A mushroom heat pump drying system based on real-time monitoring of machine vision

Abstract

The present invention relates to a mushroom heat pump drying system based on real-time monitoring of machine vision, comprising a monitoring module, a heat pump module, a drying module, a PLC controller and an IPC industrial computer, wherein the monitoring module, the heat pump module and the drying module are all connected to the PLC controller, and the PLC controller is connected to the IPC industrial computer. The present invention transmits the parameters of the mushroom drying process to the PLC controller in real time through the parameter monitoring module and the visual monitoring module, and the PLC controller can upload to the IPC industrial computer for data analysis and comparison, and feed back to the drying module and the heat pump module through the PLC controller, and the drying module and the heat pump module can adjust the drying parameters in real time, and the operation of the heat pump module and the drying module will not be interrupted during the mushroom quality detection process, which not only improves the drying quality of the mushroom, but also ensures the stability of the system.

Description

Technical Field

[0001] The invention belongs to the technical field of electrical material measurement, relates to trap energy level measurement of polymer film materials, and particularly to a mushroom heat pump drying system based on real-time monitoring of machine vision. Background Art

[0002] Shiitake mushrooms (Lentinus edodes) are the second largest edible fungi in the world, rich in nutrients such as amino acids, minerals, and polysaccharides. Fresh shiitake mushrooms have a very high water content and a vigorous metabolism. They will soften and brown in a short period of time after being picked, losing their commercial value. Therefore, after shiitake mushrooms are harvested, it is necessary to choose a suitable preservation method to extend their shelf life. Dehydration and drying is one of the important processes in the storage and processing of shiitake mushrooms. By removing water, the growth of microorganisms and the metabolic activity of the fruiting body itself are inhibited.

[0003] At present, my country's mushroom drying technology has achieved rapid development, and infrared, microwave, vacuum, freezing and other drying technologies have emerged. However, these methods have limitations. The heat pump drying technology studied in recent years has the advantages of low drying temperature, short drying time and good drying quality. The use of heat pumps to dry mushrooms can not only significantly improve the efficiency of mushroom drying, but also the mushroom products dried by heat pumps have better color and stable internal quality. The machine vision real-time monitoring system can timely adjust parameters such as temperature, humidity, wind speed, etc. according to the dehydration of the drying material and the changes in the drying medium (air), which can improve energy efficiency and further ensure the quality of the drying material, and maximize the retention of the nutritional components and color, aroma and taste of the product.

[0004] The color and shrinkage rate of shiitake mushrooms are important indicators of the drying quality of materials. The current detection method is to take out the dried materials from the drying chamber for testing after regular drying for a period of time, so as to obtain the color and shrinkage rate of the shiitake mushrooms. However, this operation will affect the drying quality of the shiitake mushrooms and the stable operation of the heat pump drying system, and it is impossible to quickly adjust the medium parameters of the heat pump dryer according to the drying state of the shiitake mushrooms. Summary of the invention

[0005] The purpose of the present invention is to overcome the deficiencies of the prior art and to provide a mushroom heat pump drying system based on real-time monitoring by machine vision.

[0006] The present invention solves the technical problem by the following technical solutions:

[0007] A mushroom heat pump drying system based on real-time monitoring of machine vision, characterized in that it comprises a monitoring module, a heat pump module, a drying module, a PLC controller and an IPC industrial computer, wherein the monitoring module, the heat pump module and the drying module are all connected to the PLC controller, and the PLC controller is connected to the IPC industrial computer;

[0008] The drying module includes a drying box and a circulating fan, a temperature regulating fan, a dehumidifying fan, a humidifier, an electric auxiliary heating mechanism and a material trolley installed on the drying box. A material trolley is slidably arranged in the drying box, and a plurality of weighing bottom plates are arranged in the material trolley. A circulating fan, a dehumidifying fan, a humidifier and an electric auxiliary heating mechanism are arranged on the inner wall of the drying box. A dehumidifying air duct is arranged on the outer side of the drying box, and the dehumidifying air duct is connected to the dehumidifying fan;

[0009] The heat pump module includes a compressor, a heating condenser, a temperature regulating condenser and an evaporator, the outlet of the compressor is connected to the heating condenser, the heating condenser is connected to the temperature regulating condenser, the temperature regulating condenser is connected to the evaporator after being regulated by an electronic expansion valve, the evaporator is connected to the compressor, and the temperature regulating fan is arranged on one side of the temperature regulating condenser;

[0010] The monitoring module includes a parameter monitoring module and a visual monitoring module. The parameter monitoring module includes a temperature and humidity sensor, a wind speed sensor and a weighing sensor. The temperature and humidity sensor and the wind speed sensor are arranged in the drying box. The weighing sensor is arranged at the lower end of the weighing base plate. The visual monitoring module includes an industrial camera, a camera protective cover and a camera fixing bracket. The camera fixing bracket is fixedly installed on the upper end of the drying box. The industrial camera is installed on the camera fixing bracket. The light source emitted by the industrial camera is aimed at the mushroom material on the weighing base plate.

[0011] Moreover, a camera protective cover is arranged on the outer side of the camera fixing bracket.

[0012] Moreover, the working process of the system is:

[0013] 1) Pull out the material cart and place the mushrooms in layers on the weighing bottom plate inside the material cart, and then push the material cart into the drying oven;

[0014] 2) Start the heat pump module and the drying module through the PLC controller. First, the compressor outside the drying box is started, and the heat pump working fluid flows through the heating condenser to condense into liquid, and the heat released by the condensation of the heat pump working fluid is used to heat the drying medium in the drying box. Then the heat pump working fluid flows through the temperature regulating condenser, and the speed of the temperature regulating fan is controlled by the frequency conversion technology, thereby controlling the heat dissipation of the temperature regulating condenser and adjusting the temperature in the drying box. The heat pump working fluid flows through the evaporator and changes from a gas-liquid mixture to saturated or superheated steam, and the heat absorbed by the evaporation of the heat pump working fluid is used to cool and dehumidify the drying medium. The drying medium flows through the heating condenser and heats up before entering the drying box. After absorbing the moisture of the mushrooms, it leaves the drying box to form a low-temperature and high-humidity drying medium, flows through the evaporator of the heat pump, removes a certain amount of moisture and becomes a low-temperature and low-humidity drying medium, then flows through the heating condenser and heats to the set temperature before entering the drying box again to complete the cycle of the drying medium.

[0015] 3) The weighing sensor detects the weight of the mushroom material in real time and transmits the weight signal to the PLC controller. The PLC controller calculates the weight of the dried mushroom product according to the initial weight of the mushroom, the initial moisture content of the mushroom and the moisture content of the dried mushroom product;

[0016] 4) When the weight of the mushrooms during the drying process does not reach the weight of the finished dried mushrooms, the PLC controller controls the industrial camera of the visual monitoring module to take pictures at a fixed time, and transmits the taken pictures to the IPC industrial computer. The IPC industrial computer uses the HALCON software to process and analyze the color and shrinkage rate of the mushrooms;

[0017] 5) The IPC industrial computer transmits the analysis results to the MATLAB software through the Visual Studio human-computer interaction platform, and uses the fuzzy controller of the SIMULINK simulation platform in the MATLAB software to take the color difference between the current color of the mushrooms and the color required at the end of drying, the difference between the current shrinkage rate of the mushrooms and the required shrinkage rate of the mushrooms as input, and the changes in temperature, humidity, and wind speed in the drying box as output, to process the data, and transmit the obtained data results to the Visual Studio human-computer interaction platform through the OPC communication protocol, and then transmit them to the PLC controller by the Visual Studio human-computer interaction platform;

[0018] 6) After receiving the signal, the PLC controller controls the heat pump module and the drying module to perform corresponding work, and strictly monitors the color value of the mushrooms through the industrial camera of the visual monitoring module to predict the change trend. When the color shows signs of darkening, the temperature regulating fan is controlled in advance to increase the frequency, increase the heat dissipation, and reduce the opening of the electronic expansion valve, and reduce the refrigerant flow, so as to effectively adjust the temperature of the drying medium in the drying box to control the color change; when the current shrinkage rate of the mushrooms is greater than the standard shrinkage rate, the circulating fan reduces the frequency, the wind speed of the drying box is reduced, the humidifier is turned on, and the humidity of the drying box is increased. When the current shrinkage rate of the mushrooms is less than the standard shrinkage rate, the dehumidification fan is turned on, the humidifier is turned off, and the opening of the electronic expansion valve is increased at the same time, the temperature of the drying medium is adjusted, and the humidity of the drying box is reduced;

[0019] 7) After the parameter reaches the specified value, the signal of the next camera photo analysis and processing is transmitted to the PLC controller. When the weight of the mushrooms reaches the weight of the dried mushrooms during the drying process, the heat pump module and the drying module are shut down to complete the drying.

[0020] The advantages and beneficial effects of the present invention are:

[0021] The mushroom drying system of the present invention transmits the parameters of the mushroom drying process to the PLC controller in real time through the parameter monitoring module and the visual monitoring module. At the same time, the PLC controller can upload the data to the IPC industrial computer for data analysis and comparison, and feed back to the drying module and the heat pump module through the PLC controller. The drying module and the heat pump module can adjust the drying parameters in real time. The operation of the heat pump module and the drying module will not be interrupted during the mushroom quality detection process, which not only improves the drying quality of the mushrooms, but also ensures the stability of the system. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 It is a front view of the present invention;

[0023] Figure 2 for Figure 1 AA section view;

[0024] Figure 3 It is a structural schematic diagram of the present invention;

[0025] Figure 4 It is a structural schematic diagram of the visual monitoring module of the present invention.

[0026] 1. IPC industrial computer; 2. PLC controller; 3. Monitoring module; 4. Heat pump module; 5. Drying module; 21. Temperature and humidity sensor; 22. Wind speed sensor; 23. Weighing sensor; 31. Industrial camera; 32. Light source; 33. Camera protective cover; 34. Camera fixing bracket; 41. Compressor; 42. Heating condenser; 43. Temperature regulating condenser; 44. Electronic expansion valve; 45. Evaporator; 51. Circulating fan; 52. Temperature regulating fan; 53. Dehumidification fan; 54. Humidifier; 55. Electric auxiliary heating device; 56. Weighing bottom plate; 57. Drying box; 58. Dehumidification duct; 59. Material trolley. DETAILED DESCRIPTION

[0027] The present invention is further described in detail below through specific examples. The following examples are only illustrative and not restrictive, and the protection scope of the present invention cannot be limited thereto.

[0028] A mushroom heat pump drying system based on real-time monitoring by machine vision, the innovation of which is that it includes a monitoring module 3, a heat pump module 4, a drying module 5, a PLC controller 2 and an IPC industrial computer 1, wherein the monitoring module 3, the heat pump module 4 and the drying module 5 are all connected to the PLC controller 2, and the PLC controller 2 is connected to the IPC industrial computer 1;

[0029] The drying module 5 includes a drying box 57 and a circulating fan 51, a temperature regulating fan 52, a dehumidifying fan 53, a humidifier 54, an electric auxiliary heating mechanism 55 and a material trolley 59 installed on the drying box 57. A material trolley is slidably arranged in the drying box 57, and a plurality of weighing bottom plates 56 are arranged in the material trolley. The circulating fan 51, the dehumidifying fan 53, the humidifier 54 and the electric auxiliary heating mechanism 55 are arranged on the inner wall of the drying box. A dehumidifying air duct 58 is arranged on the outer side of the drying box 57, and the dehumidifying air duct 58 is connected to the dehumidifying fan 53;

[0030] The heat pump module 4 includes a compressor 41, a temperature-raising condenser 42, a temperature-regulating condenser 43 and an evaporator 45. The outlet of the compressor 41 is connected to the temperature-raising condenser 42, the temperature-raising condenser 42 is connected to the temperature-regulating condenser 43, the temperature-regulating condenser 43 is connected to the evaporator 45 after being regulated by an electronic expansion valve 44, the evaporator 45 is connected to the compressor 41, and the temperature-regulating fan 52 is arranged on one side of the temperature-regulating condenser 43.

[0031] The monitoring module 3 includes a parameter monitoring module and a visual monitoring module. The parameter monitoring module includes a temperature and humidity sensor 21, a wind speed sensor 22 and a weighing sensor 23. The temperature and humidity sensor 21 and the wind speed sensor 22 are arranged in the drying box 57. The weighing sensor 23 is arranged at the lower end of the weighing base plate 56. The visual monitoring module includes an industrial camera 31, a camera protective cover 33 and a camera fixing bracket 34. The camera fixing bracket 34 is fixedly installed on the upper end of the drying box 57. The industrial camera 31 is installed on the camera fixing bracket 34. A camera protective cover 33 is arranged on the outer side of the camera fixing bracket 34. The light source 32 emitted by the industrial camera 31 is aimed at the mushroom material on the weighing base plate 56.

[0032] A mushroom heat pump drying system based on real-time monitoring by machine vision, the innovation of which lies in: the working process of the system is:

[0033] 1) Pull out the material cart and place the mushrooms in layers on the weighing bottom plate inside the material cart, and then push the material cart into the drying oven;

[0034] 2) Start the heat pump module and the drying module through the PLC controller. First, the compressor outside the drying box is started, and the heat pump working fluid flows through the heating condenser to condense into liquid, and the heat released by the condensation of the heat pump working fluid is used to heat the drying medium in the drying box. Then the heat pump working fluid flows through the temperature regulating condenser, and the speed of the temperature regulating fan is controlled by the frequency conversion technology, thereby controlling the heat dissipation of the temperature regulating condenser and adjusting the temperature in the drying box. The heat pump working fluid flows through the evaporator and changes from a gas-liquid mixture to saturated or superheated steam, and the heat absorbed by the evaporation of the heat pump working fluid is used to cool and dehumidify the drying medium. The drying medium flows through the heating condenser and heats up before entering the drying box. After absorbing the moisture of the mushrooms, it leaves the drying box to form a low-temperature and high-humidity drying medium, flows through the evaporator of the heat pump, removes a certain amount of moisture and becomes a low-temperature and low-humidity drying medium, then flows through the heating condenser and heats to the set temperature before entering the drying box again to complete the cycle of the drying medium.

[0035] 3) The weighing sensor detects the weight of the mushroom material in real time and transmits the weight signal to the PLC controller. The PLC controller calculates the weight of the dried mushroom product according to the initial weight of the mushroom, the initial moisture content of the mushroom and the moisture content of the dried mushroom product;

[0036] 4) When the weight of the mushrooms during the drying process does not reach the weight of the finished dried mushrooms, the PLC controller controls the industrial camera of the visual monitoring module to take pictures at a fixed time, and transmits the taken pictures to the IPC industrial computer. The IPC industrial computer uses the HALCON software to process and analyze the color and shrinkage rate of the mushrooms;

[0037] 5) The IPC industrial computer transmits the analysis results to the MATLAB software through the Visual Studio human-computer interaction platform, and uses the fuzzy controller of the SIMULINK simulation platform in the MATLAB software to take the color difference between the current color of the mushrooms and the color required at the end of drying, the difference between the current shrinkage rate of the mushrooms and the required shrinkage rate of the mushrooms as input, and the changes in temperature, humidity, and wind speed in the drying box as output, to process the data, and transmit the obtained data results to the Visual Studio human-computer interaction platform through the OPC communication protocol, and then transmit them to the PLC controller by the Visual Studio human-computer interaction platform;

[0038] 6) After receiving the signal, the PLC controller controls the heat pump module and the drying module to perform corresponding work, and strictly monitors the color value of the mushrooms through the industrial camera of the visual monitoring module to predict the change trend. When the color shows signs of darkening, the temperature regulating fan is controlled in advance to increase the frequency, increase the heat dissipation, and reduce the opening of the electronic expansion valve, and reduce the refrigerant flow, so as to effectively adjust the temperature of the drying medium in the drying box to control the color change; when the current shrinkage rate of the mushrooms is greater than the standard shrinkage rate, the circulating fan reduces the frequency, the wind speed of the drying box is reduced, the humidifier is turned on, and the humidity of the drying box is increased. When the current shrinkage rate of the mushrooms is less than the standard shrinkage rate, the dehumidification fan is turned on, the humidifier is turned off, and the opening of the electronic expansion valve is increased at the same time, the temperature of the drying medium is adjusted, and the humidity of the drying box is reduced;

[0039] 7) After the parameter reaches the specified value, the signal of the next camera photo analysis and processing is transmitted to the PLC controller. When the weight of the mushrooms reaches the weight of the dried mushrooms during the drying process, the heat pump module and the drying module are shut down to complete the drying.

[0040] Although the embodiments and drawings of the present invention are disclosed for illustrative purposes, those skilled in the art will appreciate that various substitutions, changes and modifications are possible without departing from the spirit and scope of the present invention and the appended claims. Therefore, the scope of the present invention is not limited to the contents disclosed in the embodiments and drawings.

Claims

1. A mushroom heat pump drying system based on real-time monitoring by machine vision, characterized in that: It comprises a monitoring module (3), a heat pump module (4), a drying module (5), a PLC controller and an IPC industrial computer (1), wherein the monitoring module (3), the heat pump module (4) and the drying module (5) are all connected to the PLC controller, and the PLC controller is connected to the IPC industrial computer (1); The drying module (5) comprises a drying box (57) and a circulating fan (51), a temperature regulating fan (52), a dehumidifying fan (53), a humidifier (54), an electric auxiliary heating mechanism (55) and a material trolley (59) installed on the drying box (57); a material trolley is slidably arranged in the drying box (57); a plurality of weighing bottom plates (56) are arranged in the material trolley; a circulating fan (51), a dehumidifying fan (53), a humidifier (54) and an electric auxiliary heating mechanism (55) are arranged on the inner side wall of the drying box; a dehumidifying air duct (58) is arranged on the outer side of the drying box (57); and the dehumidifying air duct (58) is connected to the dehumidifying fan (53); The heat pump module (4) comprises a compressor (41), a temperature-raising condenser (42), a temperature-regulating condenser (43) and an evaporator (45); the outlet of the compressor (41) is connected to the temperature-raising condenser (42); the temperature-raising condenser (42) is connected to the temperature-regulating condenser (43); the temperature-regulating condenser (43) is connected to the evaporator (45) after being regulated by an electronic expansion valve (44); the evaporator (45) is connected to the compressor (41); and the temperature-regulating fan (52) is arranged on one side of the temperature-regulating condenser (43); The monitoring module (3) comprises a parameter monitoring module and a visual monitoring module. The parameter monitoring module comprises a temperature and humidity sensor (21), a wind speed sensor (22) and a weighing sensor (23). The temperature and humidity sensor (21) and the wind speed sensor (22) are arranged in the drying box (57). The weighing sensor (23) is arranged at the lower end of the weighing base plate (56). The visual monitoring module comprises an industrial camera (31), a camera protective cover (33) and a camera fixing bracket (34). The camera fixing bracket (34) is fixedly mounted at the upper end of the drying box (57). The industrial camera (31) is mounted on the camera fixing bracket (34). The industrial camera (31) is aimed at the mushroom material on the weighing base plate (56).

2. The mushroom heat pump drying system based on machine vision real-time monitoring according to claim 1 is characterized in that: A camera protective cover (33) is arranged outside the camera fixing bracket (34).

3. The mushroom heat pump drying system based on machine vision real-time monitoring according to claim 1 or 2, characterized in that: The working process of the system is: 1) Pull out the material cart and place the mushrooms in layers on the weighing bottom plate inside the material cart, and then push the material cart into the drying oven; 2) Start the heat pump module and the drying module through the PLC controller. First, the compressor outside the drying box is started, and the heat pump working fluid flows through the heating condenser to condense into liquid, and the heat released by the condensation of the heat pump working fluid is used to heat the drying medium in the drying box. Then the heat pump working fluid flows through the temperature regulating condenser, and the speed of the temperature regulating fan is controlled by the frequency conversion technology, thereby controlling the heat dissipation of the temperature regulating condenser and adjusting the temperature in the drying box. The heat pump working fluid flows through the evaporator and changes from a gas-liquid mixture to saturated or superheated steam, and the heat absorbed by the evaporation of the heat pump working fluid is used to cool and dehumidify the drying medium. The drying medium flows through the heating condenser and heats up before entering the drying box. After absorbing the moisture of the mushrooms, it leaves the drying box to form a low-temperature and high-humidity drying medium, flows through the evaporator of the heat pump, removes a certain amount of moisture and becomes a low-temperature and low-humidity drying medium, then flows through the heating condenser and heats to the set temperature before entering the drying box again to complete the cycle of the drying medium. 3) The weighing sensor detects the weight of the mushroom material in real time and transmits the weight signal to the PLC controller. The PLC controller calculates the weight of the dried mushroom product according to the initial weight of the mushroom, the initial moisture content of the mushroom and the moisture content of the dried mushroom product; 4) When the weight of the mushrooms during the drying process does not reach the weight of the finished dried mushrooms, the PLC controller controls the industrial camera of the visual monitoring module to take pictures at a fixed time, and transmits the taken pictures to the IPC industrial computer. The IPC industrial computer uses the HALCON software to process and analyze the color and shrinkage rate of the mushrooms; 5) The IPC industrial computer transmits the analysis results to the MATLAB software through the Visual Studio human-computer interaction platform, and uses the fuzzy controller of the SIMULINK simulation platform in the MATLAB software to take the color difference between the current color of the mushrooms and the color required at the end of drying, the difference between the current shrinkage rate of the mushrooms and the required shrinkage rate of the mushrooms as input, and the changes in temperature, humidity, and wind speed in the drying box as output, to process the data, and transmit the obtained data results to the Visual Studio human-computer interaction platform through the OPC communication protocol, and then transmit them to the PLC controller by the Visual Studio human-computer interaction platform; 6) After receiving the signal, the PLC controller controls the heat pump module and the drying module to perform corresponding work, and strictly monitors the color value of the mushrooms through the industrial camera of the visual monitoring module to predict the change trend. When the color shows signs of darkening, the temperature regulating fan is controlled in advance to increase the frequency, increase the heat dissipation, and reduce the opening of the electronic expansion valve, and reduce the refrigerant flow, so as to effectively adjust the temperature of the drying medium in the drying box to control the color change; when the current shrinkage rate of the mushrooms is greater than the standard shrinkage rate, the circulating fan reduces the frequency, the wind speed of the drying box is reduced, the humidifier is turned on, and the humidity of the drying box is increased. When the current shrinkage rate of the mushrooms is less than the standard shrinkage rate, the dehumidification fan is turned on, the humidifier is turned off, and the opening of the electronic expansion valve is increased at the same time, the temperature of the drying medium is adjusted, and the humidity of the drying box is reduced; 7) After the parameter reaches the specified value, the signal of the next camera photo analysis and processing is transmitted to the PLC controller. When the weight of the mushrooms reaches the weight of the dried mushrooms during the drying process, the heat pump module and the drying module are shut down to complete the drying.

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