Automatic batching system and method for producing liquid microbial agent

Abstract

The invention discloses an automatic batching system and method for liquid microbial agent production, and relates to the technical field of microbial culture.The automatic batching system comprises a central control system, and a data driving management module is designed in the central control system; the data driving management module is used for automatically and intelligently adjusting configuration parameters in the automatic batching process; the data driving management module comprises a real-time data acquisition unit and an intelligent data analysis unit, and the real-time data acquisition unit is connected with the intelligent data analysis unit through a central database and a local area network. By installing the data driving management module, the functions of collection, storage, management and analysis of production data are achieved, the problems that data are dispersed and cannot be monitored in real time in traditional production are solved, the intelligence and controllability of the production process are improved through real-time data analysis and management, and the production efficiency is improved. Fine management of the production process is realized, the production plan and resource configuration are optimized, and the production efficiency and the quality level are improved.

Description

Technical Field

[0001] The present invention relates to the technical field of microbial cultivation, and in particular to an automatic batching system and method for producing liquid microbial inoculants. Background Art

[0002] In the production process of liquid microbial inoculants, accurate batching is a key step to ensure product quality and production efficiency. However, the traditional manual batching method has many problems and defects:

[0003] First, manual batching is easily affected by the operator's technical level and experience, resulting in errors and instability in the batching process, affecting the consistency and stability of product quality. Secondly, the manual batching process is cumbersome and time-consuming, requiring a lot of manpower, low production efficiency and prone to omissions. In addition, manual batching has the problem of difficult quality traceability, and it is impossible to achieve comprehensive monitoring and data recording of the production process, making it difficult to meet quality management and regulatory requirements.

[0004] Therefore, it is very necessary for the present application to propose an automatic batching system and method for the production of liquid microbial agents to solve the technical shortcomings of the existing manual batching.

[0005] 1. Patent document CN103421689B discloses a microbial agent production equipment. The above patent has simple structure, high degree of automation, high efficiency in producing microbial agents, high yield rate and low production cost. It can keep the workshop at a constant temperature and humidity, protect the microbial expansion production stage from contamination by foreign bacteria, ensure stable quality, and greatly increase the number of live bacteria in the production of microbial strains. However, the above patent cannot realize the functions of collecting, storing, managing and analyzing production data.

[0006] 2. Patent document CN104293706B discloses a microbial agent for kimchi production. The above patent is suitable for large-scale industrial production and can also be used for manual workshop production. The product has a large application market, but the above patent cannot realize the automatic control function of raw material weighing, supplying and stirring.

[0007] 3. Patent document CN114231404B discloses a microbial agent production device. The above patent effectively prevents the microbial agent from dying due to splashing and adsorption on the side wall of the fermentation tank body and being separated from the fermentation nutrient solution for a long time, thereby correspondingly improving the overall fermentation quality of the liquid material and avoiding waste of resources. At the same time, it can increase the activity of the sediment on the bottom surface of the fermentation tank body and avoid the sediment reducing the uniformity of the liquid material mixing. However, the above patent cannot realize the functions of predictive maintenance and technical support for the batching system.

[0008] 4. Patent document CN105441370B discloses a microbial agent and a production method thereof. The above patent achieves high bacterial content and low rate of foreign bacteria, and can effectively improve soil properties, but the above patent cannot realize the online quality monitoring function of production.

[0009] In summary, the above patents cannot realize the functions of collecting, storing, managing and analyzing production data, the automatic control functions of raw material weighing, supplying and mixing, the predictive maintenance and technical support functions of the batching system and the online quality monitoring functions of production, which leads to batching errors and instability, affects the consistency and stability of product quality, and leads to low production efficiency and low economic benefits.

[0010] To this end, the present application proposes an automatic batching system and method for the production of liquid microbial agents that can realize the functions of collecting, storing, managing and analyzing production data, automatic control of raw material weighing, supply and stirring, predictive maintenance and technical support of the batching system, and online quality monitoring of production. Summary of the invention

[0011] The object of the present invention is to provide an automatic batching system and method for the production of liquid microbial agents, so as to solve the technical problems proposed in the above-mentioned background technology that the functions of collecting, storing, managing and analyzing production data, automatic control of raw material weighing, supplying and stirring, predictive maintenance and technical support of the batching system and online quality monitoring of production cannot be realized, resulting in batching errors and instability, affecting the consistency and stability of product quality, low production efficiency and low economic benefits.

[0012] To achieve the above object, the present invention provides the following technical solutions: an automatic batching system for the production of liquid microbial inoculants, comprising a central control system, wherein a data-driven management module is designed in the central control system, and the data-driven management module is used to automatically and intelligently adjust the configuration parameters of the automatic batching process;

[0013] The data driven management module includes: a real-time data acquisition unit and an intelligent data analysis unit, wherein the real-time data acquisition unit is connected to the intelligent data analysis unit via a central database and a local area network;

[0014] The real-time data acquisition unit collects various parameter data of the production process in real time through the data acquisition system, and transmits the real-time data to the central database through the data transmission channel for storage and analysis. The real-time data acquisition unit is connected to the real-time monitoring interface through a data line to display the real-time status and trend of various data;

[0015] The intelligent data analysis unit applies big data analysis technology to conduct in-depth analysis and mining of the data collected by the real-time data acquisition unit, establishes a production optimization model based on the data analysis results, automatically identifies the optimization space in the generation process, and automatically adjusts the ingredient production parameters and processes according to the data analysis results in combination with the feedback control system in the central control system.

[0016] Preferably, the data-driven management module is connected to a precise batching module via a data signal line, and the precise batching module is used to automatically and intelligently configure production raw materials;

[0017] The precise batching module includes: an intelligent raw material weighing unit, an intelligent formula control unit and a data recording and reporting unit. The intelligent raw material weighing unit is connected to the intelligent formula control unit and the data recording and reporting unit through a data line, and the data recording and reporting unit is connected to the central database through a network API interface.

[0018] The intelligent raw material weighing unit selects a pressure sensor to measure the weight of the raw materials, designs an automatic feeding device controlled by an electronic valve, continuously supplies raw materials according to the formula requirements, and controls the weighing error within 0.1% through a feedback control system;

[0019] The intelligent formula control unit inputs formula parameters through a user-friendly touch screen interface, establishes a formula database, stores formula information of different products, and allows quick selection and modification. Combined with real-time weighing data and feedback control system, it automatically adjusts formula parameters to achieve precise batching;

[0020] The data recording and reporting unit records the real-time data of each weighing process, automatically generates a weighing report, stores the weighing data in a central database, manages and shares the data, and accesses the ERP system through a local area network.

[0021] Preferably, the central control system is connected to an intelligent mixing module via a local area network communication, and the intelligent mixing module is used to perform adaptive mixing and stirring of production raw materials;

[0022] The intelligent mixing module includes: an adaptive stirring and mixing unit, an intelligent reaction control unit and an intelligent monitoring and adjustment unit. The intelligent monitoring and adjustment unit is connected to the central control system through a network, and the central control system is connected to the adaptive stirring and mixing unit and the intelligent reaction control unit through a feedback control system API interface;

[0023] The adaptive stirring and mixing unit monitors the mixing parameters in the mixing tank through sensors via a real-time monitoring system, and uses a feedback control system to automatically adjust the stirring parameters of the stirrer according to the mixing conditions monitored by the sensors;

[0024] The intelligent reaction control unit integrates a PID temperature control system, automatically heats and cools according to the recipe requirements, monitors and adjusts the reaction liquid in real time, sets the reaction time parameters, and uses a time controller to automatically control the reaction end time;

[0025] The intelligent monitoring and adjustment unit is equipped with temperature, pH and concentration sensors to monitor the key parameters in the reaction process in real time. Combined with the feedback control system, the reaction conditions are adjusted in real time according to the sensor data, and an abnormal alarm function is set to alarm and automatically shut down when the parameters exceed the range.

[0026] Preferably, the central control system is connected to an intelligent maintenance service module via a data communication interface, and the intelligent maintenance service module is used to monitor and maintain the automatic batching system;

[0027] The intelligent maintenance service module includes: a predictive maintenance unit, a remote technical support unit and a user experience optimization unit. The predictive maintenance unit and the remote technical support unit are connected to the user experience optimization unit through a data signal line;

[0028] The predictive maintenance unit monitors the operation and status of the equipment in real time through installed vibration sensors and temperature sensors, analyzes the monitoring data using machine learning algorithms, identifies equipment failure modes and makes predictions, and generates preventive maintenance plans based on the failure prediction results;

[0029] The remote technical support unit establishes a remote monitoring system, allowing remote monitoring of the equipment's operating status, production parameters and alarm information, providing remote diagnostic services, troubleshooting and repair guidance through remote network connections, and establishing an online technical support platform to provide all-round technical support;

[0030] The user experience optimization unit is designed with an intuitive user interface that displays device status, fault alarms and maintenance prompts in real time.

[0031] Preferably, the central control system is connected to a quality control inspection module via data network communication, and the quality control inspection module is connected to the intelligent raw material weighing unit via a central database and a network communication interface;

[0032] The quality control inspection module includes: an online quality monitoring unit and a product inspection sampling unit, which are connected to the central database through a data network;

[0033] The online quality monitoring unit monitors the quality indicators of the product in real time through the microbial activity sensor and concentration sensor installed in the reaction tank, uses the feedback control system to adjust the production parameters in real time according to the monitoring data, and automatically generates a product quality report which is transmitted to the central database through the data network for storage and record;

[0034] The product inspection sampling unit regularly conducts sampling inspections on products through an automatic sampling system, establishes laboratory analysis processes, conducts detailed testing and analysis of product samples, establishes product quality files, records inspection results, batch information and production parameters, and ensures product traceability and quality management.

[0035] Preferably, the specific algorithm formula of the PID temperature control system in the intelligent reaction control unit is as follows:

[0036]

[0037] Among them, u(t) is the output of the controller, that is, the temperature control signal;

[0038] e(t) is the temperature deviation, that is, the difference between the set temperature and the actual temperature;

[0039] Kp, Ki, and Kd are the proportional, integral, and differential coefficients, respectively;

[0040] represents the integral term, which represents the integral of the temperature deviation;

[0041] Represents the differential term, which indicates the rate of change of temperature deviation.

[0042] Preferably, the production optimization model in the intelligent data analysis unit is a linear regression model, which is used to optimize energy consumption and adjust production parameters to minimize energy consumption. The specific model formula is as follows:

[0043] E=a·T+b·F+c

[0044] Among them, a, b, and c are the parameters of the model, which represent the influence relationship between energy consumption and temperature and flow rate;

[0045] T represents the reaction temperature and F represents the flow rate of liquid bacterial agent.

[0046] Preferably, the big data analysis technologies applied by the intelligent data analysis unit include data clarity, data mining and regression analysis algorithms, which clean and preprocess the collected data, use cluster analysis to discover the relationships and potential patterns among the data, apply regression analysis algorithms to establish prediction models and optimization models, and predict the production process and optimize parameters.

[0047] Preferably, the method comprises the following steps:

[0048] S1. Using the intelligent formula control unit, the operator inputs the required raw material ratio and mixing sequence formula parameters through the touch screen interface. Using the data-driven management module, the system verifies and reviews the formula parameters input by the user to ensure the rationality and accuracy of the parameters;

[0049] S2. Using intelligent raw material weighing unit, the system automatically controls the electronic valve to feed raw materials according to the formula parameters input by the user, and uses high-precision pressure sensors to weigh raw materials to ensure the accuracy and stability of ingredients;

[0050] S3, using the intelligent mixing module, the system automatically adjusts the stirring speed and time according to the formula requirements to achieve adaptive control of the mixing process;

[0051] S4. Using the quality control inspection module, the system monitors product quality indicators through online sensors and inspects the quality of the product after the ingredients are mixed in real time.

[0052] Preferably, the method further comprises the following steps:

[0053] S31, using the PID temperature control system in the intelligent reaction control unit to achieve accurate control and adjustment of the reaction liquid temperature according to the temperature sensor monitoring data;

[0054] S41. Using the data-driven management module, the system records various data in the batching process in real time and generates weighing reports and quality inspection reports for traceability and analysis.

[0055] Compared with the prior art, the present invention has the following beneficial effects:

[0056] 1. The present invention realizes the functions of collecting, storing, managing and analyzing production data by installing a data-driven management module, solving the problem of data dispersion and inability to monitor in real time in traditional production. Through real-time data analysis and management, the intelligence and controllability of the production process are improved, and the fine management of the production process, optimization of production planning and resource allocation, and improvement of production efficiency and quality level are achieved;

[0057] 2. The present invention realizes the automatic control function of raw material weighing, supplying and stirring by installing a precise batching module, solves the problems of error, instability and cumbersomeness in the manual batching process, improves the accuracy and stability of batching, reduces production costs and resource waste, and ensures the consistency and stability of product quality;

[0058] 3. The present invention realizes the functions of predictive maintenance and technical support for the batching system by installing an intelligent maintenance service module, solves the problems of difficult equipment maintenance, untimely fault handling, poor user experience, etc., prevents equipment failures in advance, reduces downtime, and improves user satisfaction and corporate image;

[0059] 4. The present invention realizes the online quality monitoring function of production by installing a quality control inspection module, solves the problems of product quality being unable to be monitored in real time, cumbersome inspection procedures, and difficult quality traceability, ensures that product quality meets requirements, improves quality management level, and reduces quality risks and legal liabilities. BRIEF DESCRIPTION OF THE DRAWINGS

[0060] Figure 1 It is a schematic diagram of a data driven management module of the present invention;

[0061] Figure 2 It is a schematic diagram of the precise batching module of the present invention;

[0062] Figure 3 It is a schematic diagram of the intelligent hybrid module of the present invention;

[0063] Figure 4 This is a schematic diagram of the intelligent maintenance service module of the present invention;

[0064] Figure 5 It is a schematic diagram of the quality control inspection module of the present invention. DETAILED DESCRIPTION

[0065] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0066] Example 1

[0067] See also Figure 1 , an embodiment provided by the present invention: an automatic batching system for the production of liquid microbial inoculants, comprising a central control system, wherein the central control system is designed with a data-driven management module, and the data-driven management module is used to automatically and intelligently adjust the configuration parameters of the automatic batching process;

[0068] The data driven management module includes: a real-time data acquisition unit and an intelligent data analysis unit, wherein the real-time data acquisition unit is connected to the intelligent data analysis unit via a central database and a local area network;

[0069] The real-time data acquisition unit collects various parameter data of the production process in real time through the data acquisition system, and transmits the real-time data to the central database through the data transmission channel for storage and analysis. The real-time data acquisition unit is connected to the real-time monitoring interface through a data line to display the real-time status and trend of various data;

[0070] The intelligent data analysis unit applies big data analysis technology to deeply analyze and mine the data collected by the real-time data collection unit, establishes a production optimization model based on the data analysis results, automatically identifies the optimization space in the generation process, and automatically adjusts the batching production parameters and processes according to the data analysis results in combination with the feedback control system in the central control system;

[0071] Furthermore, various sensors, such as temperature sensors, pressure sensors, flow sensors, etc., are installed in the batching system to collect various parameter data in the production process in real time. The collected real-time data is transmitted to the data-driven management module through the data transmission channel. The data-driven management module is responsible for storing these data in the central database for subsequent analysis and use, and establishing a real-time monitoring interface to display the real-time status and trend of various data, supporting operators to monitor and control the production process in real time. The real-time data acquisition unit records each collected data, including timestamp, sensor name, parameter value, etc., for subsequent data analysis and report generation;

[0072] Clean and preprocess the collected real-time data, including removing outliers, filling missing values, data conversion, etc., to ensure data quality and availability; use data mining techniques, such as association rule mining, cluster analysis, anomaly detection, etc., to mine the potential patterns and valuable information in the data; establish prediction models, such as time series prediction models, regression models, etc., based on historical data and data analysis results, to predict future production trends and changes; establish production optimization models based on data analysis results and prediction models, solve them through optimization algorithms, and achieve optimal adjustment of the production process; provide data analysis results and the output of the optimization model to decision makers to support their production scheduling, resource allocation, and decision making, so as to achieve optimization and improvement of the production process.

[0073] Example 2

[0074] See also Figure 1 and Figure 2 , an embodiment provided by the present invention: an automatic batching system for the production of liquid microbial inoculants, wherein the data-driven management module is connected to a precise batching module via a data signal line, and the precise batching module is used to automatically and intelligently configure production raw materials;

[0075] The precise batching module includes: an intelligent raw material weighing unit, an intelligent formula control unit and a data recording and reporting unit. The intelligent raw material weighing unit is connected to the intelligent formula control unit and the data recording and reporting unit through a data line, and the data recording and reporting unit is connected to the central database through a network API interface.

[0076] The intelligent raw material weighing unit selects a pressure sensor to measure the weight of the raw materials, designs an automatic feeding device controlled by an electronic valve, continuously supplies raw materials according to the formula requirements, and controls the weighing error within 0.1% through a feedback control system;

[0077] The intelligent formula control unit inputs formula parameters through a user-friendly touch screen interface, establishes a formula database, stores formula information of different products, and allows quick selection and modification. Combined with real-time weighing data and feedback control system, it automatically adjusts formula parameters to achieve precise batching;

[0078] The data recording and reporting unit records the real-time data of each weighing process, automatically generates a weighing report, stores the weighing data in the central database, manages and shares the data, and accesses the ERP system through the local area network;

[0079] Furthermore, the intelligent formula control unit obtains the formula parameters input by the user, including the types, proportions and mixing order of the raw materials. According to the formula parameters, the intelligent raw material weighing unit controls the electronic valves and conveyor belts and other devices to accurately control the supply of the raw materials. A high-precision pressure sensor is used to weigh each raw material. During the weighing process, the weighing data is monitored in real time, and feedback control is performed on the weighing process to ensure the weighing accuracy and stability.

[0080] The operator inputs the formula parameters, including the type, proportion, and mixing order of raw materials, through the interface of the intelligent formula control unit. The intelligent formula control unit verifies and reviews the input formula parameters to ensure the rationality and accuracy of the parameters. According to the real-time data and feedback information in the production process, the intelligent formula control unit can adjust the formula parameters in real time and optimize the batching process. The intelligent formula control unit stores the set formula parameters in the database and supports formula management and version control.

[0081] The data recording and reporting unit records various data in the batching process in real time, including formula parameters, raw material weighing data, mixing time, etc., and stores the data in the batching process in the database, supporting data traceability and historical query. The data recording and reporting unit can generate batching reports, including formula details, weighing records, mixing process records, etc., for quality management and traceability needs. Quality inspection is carried out during the batching process, and quality inspection results and exception handling records are recorded. The weighing data is stored in the central database for data management and sharing. At the same time, the ERP system is connected through the local area network to ensure the quality and traceability of the ingredients.

[0082] Example 3

[0083] See also Figure 2 and Figure 3, an embodiment provided by the present invention: an automatic batching system for the production of liquid microbial inoculants, wherein the central control system is connected to an intelligent mixing module via a local area network communication, and the intelligent mixing module is used to perform adaptive mixing and stirring of production raw materials;

[0084] The intelligent mixing module includes: an adaptive stirring and mixing unit, an intelligent reaction control unit and an intelligent monitoring and adjustment unit. The intelligent monitoring and adjustment unit is connected to the central control system through a network, and the central control system is connected to the adaptive stirring and mixing unit and the intelligent reaction control unit through a feedback control system API interface;

[0085] The adaptive stirring and mixing unit monitors the mixing parameters in the mixing tank through sensors via a real-time monitoring system, and uses a feedback control system to automatically adjust the stirring parameters of the stirrer according to the mixing conditions monitored by the sensors;

[0086] The intelligent reaction control unit integrates a PID temperature control system, automatically heats and cools according to the recipe requirements, monitors and adjusts the reaction liquid in real time, sets the reaction time parameters, and uses a time controller to automatically control the reaction end time;

[0087] The intelligent monitoring and adjustment unit is equipped with temperature, pH and concentration sensors to monitor the key parameters in the reaction process in real time. Combined with the feedback control system, the reaction conditions are adjusted in real time according to the sensor data, and an abnormal alarm function is set to alarm and automatically shut down when the parameters exceed the range.

[0088] Furthermore, the formula parameters input by the user, including mixing time, stirring speed, etc., are obtained from the intelligent formula control unit. The adaptive stirring and mixing unit controls the start and stop, stirring speed, stirring time and other parameters of the stirring equipment according to the formula parameters. During the mixing process, the temperature, pressure and stirring effect in the mixing tank are monitored in real time, and the feedback is given to the intelligent reaction control unit for adjustment. According to the real-time monitoring data, the adaptive stirring and mixing unit can automatically adjust the stirring speed and time to achieve the best mixing effect.

[0089] The intelligent reaction control unit monitors the temperature, pressure and other reaction parameters in the mixing tank in real time to ensure the stability and safety of the reaction process. It uses the PID temperature control system to accurately control the reaction process, adjust the heating / cooling equipment, and keep the temperature of the reaction liquid stable. When an abnormal reaction is detected, the intelligent reaction control unit can promptly issue an alarm and take corresponding emergency measures to ensure production safety.

[0090] The intelligent monitoring and adjustment unit monitors various parameters in the mixing process in real time, including temperature, flow rate, concentration, etc., analyzes the monitored data, and determines whether there are abnormalities or instabilities in the mixing process. If an abnormal situation occurs, the abnormal alarm function is triggered. If the parameters exceed the range, an alarm and automatic shutdown operation will be performed. According to the data analysis results, the intelligent monitoring and adjustment unit can automatically adjust the mixing parameters, such as stirring speed, temperature of heating / cooling equipment, etc., to ensure the stability of the mixing process and product quality.

[0091] Example 4

[0092] See also Figure 4 , an embodiment provided by the present invention: an automatic batching system for the production of liquid microbial inoculants, wherein the central control system is connected to an intelligent maintenance service module via a data communication interface, and the intelligent maintenance service module is used to monitor and maintain the automatic batching system;

[0093] The intelligent maintenance service module includes: a predictive maintenance unit, a remote technical support unit and a user experience optimization unit. The predictive maintenance unit and the remote technical support unit are connected to the user experience optimization unit through a data signal line;

[0094] The predictive maintenance unit monitors the operation and status of the equipment in real time through installed vibration sensors and temperature sensors, analyzes the monitoring data using machine learning algorithms, identifies equipment failure modes and makes predictions, and generates preventive maintenance plans based on the failure prediction results;

[0095] The remote technical support unit establishes a remote monitoring system, allowing remote monitoring of the equipment's operating status, production parameters and alarm information, providing remote diagnostic services, troubleshooting and repair guidance through remote network connections, and establishing an online technical support platform to provide all-round technical support;

[0096] The user experience optimization unit is designed with an intuitive user interface that displays device status, fault alarms, and maintenance prompts in real time;

[0097] Furthermore, the equipment operation data, such as temperature, pressure, current, etc., are collected in real time to monitor the equipment's operating status and performance parameters. The collected data is analyzed, and a prediction model is established using a machine learning algorithm to predict the possible failure modes and maintenance cycles of the equipment. Based on the results of the prediction model, the intelligent maintenance service module will issue early warnings and reminders to notify maintenance personnel to perform preventive maintenance and overhaul. Based on the results of the prediction model, regular maintenance plans are formulated to optimize the allocation and use of maintenance resources and reduce equipment failures and downtime.

[0098] Establish a remote monitoring system to monitor the equipment operation status in real time, remotely diagnose equipment failures and provide technical support. When equipment failure occurs, the remote technical support unit can remotely operate the equipment for repair and debugging, reduce on-site maintenance time, provide remote training and guidance, and help operators and maintenance personnel master equipment operation skills and troubleshooting methods;

[0099] Design an intuitive and easy-to-use user interface to display equipment status, fault alarms and maintenance prompts in real time, provide operation guides and help documents, simplify user operation processes, provide user training courses, cultivate the skills and awareness of operators and maintenance personnel, reduce the operating error rate, design fault handling processes, provide users with quick responses and solutions, and ensure the stable operation of the system.

[0100] Example 5

[0101] See also Figure 1 , Figure 2 and Figure 5 , an embodiment provided by the present invention: an automatic batching system for the production of liquid microbial inoculants, wherein the central control system is connected to a quality control inspection module via data network communication, and the quality control inspection module is connected to an intelligent raw material weighing unit via a central database and a network communication interface;

[0102] The quality control inspection module includes: an online quality monitoring unit and a product inspection sampling unit, which are connected to the central database through a data network;

[0103] The online quality monitoring unit monitors the quality indicators of the product in real time through the microbial activity sensor and concentration sensor installed in the reaction tank, uses the feedback control system to adjust the production parameters in real time according to the monitoring data, and automatically generates a product quality report which is transmitted to the central database through the data network for storage and record;

[0104] The product inspection sampling unit conducts regular sampling inspections on products through an automatic sampling system, establishes laboratory analysis procedures, conducts detailed testing and analysis on product samples, establishes product quality files, records inspection results, batch information and production parameters, and ensures product traceability and quality management;

[0105] Furthermore, during the production process, the online quality monitoring unit monitors the quality indicators of the product in real time through the microbial activity sensor and concentration sensor installed in the reaction tank, collects key quality parameter data in real time, such as temperature, pressure, pH value, concentration, etc., analyzes and monitors the collected data in real time, compares the actual data with the set standard, and determines whether the product quality meets the requirements. When the data is found to be abnormal or exceeds the set range, the online quality monitoring unit will issue an alarm and provide real-time abnormal information to notify the operator to handle it. The online quality monitoring unit can automatically adjust the production parameters, such as stirring speed, temperature control, etc., according to the real-time monitoring data to ensure product quality;

[0106] According to the production batches and quality control requirements, formulate a product sampling plan, including sampling time, sampling quantity, etc. During the production process, carry out product sampling according to the sampling plan, obtain samples for subsequent inspection, and send the sampled samples to the laboratory for detailed chemical and physical inspections, such as content analysis, component analysis, quality assessment, etc. Analyze the laboratory test results and compare them with the online monitoring data to evaluate the actual quality of the product, record the test results and evaluation reports, and form a quality data file for quality traceability and quality improvement.

[0107] Working principle: First, the automatic batching system obtains the formula parameters input by the user through the intelligent formula control unit, including the composition ratio and mixing order of the microbial inoculant. These parameters are transmitted to the intelligent raw material weighing unit, which automatically controls the supply of raw materials according to the formula parameters and uses high-precision weighing sensors to accurately weigh each raw material, ensuring the accuracy and stability of the batching process.

[0108] Then, after the raw materials are weighed, the automatic batching system feeds the raw materials into the intelligent mixing module. The adaptive stirring and mixing unit controls the start and stop, stirring speed and stirring time of the stirring equipment according to the formula parameters to achieve adaptive control of the mixing process. At the same time, the intelligent reaction control unit monitors the temperature, pressure and reaction parameters in the mixing tank, and uses the PID temperature control system to accurately control the temperature of the reaction liquid to ensure the stability and quality of the reaction process.

[0109] Finally, the automatic batching system records various data in the batching process through the data recording and reporting unit, including formula parameters, raw material weighing data, mixing process data, etc. These data are stored in the database for quality traceability and historical query. At the same time, the quality control and inspection module performs real-time quality inspection on the mixed product to ensure that the quality of the product meets the requirements, thus realizing the automation, precision and traceability of the liquid microbial agent production process.

[0110] It will be apparent to those skilled in the art that the invention is not limited to the details of the exemplary embodiments described above and that the invention can be implemented in other specific forms without departing from the spirit or essential features of the invention. Therefore, the embodiments should be considered exemplary and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description, and it is intended that all variations falling within the meaning and scope of the equivalent elements of the claims be included in the invention. Any reference numeral in a claim should not be considered as limiting the claim to which it relates.

Claims

1. An automatic batching system for the production of liquid microbial agents, characterized in that: It includes a central control system, wherein the central control system is designed with a data-driven management module, and the data-driven management module is used to automatically and intelligently adjust the configuration parameters of the automatic batching process; The data driven management module includes: a real-time data acquisition unit and an intelligent data analysis unit, wherein the real-time data acquisition unit is connected to the intelligent data analysis unit via a central database and a local area network; The real-time data acquisition unit collects various parameter data of the production process in real time through the data acquisition system, and transmits the real-time data to the central database through the data transmission channel for storage and analysis. The real-time data acquisition unit is connected to the real-time monitoring interface through a data line to display the real-time status and trend of various data; The intelligent data analysis unit applies big data analysis technology to conduct in-depth analysis and mining of the data collected by the real-time data acquisition unit, establishes a production optimization model based on the data analysis results, automatically identifies the optimization space in the generation process, and automatically adjusts the ingredient production parameters and processes according to the data analysis results in combination with the feedback control system in the central control system.

2. The automatic batching system for producing liquid microbial agents according to claim 1, characterized in that: The data driven management module is connected to the precise batching module via a data signal line, and the precise batching module is used to automatically and intelligently configure the production raw materials; The precise batching module includes: an intelligent raw material weighing unit, an intelligent formula control unit and a data recording and reporting unit. The intelligent raw material weighing unit is connected to the intelligent formula control unit and the data recording and reporting unit through a data line, and the data recording and reporting unit is connected to the central database through a network API interface. The intelligent raw material weighing unit selects a pressure sensor to measure the weight of the raw materials, designs an automatic feeding device controlled by an electronic valve, continuously supplies raw materials according to the formula requirements, and controls the weighing error within 0.1% through a feedback control system; The intelligent formula control unit inputs formula parameters through a user-friendly touch screen interface, establishes a formula database, stores formula information of different products, and allows quick selection and modification. Combined with real-time weighing data and feedback control system, it automatically adjusts formula parameters to achieve precise batching; The data recording and reporting unit records the real-time data of each weighing process, automatically generates a weighing report, stores the weighing data in a central database, manages and shares the data, and accesses the ERP system through a local area network.

3. The automatic batching system for producing liquid microbial inoculants according to claim 1, characterized in that: The central control system is connected to an intelligent mixing module via a local area network communication, and the intelligent mixing module is used to perform adaptive mixing and stirring of production raw materials; The intelligent mixing module includes: an adaptive stirring and mixing unit, an intelligent reaction control unit and an intelligent monitoring and adjustment unit. The intelligent monitoring and adjustment unit is connected to the central control system through a network, and the central control system is connected to the adaptive stirring and mixing unit and the intelligent reaction control unit through a feedback control system API interface; The adaptive stirring and mixing unit monitors the mixing parameters in the mixing tank through sensors via a real-time monitoring system, and uses a feedback control system to automatically adjust the stirring parameters of the stirrer according to the mixing conditions monitored by the sensors; The intelligent reaction control unit integrates a PID temperature control system, automatically heats and cools according to the recipe requirements, monitors and adjusts the reaction liquid in real time, sets the reaction time parameters, and uses a time controller to automatically control the reaction end time; The intelligent monitoring and adjustment unit is equipped with temperature, pH and concentration sensors to monitor the key parameters in the reaction process in real time. Combined with the feedback control system, the reaction conditions are adjusted in real time according to the sensor data, and an abnormal alarm function is set to alarm and automatically shut down when the parameters exceed the range.

4. The automatic batching system for producing liquid microbial inoculants according to claim 1, characterized in that: The central control system is connected to an intelligent maintenance service module via a data communication interface, and the intelligent maintenance service module is used to monitor and maintain the automatic batching system; The intelligent maintenance service module includes: a predictive maintenance unit, a remote technical support unit and a user experience optimization unit. The predictive maintenance unit and the remote technical support unit are connected to the user experience optimization unit through a data signal line; The predictive maintenance unit monitors the operation and status of the equipment in real time through installed vibration sensors and temperature sensors, analyzes the monitoring data using machine learning algorithms, identifies equipment failure modes and makes predictions, and generates preventive maintenance plans based on the failure prediction results; The remote technical support unit establishes a remote monitoring system, allowing remote monitoring of the equipment's operating status, production parameters and alarm information, providing remote diagnostic services, troubleshooting and repair guidance through remote network connections, and establishing an online technical support platform to provide all-round technical support; The user experience optimization unit is designed with an intuitive user interface that displays device status, fault alarms and maintenance prompts in real time.

5. The automatic batching system for producing liquid microbial agents according to claim 1, characterized in that: The central control system is connected to a quality control inspection module via a data network communication, and the quality control inspection module is connected to an intelligent raw material weighing unit via a central database and a network communication interface; The quality control inspection module includes: an online quality monitoring unit and a product inspection sampling unit, which are connected to the central database through a data network; The online quality monitoring unit monitors the quality indicators of the product in real time through the microbial activity sensor and concentration sensor installed in the reaction tank, uses the feedback control system to adjust the production parameters in real time according to the monitoring data, and automatically generates a product quality report which is transmitted to the central database through the data network for storage and record; The product inspection sampling unit regularly conducts sampling inspections on products through an automatic sampling system, establishes laboratory analysis processes, conducts detailed testing and analysis of product samples, establishes product quality files, records inspection results, batch information and production parameters, and ensures product traceability and quality management.

6. The automatic batching system for producing liquid microbial inoculants according to claim 3, characterized in that: The specific algorithm formula of the PID temperature control system in the intelligent reaction control unit is as follows: Among them, u(t) is the output of the controller, that is, the temperature control signal; e(t) is the temperature deviation, that is, the difference between the set temperature and the actual temperature; Kp, Ki, and Kd are the proportional, integral, and differential coefficients, respectively; represents the integral term, which represents the integral of the temperature deviation; Represents the differential term, which indicates the rate of change of temperature deviation.

7. The automatic batching system for producing liquid microbial agents according to claim 1, characterized in that: The production optimization model in the intelligent data analysis unit is a linear regression model, which is used to optimize energy consumption and adjust production parameters to minimize energy consumption. The specific model formula is as follows: E=a·T+b·F+c Among them, a, b, and c are the parameters of the model, which represent the influence relationship between energy consumption and temperature and flow rate; T represents the reaction temperature and F represents the flow rate of liquid bacterial agent.

8. The automatic batching system for producing liquid microbial inoculants according to claim 1, characterized in that: The big data analysis technologies applied by the intelligent data analysis unit include data clarity, data mining and regression analysis algorithms. The collected data are cleaned and preprocessed, cluster analysis is used to discover the relationships and potential patterns between the data, and regression analysis algorithms are used to establish prediction models and optimization models to predict the production process and optimize parameters.

9. An automatic batching method for producing liquid microbial inoculants, applicable to an automatic batching system for producing liquid microbial inoculants according to any one of claims 1 to 8, characterized in that: The method comprises the following steps: S1. Using the intelligent formula control unit, the operator inputs the required raw material ratio and mixing sequence formula parameters through the touch screen interface. Using the data-driven management module, the system verifies and reviews the formula parameters input by the user to ensure the rationality and accuracy of the parameters; S2. Using intelligent raw material weighing unit, the system automatically controls the electronic valve to feed raw materials according to the formula parameters input by the user, and uses high-precision pressure sensors to weigh raw materials to ensure the accuracy and stability of ingredients; S3, using the intelligent mixing module, the system automatically adjusts the stirring speed and time according to the formula requirements to achieve adaptive control of the mixing process; S4. Using the quality control inspection module, the system monitors product quality indicators through online sensors and inspects the quality of the product after the ingredients are mixed in real time.

10. The automatic batching method for producing liquid microbial inoculants according to claim 9, characterized in that: The method further comprises the following steps: S31, using the PID temperature control system in the intelligent reaction control unit to achieve accurate control and adjustment of the reaction liquid temperature according to the temperature sensor monitoring data; S41. Using the data-driven management module, the system records various data in the batching process in real time and generates weighing reports and quality inspection reports for traceability and analysis.

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