocking mechanisms between steps makes it prone to operational omissions, incorrect sequences, or inaccurate control of sterilization parameters. For example, inaccurate positioning of the sterilization rack can lead to poor steam circulation, excessively rapid pressure drop after sterilization can create negative pressure and introduce contaminants, and residual condensate or incomplete drainage of sterilization solution can cause bacterial contamination, creating potential contamination risks. Secondly, steam sterilization processes are mostly open-loop controlled, with operators adjusting valves based on experience, making it difficult to ensure precise and stable sterilization temperature and pressure under complex conditions, resulting in inconsistent sterilization effects. Finally, the valve reset, mode switching, and subsequent automatic inoculation program of the inoculation machine are poorly integrated, lacking standardized reset procedures and clean environment maintenance mechanisms. The reset process can easily introduce contamination, causing the previous disinfection work to fail.

[0004] Therefore, the existing disinfection methods for bag-planting inoculation machines have problems such as disjointed processes, low control precision, unclear job responsibilities, and imperfect anti-contamination systems. There is an urgent need for a systematic disinfection method that can achieve closed-loop control of the entire process, separation of job authority, precise sterilization, and multiple anti-contamination measures to improve the inoculation success rate and product quality stability. Summary of the Invention

[0005] The purpose of this invention is to provide a disinfection method for a bag-planting inoculation machine, which has the advantages of preventing contamination throughout the entire process, high degree of automation, safe and reliable operation, stable and traceable sterilization effect, and solves the problems of scattered disinfection steps before inoculation, reliance on manual experience, and easy sterilization failure or secondary contamination due to improper operation in the prior art.

[0006] To achieve the above objectives, the present invention provides the following technical solution: A disinfection method for a bag-cultivation inoculation machine includes six sequentially connected steps: pre-sterilization positioning and verification preparation, collaborative steam sterilization negative feedback control, gradient pressure reduction and anti-contamination sequential interlocking, pre-flushing and residual removal of inoculum pipelines, terminal double disinfection, standardized reset and automatic inoculation triggering. Each step is connected to form a unidirectional and irreversible full-process anti-contamination closed-loop system through cross-position operation authority separation, status verification interlocking and negative feedback control mechanism; wherein, if the status verification of the previous step fails, the inoculation machine control system automatically locks and prohibits entry into the next step; (1) Preparation steps for positioning and verification before sterilization: After the inoculator is turned on, switch to manual mode and place the sterilization rack in the direction of the inoculator basket. Control the raising of the back baffle of the inoculator through manual mode, and face the end of the sterilization rack with the limiting structure towards the direction of the basket. Make the two limiting parts on the left side of the sterilization rack fit against the straight edge of the conveyor belt of the inoculator. The spatial position of the sterilization rack is locked by the three-point cooperation of the back baffle, the two limiting parts and the straight edge of the conveyor belt. After the three-point positioning is completed, manually push the sterilization rack along the direction of the conveyor belt. The pushing range should not exceed 5mm. Verify that there is no displacement. Then control the bottle pressure valve to descend, the cap clamp valve to operate, the cap opening valve to operate, the needle rack valve to operate and the inoculation valve to operate in sequence through the display screen of the inoculator to complete the pre-positioning of the valves before sterilization. (2) Collaborative Steam Sterilization Negative Feedback Control Steps: After the inoculation machine operator and the seed tank operator complete the cross-post authorization confirmation, the seed tank operator opens the main steam valve and controls the steam pressure in the front-end pipeline between the main valve and the sterilization rack at 0.15-0.2 MPa through the steam pressure reducing valve; the inoculation machine operator sequentially opens the valve in front of the storage tank, the two valves at the end of the sterilization rack, and the main valve of the exhaust pipeline to regulate the steam pressure in the sterilization rack to stabilize at 0.1-0.15 MPa, corresponding to a temperature of 121-124℃. After the pressure stabilizes, the inoculation machine first... The system automatically detects air / water leaks at each nozzle positioning point. If an abnormality is detected, an alarm is immediately triggered. Operators then check and address any sealing defects such as raw rubber tape or material residue at the nozzle-base contact area. If the defects cannot be addressed, the system is stopped, reported, and the sterilization process is terminated. After confirming that there are no abnormalities, the system enters a 40-minute pressure sterilization process. During the pressure holding process, the inoculation machine control system monitors the pressure and temperature inside the sterilization rack in real time. When the pressure or temperature deviates from the preset range, the system automatically adjusts the steam input or the opening of the exhaust pipe to form a pressure-temperature negative feedback control loop, which together constitutes a negative feedback closed loop for sterilization stability. (3) Gradient pressure reduction and anti-contamination interlocking steps: After the sterilization time reaches the target, the seed tank operator first reduces the opening of the steam valve to reduce the steam pressure in the front pipeline to 0.1MPa; when the pressure gauge value of the sterilization rack drops to 0.05MPa, the inoculation machine operator closes the two valves at the end of the sterilization rack and the main valve of the exhaust pipeline in sequence, and then notifies the seed tank operator to close the main steam valve. The fixed-sequence gradient pressure reduction operation forms a time-sequence interlock to prevent negative pressure in the pipeline; after the main steam valve is closed, the control system continuously monitors the pressure change of the sterilization rack. If a negative pressure trend occurs, that is, the pressure is lower than 0.02MPa, the operator is immediately prompted to slightly open the main exhaust pipeline valve to balance the pressure, forming a pressure-action negative feedback interlock; (4) Pre-flushing and residual discharge steps of inoculum pipeline: After connecting the inoculum tank and sterilization rack and verifying the sealing, open the two exhaust valves of sterilization rack and the main valve of pipeline in sequence, so that the inoculum liquid flows through the pipeline for 3-5 seconds to complete the pipeline rinsing and residual liquid discharge. The waste liquid after rinsing is discharged through the independent outlet of sterilization rack and immediately isolated, and does not return to the inoculum tank. Then quickly close the main inlet valve of inoculum tank to form the pre-discharge and quick disconnection operation of inoculum pipeline; (5) Terminal double disinfection steps: After closing the inoculation valve and removing the sterilization rack, first use 95% alcohol cotton balls to flame-sterilize each inoculation nozzle. The flame-sterilization time is controlled at 10-12 seconds. The flame-sterilization flame completely covers the outer wall of the nozzle, the liquid outlet and the upper opening area. Then spray disinfection is carried out on the space inside the laminar flow hood of the inoculation machine. Flame disinfection and spray disinfection are performed sequentially and complementary in function to form a multi-level disinfection synergy mechanism. (6) Standardized reset and automatic inoculation triggering steps: After disinfection, enter the manual operation interface of the inoculation machine, and control the opening valve to stop, the clamping valve to stop, and the bottle pressing valve to rise to the initial position in sequence. Then switch the inoculation machine to automatic mode and start the automatic inoculation program.

[0007] Preferably, in the collaborative steam sterilization negative feedback control step, the steam pressure of the sterilization rack is precisely checked every 5 minutes during the pressure holding process. If the pressure fluctuation exceeds the range of 0.1-0.15MPa, the control system immediately adjusts the opening degree of the steam pressure reducing valve and the exhaust pipe valve to make the pressure return to the set range within 30 seconds, forming a two-stage negative feedback closed loop for pressure regulation.

[0008] Preferably, in the collaborative steam sterilization negative feedback control step, when checking for nozzle sealing defects, a lint-free cloth is used to remove residual raw rubber tape, material residue, and other foreign matter from the contact area between the nozzle and the base. After reinstallation, pressure is maintained for 3 minutes to conduct a sealing test until there is no abnormal air / water leakage.

[0009] Preferably, in the gradient pressure reduction and anti-contamination interlocking step, after closing the main steam valve, the control system continuously monitors the pressure of the sterilization rack for no less than 5 minutes. If a negative pressure trend occurs, i.e. the pressure is lower than 0.02MPa, an operation prompt will pop up automatically. The operator will slightly open the main exhaust valve until the pressure recovers to 0.03-0.05MPa and then close it to prevent the backflow of external bacteria.

[0010] Preferably, in the pre-flushing and residual removal step of the inoculum pipeline, the rinsing flow rate of the inoculum solution is controlled at 0.8-1.2 m / s, and the rinsing time is precisely controlled at 4 seconds. The flow rate is monitored in real time by the pipeline flow sensor to ensure that the residual condensate and sterilization residue in the pipeline are completely discharged.

[0011] Preferably, in the terminal dual disinfection step, the alcohol content of the alcohol cotton ball is controlled at 95%±2% during flame scorching disinfection, and it moves at a uniform speed of 5cm / s along the circumference of the nozzle during the scorching process to ensure that all contact surfaces of the nozzle outer wall, the liquid outlet and the upper cap opening mechanism are continuously covered by the flame.

[0012] Preferably, in the terminal dual disinfection step, the spray disinfection inside the laminar flow hood uses a food-grade hydrogen peroxide disinfectant solution with a concentration of 3%-5%, and the spray volume is 10-15ml per cubic meter of space. After spraying, the laminar flow hood is sealed for 3-5 minutes to complete the sterilization of the space environment.

[0013] Preferably, in the standardized reset and automatic inoculation triggering steps, the operation interval between valve stopping and bottle valve reset does not exceed 5 seconds, and the laminar flow hood is kept in a positive pressure air supply state throughout the reset process, with the pressure inside the hood being 5-10 Pa higher than the outside pressure, to prevent external bacteria from entering the inoculation area during the reset process.

[0014] Preferably, in the closed-loop system for preventing contamination throughout the entire process, the operating permissions for each step are set separately according to job responsibilities: the operator of the inoculation machine only has the authority to operate the sterilization rack, control the valve, disinfect and reset, and the operator of the seed tank only has the authority to open, adjust and close the main steam valve, forming cross-job permission interlocking to avoid process disorder caused by single-person operation.

[0015] In the preferred, unidirectional, irreversible, closed-loop system for preventing bacterial contamination throughout the entire process, if the status verification of any step fails, the inoculation machine control system will automatically lock the current operation interface and issue an audible and visual alarm. Only after the fault is cleared and the status verification passes can authorized personnel unlock the system and continue to execute subsequent steps.

[0016] Compared with the prior art, the beneficial effects of the present invention are as follows: 1. This invention sets up a pre-sterilization positioning and verification preparation step, and uses the three-point cooperation of the rear baffle, two limiting parts and the straight edge of the conveyor belt to lock the spatial position of the sterilization rack. By manually pushing the verification displacement and pre-positioning the valve, it ensures that the position of the sterilization rack is accurate and the valve status is reliable before sterilization. This solves the problem of sterilization dead corners or operational failures caused by inaccurate positioning of the sterilization rack and failure of valves in the prior art, and provides a stable physical basis for subsequent sterilization steps. 2. This invention achieves cross-post authority separation and linkage by setting up a collaborative steam sterilization negative feedback control step. The pressure in the front-end pipeline and sterilization rack is controlled in stages. During the pressure holding process, the control system monitors the pressure and temperature in real time and automatically adjusts the steam input and exhaust opening to form a pressure-temperature negative feedback control loop. At the same time, combined with the automatic detection and manual troubleshooting mechanism for nozzle leakage, a sterilization stability negative feedback closed loop is constructed. This solves the problems of traditional sterilization methods that rely on manual experience, have large parameter fluctuations, and have unstable sterilization effects, and significantly improves the consistency and reliability of sterilization. 3. This invention sets up a gradient pressure reduction and anti-contamination sequential interlocking step, adopting a fixed sequence of operations: first reducing the front-end pressure, then closing the end valve of the sterilization rack, and finally closing the main valve. This forms a sequential interlock to prevent negative pressure in the pipeline. After closing the main valve, the pressure is continuously monitored. If a negative pressure trend is observed, the system will automatically prompt the micro-opening of the exhaust valve to balance the pressure. This effectively avoids the risk of backflow of external bacteria due to negative pressure and solves the problem of secondary contamination caused by improper pressure reduction operation in existing sterilization processes. 4. This invention sets up a pre-flushing and residual removal step for the inoculum pipeline. After inoculum inoculation, the pipeline is briefly rinsed by the inoculum solution itself and then quickly cut off. Waste liquid is isolated through an independent discharge outlet, ensuring that residual condensate or sterilization residue in the pipeline is completely removed and does not flow back. This solves the problem of inoculum contamination and inoculation quality caused by pipeline residues, and provides a clean transport channel for aseptic inoculation. 5. This invention sets up a dual disinfection step at the terminal, executing flame scorching disinfection and spray disinfection sequentially and complementing each other in function. Flame scorching achieves physical sterilization of the nozzle and the open area, while spray disinfection achieves chemical sterilization of the space environment inside the laminar flow hood. The two work together to solve the problems of dead corners and incomplete sterilization caused by single disinfection methods, forming a multi-level disinfection synergy mechanism, which further improves the sterility assurance level of the inoculation area. 6. By setting standardized reset and automatic inoculation triggering steps, the present invention sequentially completes valve stopping, bottle valve reset and mode switching after disinfection. During the reset process, the laminar flow hood is kept under positive pressure to prevent the intrusion of external bacteria. This achieves a seamless connection from the completion of disinfection to the start of automatic inoculation, solves the problem of non-standard reset operation and easy introduction of contamination in the existing process, and improves the automation level and operation safety of the whole process. 7. This invention establishes a one-way, irreversible, closed-loop system for preventing contamination by constructing a cross-position operation authority separation, status verification interlocking, and negative feedback control mechanism. When the status verification of any step fails, the control system automatically locks and prohibits entry into the next step, effectively avoiding the risk of sterilization failure or contamination caused by human error, step omission, or disordered sequence. It realizes the systematization, standardization, and traceability of the pre-inoculation disinfection process, and significantly improves the stability and reliability of the edible mushroom bag cultivation inoculation process. Attached Figure Description

[0017] Figure 1 is a schematic flowchart of the disinfection method for the bag-planting inoculation machine of the present invention, wherein... Figure 1-A , Figure 1-B , Figure 1-C The complete flowchart is constructed by piecing the components together sequentially. Figure 2 This is a schematic diagram of the negative feedback control loop for steam sterilization according to the present invention. Detailed Implementation

[0018] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0019] To address the problems of fragmented pre-inoculation disinfection steps, reliance on manual experience, and susceptibility to sterilization failure or secondary contamination due to improper operation in existing technologies, the following technical solution is proposed (see Figure 1). Figure 2 Figure 1 shows the overall process of this method, which includes six steps that are sequentially connected in a closed loop. A disinfection method for a bag-cultivation inoculation machine includes six sequentially connected steps: pre-sterilization positioning and verification preparation, collaborative steam sterilization negative feedback control, gradient pressure reduction and anti-contamination sequential interlocking, pre-flushing and residual removal of inoculum pipelines, terminal double disinfection, standardized reset and automatic inoculation triggering. Each step is connected to form a unidirectional and irreversible full-process anti-contamination closed-loop system through cross-position operation authority separation, status verification interlocking and negative feedback control mechanism. If the status verification of the previous step fails, the inoculation machine control system automatically locks and prohibits entry into the next step.

[0020] In this embodiment, the pre-sterilization positioning and verification preparation steps specifically include: after the inoculation machine is turned on, switch to manual mode, place the sterilization rack along the inoculation machine's basket inlet direction, raise the inoculation machine's rear baffle through manual mode, and align the end of the sterilization rack with the limiting structure towards the basket inlet direction, so that the two limiting parts on the left side of the sterilization rack are aligned with the straight edge of the inoculation machine's conveyor belt. The spatial position of the sterilization rack is locked through the three-point cooperation of the rear baffle, the two limiting parts, and the straight edge of the conveyor belt. After the three-point positioning is completed, manually push the sterilization rack along the conveyor belt direction, with a pushing amplitude not exceeding 5mm, and verify that there is no displacement. Then, control the bottle pressure valve to descend, the cap clamp valve to operate, the cap opening valve to operate, the needle holder valve to operate, and the inoculation valve to operate in sequence through the inoculation machine's display screen, thus completing the pre-positioning of the valves before sterilization.

[0021] It is worth noting that the three-point positioning structure of the sterilization rack effectively eliminates the problems of easy displacement due to single-point positioning and position deviation of the sterilization rack caused by operator visual error in traditional positioning methods, ensuring that each nozzle of the sterilization rack maintains precise alignment with the bottle mouth during steam sterilization; the manual push to check the displacement further verifies the reliability of positioning, while the valve pre-positioning operation puts each actuator into a standby state before sterilization, avoiding connection delays or operational errors caused by valves not being ready after sterilization.

[0022] It should be noted that the rear baffle is a liftable baffle structure at the rear of the inoculation machine, and the two limiting parts are positioning blocks that protrude outward on the left side of the sterilization rack. The straight edge of the conveyor belt is the straight edge of the inoculation machine's conveyor belt. When the rear baffle is raised, the rear end of the sterilization rack is limited by the rear baffle, and the two limiting blocks on the left side are in contact with the straight edge of the conveyor belt, thereby restricting the displacement and rotation of the sterilization rack in the horizontal plane and achieving three-point positioning.

[0023] In this embodiment, specifically, the collaborative steam sterilization negative feedback control steps include: after the inoculation machine operator and the seed tank operator complete the cross-position authorization confirmation, the seed tank operator opens the main steam valve, and controls the steam pressure in the front-end pipeline between the main valve and the sterilization rack at 0.15-0.2 MPa through the steam pressure reducing valve; the inoculation machine operator sequentially opens the valve in front of the storage tank, the two valves at the end of the sterilization rack, and the main valve of the exhaust pipeline, adjusting the steam pressure in the sterilization rack to stabilize at 0.1-0.15 MPa, corresponding to a temperature of 121-124°C. After the pressure stabilizes at ℃, the system automatically detects air / water leaks at each nozzle positioning point. If an abnormality is detected, an alarm is immediately triggered. Operators then inspect and address any sealing defects such as raw rubber tape or residue at the nozzle-base contact points. If the defects cannot be resolved, the machine is stopped, reported, and the sterilization process terminated. After confirming no abnormalities, the system enters a 40-minute pressure-holding sterilization process. During this process, the inoculation machine control system monitors the pressure and temperature within the sterilization rack in real time. When the pressure or temperature deviates from the preset range, the system automatically adjusts the steam input or exhaust pipe opening, forming a pressure-temperature negative feedback control loop. Figure 2As shown, the negative feedback control loop collects data from the pressure and temperature sensors inside the sterilization rack in real time through the control system, compares it with the preset threshold, and automatically outputs control signals to adjust the opening of the steam pressure reducing valve and the exhaust pipe valve when the parameters deviate, forming a closed-loop automatic control, which together constitutes a negative feedback closed loop for sterilization stability.

[0024] It is worth noting that the cross-positional authorization design separates the control of the main steam valve from the control of the valves inside the sterilization rack, avoiding the problem of mismatch between the front-end pressure and the internal pressure due to confusion or negligence in the process during single-person operation; the phased regulation of the front-end pipeline pressure and the internal pressure of the sterilization rack ensures both stable output of steam supply and precise control within the sterilization chamber; the pressure-temperature negative feedback control loop can respond quickly to parameter fluctuations and automatically maintain the stability of sterilization conditions, which is significantly better than the traditional method of manual observation and adjustment; the automatic nozzle leakage / water leakage detection function verifies the sealing performance in advance, ensuring that all nozzles are in a reliable sealing state before formal pressure holding, preventing sterilization dead zones caused by local sealing failure.

[0025] Furthermore, during the pressure holding process, the steam pressure of the sterilization rack is precisely calibrated every 5 minutes. If the pressure fluctuation exceeds the range of 0.1-0.15 MPa, the control system immediately adjusts the opening of the steam pressure reducing valve and the exhaust pipe valve to bring the pressure back to the set range within 30 seconds, forming a two-stage negative feedback closed loop for pressure regulation. This two-stage regulation mechanism further improves the accuracy and response speed of pressure control, ensuring that the parameters remain within the optimal range throughout the sterilization process.

[0026] Furthermore, when troubleshooting nozzle sealing defects, a lint-free cloth should be used to remove any residual raw rubber tape, material residue, or other foreign matter from the contact area between the nozzle and the base. After reinstallation, a pressure test should be conducted again for 3 minutes until no air or water leakage is observed. This procedure clarifies standardized methods and verification procedures for defect troubleshooting, avoiding repeated leaks or sealing failures caused by haphazard handling.

[0027] In this embodiment, specifically, the gradient pressure reduction and anti-contamination sequential interlocking steps include: after the sterilization time reaches the target, the seed tank operator first reduces the opening of the steam valve to lower the steam pressure in the front pipeline to 0.1 MPa; when the pressure gauge value of the sterilization rack drops to 0.05 MPa, the inoculation machine operator sequentially closes the two valves at the end of the sterilization rack and the main valve of the exhaust pipeline, and then notifies the seed tank operator to close the main steam valve. Through the fixed-sequence gradient pressure reduction operation, a sequential interlocking to prevent negative pressure in the pipeline is formed; after closing the main steam valve, the control system continuously monitors the pressure change of the sterilization rack. If a negative pressure trend occurs, i.e., the pressure is lower than 0.02 MPa, the operator is immediately prompted to slightly open the main exhaust pipeline valve to balance the pressure, forming a pressure-action negative feedback interlock.

[0028] It is worth noting that the gradient depressurization operation, through a fixed sequence of first reducing the front-end pressure, then closing the valve at the end of the sterilization rack, and finally closing the main valve, ensures a smooth decrease in system pressure. This avoids negative pressure caused by the sudden closure of the main valve and the rapid condensation of high-temperature steam in the pipeline. If a negative pressure trend occurs, the control system automatically prompts the operator to intervene in pressure balancing through a pressure-action negative feedback interlock mechanism. This effectively prevents unsterilized air or bacteria from the outside from being drawn back into the sterilization rack through valve gaps, pipeline interfaces, etc., thereby ensuring the sterility of the internal space after sterilization.

[0029] Furthermore, after closing the main steam valve, the control system continuously monitors the sterilization rack pressure for at least 5 minutes. If a negative pressure trend occurs, i.e., the pressure drops below 0.02 MPa, an automatic operation prompt will immediately pop up. The operator should then slightly open the main exhaust valve until the pressure recovers to 0.03-0.05 MPa before closing it to prevent backflow of external bacteria. This design clearly quantifies the timeliness of negative pressure monitoring and intervention, ensuring that operators can perform balancing operations promptly and accurately in the event of abnormal pressure, further enhancing safety against contamination.

[0030] In this embodiment, specifically, the pre-flushing and residual discharge step of the inoculum pipeline includes: after connecting the inoculum tank and the sterilization rack and verifying the seal, opening the two exhaust valves of the sterilization rack and the main valve of the pipeline in sequence, allowing the inoculum liquid to flow through the pipeline for 3-5 seconds to complete the pipeline rinsing and residual liquid discharge. The waste liquid after rinsing is discharged through the independent outlet of the sterilization rack and immediately isolated, without returning to the inoculum tank. Then, the main inlet valve of the inoculum tank is quickly closed, forming the pre-discharge and quick-stop operation of the inoculum pipeline.

[0031] It is worth noting that this step uses the inoculum solution itself as the rinsing medium, which avoids the risk of contamination that may be introduced by using additional cleaning solution, and effectively removes impurities such as residual condensate and sterilization residue from the pipeline through a brief rinsing. The waste liquid is isolated through an independent outlet to ensure that the discharged residue will not flow back to the inoculum tank or contaminate other pipelines. The quick-stop operation immediately cuts off the inoculum supply after rinsing to prevent the inoculum solution from remaining in the pipeline for a long time, causing contamination or changes in physicochemical properties, and provides a clean and fresh inoculum delivery channel for subsequent inoculation.

[0032] Furthermore, the rinsing flow rate of the inoculum solution is controlled at 0.8-1.2 m / s, and the rinsing time is precisely controlled at 4 seconds. The flow rate is monitored in real time by a pipeline flow sensor to ensure that residual condensate and sterilization residue in the pipeline are completely discharged. This parameter design ensures the rinsing effect while avoiding the waste of inoculum caused by excessively long rinsing or the risk of pipeline impact caused by excessively high flow rates, thus achieving a balance between efficiency and effectiveness.

[0033] In this embodiment, specifically, the terminal dual disinfection steps include: after closing the inoculation valve and removing the sterilization rack, firstly, each inoculation nozzle is flame-sterilized using 95% alcohol cotton balls, with the sterilization time controlled at 10-12 seconds, and the flame completely covering the outer wall of the nozzle, the liquid outlet, and the upper open area; then, the space inside the laminar flow hood of the inoculation machine is spray-sterilized. The flame disinfection and spray disinfection are performed sequentially and complementaryly in function, forming a multi-level disinfection synergy mechanism.

[0034] It is worth noting that flame sterilization directly sterilizes the nozzles and open areas through high-temperature physical means, rapidly killing any microorganisms that may remain on the metal surface; while spray sterilization uses chemical disinfectants to comprehensively cover the space inside the laminar flow hood, eliminating airborne bacteria and microorganisms in hidden areas that have not directly contacted the flame. The two sterilization methods are executed sequentially and complement each other, avoiding the blind spots or incomplete sterilization problems inherent in single sterilization methods, thus forming a reliable multi-level synergistic sterilization mechanism.

[0035] Furthermore, during flame sterilization, the alcohol content of the alcohol swabs is controlled at 95% ± 2%, and the swabs move uniformly at a speed of 5 cm / s along the circumference of the nozzle during the sterilization process, ensuring that all contact surfaces of the nozzle outer wall, the liquid outlet, and the upper cap opening mechanism are continuously covered by the flame. These operating parameters ensure the uniformity and full coverage of the flame sterilization, avoiding insufficient sterilization time or blind spots in certain areas.

[0036] Furthermore, the laminar flow hood uses a 3%-5% food-grade hydrogen peroxide disinfectant solution for spray disinfection, with a spray volume of 10-15 ml per cubic meter of space. After spraying, the laminar flow hood is sealed for 3-5 minutes to complete the sterilization of the space environment. The selection of this disinfectant and the parameter settings take into account both sterilization effectiveness and safety. The food-grade hydrogen peroxide leaves no residue after decomposition, making it suitable for inoculation environments that come into contact with food and pharmaceuticals.

[0037] In this embodiment, specifically, the standardized reset and automatic inoculation triggering steps include: after disinfection, entering the manual operation interface of the inoculation machine, sequentially controlling the cap opening valve to stop, the cap clamping valve to stop, and the bottle pressing valve to rise to the initial working position, then switching the inoculation machine to automatic mode, and starting the automatic inoculation program.

[0038] It is worth noting that the reset operation is performed in the order of stopping the valve first and then resetting the pressure valve, which avoids mechanical jamming or bottle damage caused by interference between the valve and the pressure valve. After the reset is completed, the system switches to automatic mode and starts the inoculation program, achieving a seamless connection from the completion of disinfection to the start of inoculation, ensuring the continuity and automation of the entire process.

[0039] Furthermore, the interval between the valve stopping and the bottle valve resetting operation does not exceed 5 seconds, and the laminar flow hood maintains a positive pressure airflow throughout the resetting process, with the pressure inside the hood 5-10 Pa higher than the outside pressure, preventing external bacteria from entering the inoculation area during the resetting process. This design effectively blocks the risk of external bacteria intrusion caused by local airflow turbulence due to the resetting action by maintaining positive pressure in the laminar flow hood during the resetting phase, ensuring that the sterile area after disinfection is not damaged during the resetting process.

[0040] In this embodiment, specifically, in the whole-process anti-contamination closed-loop system, the operation permissions of each step are set separately according to the job responsibilities: the inoculation machine operator only has the permissions to operate the sterilization rack, control the valve, disinfect and reset, and the seed tank operator only has the permissions to open, adjust and close the main steam valve, forming cross-job permission interlocking to avoid process disorder caused by single-person operation.

[0041] It is worth noting that the separation of permissions design strengthens the standardization of the process from the management system level, ensuring that key operation steps must be completed collaboratively by personnel in different positions. This effectively avoids problems such as missing steps, incorrect parameter settings, or disordered operation sequence that may occur when operating alone, and improves the reliability of the entire process.

[0042] In this embodiment, specifically in the unidirectional, irreversible, full-process anti-contamination closed-loop system, if the status verification of any step fails, the inoculation machine control system automatically locks the current operation interface and issues an audible and visual alarm. Only after the fault is cleared and the status verification passes can authorized personnel unlock the interface and continue to execute subsequent steps.

[0043] It is worth noting that this status verification and locking mechanism forms a strict process control, ensuring that each operation is performed under the premise of meeting the conditions. Any abnormality in any step will block the subsequent process, avoiding the risk of sterilization failure or contamination caused by forcibly operating when the status is not met, and realizing the controllability and traceability of the entire process.

[0044] Working principle: When using, first turn on the inoculation machine and switch to manual mode. Follow the pre-sterilization positioning and calibration preparation steps to complete the three-point positioning, displacement calibration and valve pre-positioning of the sterilization rack, ensuring that the sterilization rack is in a precise position and that all actuators are in standby mode. The process then proceeds to the collaborative steam sterilization negative feedback control step. After the inoculation machine operator and the seed tank operator complete the cross-position authorization confirmation, the seed tank operator opens the main steam valve and adjusts the pressure of the front-end pipeline. The inoculation machine operator sequentially opens the valve before the storage tank, the valve at the end of the sterilization rack, and the main valve of the exhaust pipeline to stabilize the pressure inside the sterilization rack at 0.1-0.15MPa and the temperature at 121-124℃. After the pressure stabilizes, the system first automatically detects the nozzle for air / water leakage. If an abnormality is detected, an alarm is triggered and a troubleshooting prompt is given. After confirming that there are no abnormalities, the system enters the pressure holding sterilization process for 40 minutes. During the pressure holding process, the control system monitors the pressure and temperature in real time and automatically maintains the parameters stable through the negative feedback control loop to ensure a stable and reliable sterilization process. After the sterilization time reaches the target, a gradient pressure reduction and anti-contamination interlocking procedure is executed: the seed tank operator first reduces the opening of the steam valve to lower the pressure in the front pipeline to 0.1 MPa. When the sterilization rack pressure drops to 0.05 MPa, the inoculation machine operator sequentially closes the end valve of the sterilization rack and the main valve of the exhaust pipeline, and then notifies the seed tank operator to close the main steam valve, thus achieving gradient pressure reduction and interlocking. After the main valve is closed, the control system continuously monitors the sterilization rack pressure. If a negative pressure trend is observed, it automatically prompts the operator to slightly open the main exhaust pipeline valve to balance the pressure and prevent backflow of external bacteria. After the sterilization rack cools down, connect the inoculum tank to the sterilization rack and proceed to the inoculum pipeline pre-flushing and residual removal step: sequentially open the two exhaust valves of the sterilization rack and the main pipeline valve, allowing the inoculum liquid to flow through the pipeline for 3-5 seconds to complete the rinsing, and the waste liquid to be discharged through the independent outlet. Then quickly close the main feed valve to complete the pipeline pre-flushing and quick disconnection. After closing the inoculation valve and removing the sterilization rack, perform a double disinfection procedure at the terminal: First, use 95% alcohol cotton balls to flame-sterilize each inoculation nozzle for 10-12 seconds, ensuring complete coverage of the nozzle outer wall, outlet, and upper open area; then, spray disinfection is performed on the space inside the laminar flow hood using 3%-5% food-grade hydrogen peroxide disinfectant, with a spray volume of 10-15 ml per cubic meter, and the space is sealed for 3-5 minutes to complete the sterilization of the space environment; Finally, perform the standardized reset and automatic inoculation triggering steps: sequentially control the cap opening valve to stop, the cap clamping valve to stop, and the bottle pressing valve to rise to the initial position. During the reset process, maintain positive pressure air supply in the laminar flow hood, with the pressure 5-10 Pa higher than the outside pressure. After the reset is completed, switch the inoculation machine to automatic mode, start it, and enter the automatic inoculation program to complete the entire pre-inoculation disinfection process.

[0045] Throughout the process, the control system monitors the status of each step in real time. If the previous step fails the status verification, it is automatically locked and prohibited from entering the next step. Operators at each position work together in accordance with the principle of separation of permissions, forming a one-way irreversible full-process anti-contamination closed-loop system to ensure the standardization, automation and traceability of the disinfection process before inoculation.

[0046] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0047] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A method for disinfecting a bag-planting inoculation machine, characterized in that, The system comprises six sequentially connected steps: pre-sterilization positioning and verification preparation, collaborative steam sterilization negative feedback control, gradient pressure reduction and anti-contamination sequential interlocking, pre-flushing and residual removal of inoculum pipelines, terminal double disinfection, standardized reset and automatic inoculation triggering. Each step is connected by cross-position operation authority separation, status verification interlocking, and negative feedback control mechanisms to form a unidirectional and irreversible full-process anti-contamination closed-loop system. If the status verification of the previous step fails, the inoculation machine control system automatically locks and prevents entry into the next step. (1) Preparation steps for positioning and verification before sterilization: After the inoculator is turned on, switch to manual mode and place the sterilization rack in the direction of the inoculator basket. Control the raising of the back baffle of the inoculator through manual mode, and face the end of the sterilization rack with the limiting structure towards the direction of the basket. Make the two limiting parts on the left side of the sterilization rack fit against the straight edge of the conveyor belt of the inoculator. The spatial position of the sterilization rack is locked by the three-point cooperation of the back baffle, the two limiting parts and the straight edge of the conveyor belt. After the three-point positioning is completed, manually push the sterilization rack along the direction of the conveyor belt. The pushing range should not exceed 5mm. Verify that there is no displacement. Then control the bottle pressure valve to descend, the cap clamp valve to operate, the cap opening valve to operate, the needle rack valve to operate and the inoculation valve to operate in sequence through the display screen of the inoculator to complete the pre-positioning of the valves before sterilization. (2) Collaborative Steam Sterilization Negative Feedback Control Steps: After the inoculation machine operator and the seed tank operator complete the cross-post authorization confirmation, the seed tank operator opens the main steam valve and controls the steam pressure in the front-end pipeline between the main valve and the sterilization rack at 0.15-0.2 MPa through the steam pressure reducing valve; the inoculation machine operator sequentially opens the valve in front of the storage tank, the two valves at the end of the sterilization rack, and the main valve of the exhaust pipeline to regulate the steam pressure in the sterilization rack to stabilize at 0.1-0.15 MPa, corresponding to a temperature of 121-124℃. After the pressure stabilizes, the inoculation machine first... The system automatically detects air / water leaks at each nozzle positioning point. If an abnormality is detected, an alarm is immediately triggered. Operators then check and address any sealing defects such as raw rubber tape or material residue at the nozzle-base contact area. If the defects cannot be addressed, the system is stopped, reported, and the sterilization process is terminated. After confirming that there are no abnormalities, the system enters a 40-minute pressure sterilization process. During the pressure holding process, the inoculation machine control system monitors the pressure and temperature inside the sterilization rack in real time. When the pressure or temperature deviates from the preset range, the system automatically adjusts the steam input or the opening of the exhaust pipe to form a pressure-temperature negative feedback control loop, which together constitutes a negative feedback closed loop for sterilization stability. (3) Gradient pressure reduction and anti-contamination interlocking steps: After the sterilization time reaches the target, the seed tank operator first reduces the opening of the steam valve to reduce the steam pressure in the front pipeline to 0.1MPa; when the pressure gauge value of the sterilization rack drops to 0.05MPa, the inoculation machine operator closes the two valves at the end of the sterilization rack and the main valve of the exhaust pipeline in sequence, and then notifies the seed tank operator to close the main steam valve. The fixed-sequence gradient pressure reduction operation forms a time-sequence interlock to prevent negative pressure in the pipeline; after the main steam valve is closed, the control system continuously monitors the pressure change of the sterilization rack. If a negative pressure trend occurs, that is, the pressure is lower than 0.02MPa, the operator is immediately prompted to slightly open the main exhaust pipeline valve to balance the pressure, forming a pressure-action negative feedback interlock; (4) Pre-flushing and residual discharge steps of inoculum pipeline: After connecting the inoculum tank and sterilization rack and verifying the sealing, open the two exhaust valves of sterilization rack and the main valve of pipeline in sequence, so that the inoculum liquid flows through the pipeline for 3-5 seconds to complete the pipeline rinsing and residual liquid discharge. The waste liquid after rinsing is discharged through the independent outlet of sterilization rack and immediately isolated, and does not return to the inoculum tank. Then quickly close the main inlet valve of inoculum tank to form the pre-discharge and quick disconnection operation of inoculum pipeline; (5) Terminal double disinfection steps: After closing the inoculation valve and removing the sterilization rack, first use 95% alcohol cotton balls to flame-sterilize each inoculation nozzle. The flame-sterilization time is controlled at 10-12 seconds. The flame-sterilization flame completely covers the outer wall of the nozzle, the liquid outlet and the upper opening area. Then spray disinfection is carried out on the space inside the laminar flow hood of the inoculation machine. Flame disinfection and spray disinfection are performed sequentially and complementary in function to form a multi-level disinfection synergy mechanism. (6) Standardized reset and automatic inoculation triggering steps: After disinfection, enter the manual operation interface of the inoculation machine, and control the opening valve to stop, the clamping valve to stop, and the bottle pressing valve to rise to the initial position in sequence. Then switch the inoculation machine to automatic mode and start the automatic inoculation program.

2. The disinfection method for the bag-planting inoculation machine according to claim 1, characterized in that, In the collaborative steam sterilization negative feedback control process, the steam pressure of the sterilization rack is precisely checked every 5 minutes during the pressure holding process. If the pressure fluctuation exceeds the range of 0.1-0.15MPa, the control system immediately adjusts the opening degree of the steam pressure reducing valve and the exhaust pipe valve to make the pressure return to the set range within 30 seconds, forming a two-level negative feedback closed loop for pressure regulation.

3. The disinfection method for the bag-planting inoculation machine according to claim 1, characterized in that, In the collaborative steam sterilization negative feedback control process, when troubleshooting nozzle sealing defects, first use a lint-free cloth to remove residual raw rubber tape, material residue, and other foreign matter from the contact area between the nozzle and the base. After reinstallation, pressurize again for 3 minutes to conduct a sealing test until there is no abnormal air / water leakage.

4. The disinfection method for the bag-planting inoculation machine according to claim 1, characterized in that, In the gradient pressure reduction and anti-contamination interlocking procedure, after closing the main steam valve, the control system continuously monitors the pressure of the sterilization rack for no less than 5 minutes. If a negative pressure trend occurs, i.e. the pressure is lower than 0.02MPa, an operation prompt will pop up automatically. The operator should slightly open the main exhaust valve until the pressure recovers to 0.03-0.05MPa and then close it to prevent the backflow of external bacteria.

5. The disinfection method for the bag-planting inoculation machine according to claim 1, characterized in that, During the pre-flushing and residual removal step of the inoculum pipeline, the rinsing flow rate of the inoculum solution is controlled at 0.8-1.2 m / s, and the rinsing time is precisely controlled at 4 seconds. The flow rate is monitored in real time by the pipeline flow sensor to ensure that the residual condensate and sterilization residue in the pipeline are completely discharged.

6. The disinfection method for the bag-planting inoculation machine according to claim 1, characterized in that, In the terminal dual disinfection step, the alcohol content of the alcohol cotton ball is controlled at 95%±2% during flame scorching disinfection. During the scorching process, it moves at a uniform speed of 5cm / s along the circumference of the nozzle to ensure that all contact surfaces of the nozzle outer wall, the liquid outlet and the upper cap opening mechanism are continuously covered by the flame.

7. The disinfection method for the bag-planting inoculation machine according to claim 1, characterized in that, In the terminal dual disinfection process, the spray disinfection inside the laminar flow hood uses a 3%-5% food-grade hydrogen peroxide disinfectant solution, with a spray volume of 10-15 ml per cubic meter of space. After spraying, the laminar flow hood is sealed for 3-5 minutes to complete the sterilization of the space environment.

8. The disinfection method for the bag-planting inoculation machine according to claim 1, characterized in that, In the standardized reset and automatic inoculation triggering steps, the operation interval between valve stopping and bottle valve reset shall not exceed 5 seconds, and the laminar flow hood shall be kept in a positive pressure air supply state throughout the reset process, with the pressure inside the hood being 5-10 Pa higher than the outside pressure, to prevent external bacteria from entering the inoculation area during the reset process.

9. The disinfection method for the bag-planting inoculation machine according to claim 1, characterized in that, In the closed-loop system for preventing contamination throughout the entire process, the operating permissions for each step are set separately according to job responsibilities: the operator of the inoculation machine only has the authority to operate the sterilization rack, control the valve, disinfect and reset, and the operator of the seed tank only has the authority to open, adjust and close the main steam valve, forming a cross-job permission interlock to avoid process disorder caused by single-person operation.

10. The disinfection method for the bag-planting inoculation machine according to claim 1, characterized in that, In the one-way, irreversible, closed-loop system for preventing bacterial contamination throughout the entire process, if the status verification of any step fails, the inoculation machine control system will automatically lock the current operation interface and issue an audible and visual alarm. Only after the fault is cleared and the status verification passes can authorized personnel unlock the interface and continue to execute subsequent steps.

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