Risk grading intelligent management and control method for safety production

Abstract

The invention relates to the technical field of risk management and control, and discloses a risk grading intelligent management and control method for safety production, and the method comprises the steps: simulating the operation states of chemical solution containers with different capacities on a conveyor belt through building a risk simulation experiment model, and predicting the fluctuation of a liquid level at different deceleration; according to the risk simulation experiment model, second-level anti-contamination control is executed in the filling process, and the contamination risk is avoided by accurately controlling the liquid level rising speed and the stretching depth of a filling rod; when the speed of the conveying belt needs to be reduced, proper deceleration is obtained according to simulation experiment data, and the risk of displacement splashing is avoided; in addition, in combination with a risk simulation experiment, whether filling can be continued after the speed of the conveying belt is reduced is judged, and the contamination risk caused by continued filling is avoided; when the conveying belt suddenly stops, the position of the filling rod is adjusted, and the container dumping risk is prevented.

Description

Technical Field

[0001] The present invention relates to the technical field of risk management and control, and specifically to a risk classification intelligent management and control method for safe production. Background Art

[0002] In the modern chemical production process, production safety management is a key issue, especially when it comes to chemical solution delivery and filling operations. How to effectively prevent risks such as solution leakage, splashing, and dumping, and ensure the safety of operators and the environment has become a problem that major companies need to solve urgently. At present, traditional safety management relies more on manual operation and experience judgment. Although this method can ensure production safety to a certain extent, it relies on the judgment and experience of operators and is difficult to adapt to complex and changing production environments, so there are certain risks.

[0003] The conveying equipment control system in the prior art usually uses simple sensors and control algorithms to control the conveyor belt speed. However, this method fails to fully consider the liquid level changes of the chemical solution in the container and the physical properties of the solution, which makes it difficult to accurately control the liquid level fluctuations during container transportation, which can easily lead to problems such as solution overflow and splashing. In addition, due to the unpredictability of liquid level fluctuations, the prior art is difficult to effectively make real-time adjustments to prevent the risk of solution dumping or splashing when encountering a fault.

[0004] In terms of filling operations, existing anti-contamination measures are mostly focused on preventing and controlling excessively high liquid levels. However, existing technologies fail to provide effective real-time control strategies for the speed of liquid level rise and the complex liquid level changes inside the container, which often causes liquid to splash onto the filling rod during transportation.

[0005] At the same time, the fault emergency measures in the existing technology are relatively simple. When a temporary fault occurs, most systems only adopt a single speed adjustment or emergency shutdown strategy, and fail to combine the flow of liquid in the container with the liquid level fluctuation for real-time regulation, resulting in the risks of container displacement, solution splashing, and solution contamination of the filling rod during container transportation. These risks are not effectively prevented.

[0006] To address these shortcomings, this method combines liquid level changes, container transportation status and solution flow characteristics, and realizes graded risk management through precise simulation experiments and dynamic adjustment algorithms, ensuring that different production safety risks can be effectively addressed under normal and abnormal conditions; in addition, the speed adjustment of the conveyor belt and the state changes of the container are combined for comprehensive control to further optimize the production safety process and improve overall production safety and efficiency. Summary of the invention

[0007] The present invention provides a risk classification intelligent management and control method for safe production, which promotes solving the problems mentioned in the above background technology.

[0008] The present invention provides the following technical solution: a risk classification intelligent management and control method for safe production, comprising:

[0009] A risk simulation experiment was conducted on the running state of containers with different volumes of chemical solutions on a conveyor belt to form a risk simulation experiment model, including:

[0010] Add chemical solutions to the simulation container piece by piece;

[0011] After each filling, the simulated container is placed on the conveyor belt to start the transport;

[0012] Set the deceleration position and start deceleration at this position;

[0013] During the deceleration process, the deceleration of the conveyor belt is controlled to decrease gradually from the maximum deceleration;

[0014] and monitor the position change of the container and the liquid level change in the container after deceleration;

[0015] Implement secondary contamination risk control when using a filling rod to fill chemical solutions into containers;

[0016] The secondary anti-contamination risk control is specifically as follows:

[0017] When the container is transported by the conveyor belt, the liquid level growth rate in the container is obtained when the filling rod fills the chemical solution into the container, which is recorded as the liquid level rising speed;

[0018] When the filling rod is set to fill the chemical solution into the container, the distance between the liquid outlet of the filling rod and the liquid surface is recorded as H;

[0019] After the filling rod is extended into the container, the distance between it and the bottom of the container is equal to H;

[0020] When the filling rod starts to fill the chemical solution, the filling rod is controlled to rise at the speed of the liquid level rising, and the chemical solution is continuously poured into the container during the rising process;

[0021] When a temporary failure occurs and the conveying speed of the conveyor belt needs to be reduced, according to the risk simulation experimental model, anti-shift and anti-splash risk control is implemented in the process of using the conveyor belt to transport containers; at the same time, the first-level anti-contamination risk control is implemented in the process of the filling rod pouring the chemical solution into the container;

[0022] When a temporary failure occurs and the conveyor belt needs to be controlled to stop urgently, anti-dumping risk control is implemented.

[0023] Optionally, the risk simulation experiment is conducted on the operating state of containers with different volumes of chemical solutions on the conveyor line to form a risk simulation experiment model, specifically including:

[0024] Place a container on the conveyor belt, which is referred to as the simulated container;

[0025] Set the volume of chemical solution poured into the container in each simulation experiment, and record it as the pouring increment;

[0026] In each simulation experiment, a deceleration difference is set to control the deceleration of the conveyor belt speed to gradually decrease, and it is recorded as the deceleration decrease amount;

[0027] Conduct simulation experiments on simulated containers:

[0028] Add chemical solution in a volume equal to the injection increment into the simulation container step by step;

[0029] After the simulation container is filled with the chemical solution each time, the simulation container is placed on the conveyor belt, and the conveyor belt is controlled to transport the simulation container.

[0030] Optionally, the risk simulation experiment is performed on the operating state of containers containing chemical solutions of different capacities on the conveyor line to form a risk simulation experiment model, and further includes:

[0031] Setting a deceleration position on the conveyor belt for starting deceleration;

[0032] When the simulated container is transported to the deceleration position by the conveyor belt, the conveyor belt is controlled to decelerate at different deceleration rates, specifically:

[0033] Set the maximum simulated deceleration;

[0034] Each time the conveyor belt is controlled to transport the simulated container from the starting point of the conveyor belt to the deceleration position, the deceleration of the conveyor belt is controlled to decrease gradually from the maximum simulated deceleration, so that the difference of the successively decreasing decelerations is equal to the deceleration decreasing amount;

[0035] When the simulated container is transported by the conveyor belt, the state of the simulated container on the conveyor belt after passing the deceleration position is obtained.

[0036] Optionally, obtaining the state of the simulated container on the conveyor belt after passing the deceleration position specifically includes:

[0037] In each simulation:

[0038] Obtaining the relative position of the simulated container on the conveyor belt of the conveyor when the conveyor belt is started, and recording it as the initial position;

[0039] Obtaining the relative position of the simulated container on the conveyor belt of the conveyor belt after the simulated container passes through the deceleration position on the conveyor belt, and recording it as the position after deceleration;

[0040] After the simulated container passes the deceleration position on the conveyor belt, the highest point and the lowest point of the liquid level in the simulated container are obtained, and the capacity of the chemical solution in the simulated container and the deceleration of the conveyor belt are obtained at this time. The highest point of the liquid level is recorded as the highest point of the liquid level under the capacity and deceleration, and the lowest point of the liquid level is recorded as the lowest point of the liquid level under the capacity and conveying speed;

[0041] Get the height of the inner wall of the container, recorded as the inner wall height;

[0042] If the position after deceleration is different from the initial position or the highest point of the liquid surface is equal to the inner wall height, then record the volume of the chemical solution in the simulated container, and record the deceleration of the conveyor belt after the simulated container passes the deceleration position, and record the deceleration as the removal deceleration under the volume;

[0043] If the position after deceleration is the same as the initial position and the highest point of the liquid surface is less than the inner wall height, record the capacity of the chemical solution in the simulated container, and record the deceleration of the conveyor belt after the simulated container passes the deceleration position, and record this speed as the preferred deceleration under this capacity.

[0044] Optionally, the anti-displacement and anti-splash risk management and control includes:

[0045] When a temporary failure occurs, the container currently in the filling state is obtained, and the volume of the chemical solution in the container is obtained, which is recorded as the current volume;

[0046] According to the simulation experiment, the optimal deceleration when the capacity of the chemical solution in the container is the current capacity is obtained;

[0047] When a temporary fault occurs, the deceleration of the conveyor belt is controlled to be less than or equal to the preferred deceleration.

[0048] Optionally, the first-level anti-contamination risk control is performed during the process of the filling rod filling the chemical solution into the container, including:

[0049] When a temporary fault occurs and the conveying speed of the conveyor belt needs to be controlled to decrease, the deceleration of the conveyor belt is obtained and recorded as the fault deceleration, and the capacity of the chemical solution in the current container is obtained and recorded as the fault capacity;

[0050] According to the simulation experiment, the lowest point and the highest point of the liquid level under the fault capacity and fault deceleration are obtained, and they are recorded as the emergency lowest point and the emergency highest point of the liquid level respectively;

[0051] Set the maximum and minimum distances between the liquid outlet of the filling rod and the liquid level of the chemical solution in the container, which are recorded as the upper and lower limits of the distance respectively;

[0052] The four faces of the container on the conveyor belt that are perpendicular to the bottom of the container are recorded as four container vertical faces;

[0053] Among the four container elevations, two container elevations parallel to the conveying direction of the conveyor belt are obtained and recorded as marked container elevations;

[0054] Make a plane passing through the lowest and highest points of the emergency liquid level and perpendicular to the vertical surface of the marked container, and record it as the emergency simulation slope;

[0055] Draw a plane passing through the center point of the bottom surface of the container and perpendicular to the vertical surface of the marked container, and record it as the marking reference surface;

[0056] Taking the marked reference surface as the symmetry reference surface, obtaining the symmetry surface of the emergency simulation slope, and recording it as the symmetry simulation slope;

[0057] Get the center point of the plane covered by the liquid outlet of the filling rod and record it as the liquid outlet point.

[0058] Optionally, performing primary anti-contamination risk control during the process of the filling rod filling the chemical solution into the container also includes:

[0059] Draw a straight line perpendicular to the bottom of the container through the discharge point and record it as the reference vertical line;

[0060] Obtaining the intersection of the reference vertical line and the emergency simulation slope, and obtaining the distance between the intersection and the liquid discharge point, and recording the distance as the minimum distance;

[0061] Obtaining the intersection of the reference vertical line and the symmetrical simulated inclined plane, and obtaining the distance between the intersection and the liquid outlet point, and recording the distance as the maximum distance;

[0062] The maximum distance and the minimum distance are compared with the upper and lower interval limits respectively;

[0063] If the maximum distance is ≤ the upper limit of the spacing and the minimum distance is ≥ the lower limit of the spacing, no adjustment is made and the filling rod is controlled to continue to fill the chemical solution into the container;

[0064] If the maximum distance is greater than the upper limit of the spacing or the minimum distance is less than the lower limit of the spacing, it is determined whether there is a filling adjustment point.

[0065] Optionally, the determining whether there is a filling adjustment point includes:

[0066] Obtain the maximum distance that the filling rod moves in the opposite direction of the conveying direction of the conveyor belt after it extends into the container, and record it as the maximum adjustment distance;

[0067] Obtain the maximum adjustment distance of the filling rod moving horizontally in the direction opposite to the conveying direction and descending downward so that the distance between the liquid outlet point of the filling rod and the emergency simulation slope is equal to the lower limit of the spacing, and record it as the distance extreme value;

[0068] Compare the distance extreme value with the spacing upper limit;

[0069] If the distance extreme value is greater than the spacing upper limit, it is determined that there is no filling adjustment point, and when the conveyor belt starts to decelerate, the filling rod is controlled to stop discharging liquid and rise to the container opening of the container;

[0070] If the extreme distance value is ≤ the upper limit of the spacing, it is determined that there is a filling adjustment point, and the filling rod is controlled to move horizontally in the opposite direction of the conveying direction by the maximum adjustment distance and move downward so that the distance between the liquid outlet point of the filling rod and the emergency simulation slope is equal to the lower limit of the spacing, and the chemical solution continues to be poured into the container.

[0071] Optionally, when a temporary failure occurs and the conveyor belt needs to be controlled to stop urgently, anti-dumping risk control is performed, including:

[0072] When the conveyor belt needs to stop urgently, the filling rod is controlled to stop filling;

[0073] After the filling rod stops filling, the filling rod is controlled to move horizontally in the opposite direction of the conveying direction by the maximum adjustment distance.

[0074] The present invention has the following beneficial effects:

[0075] 1. Through simulation experiments, the operating status of the container with different volumes of chemical solutions is tested, focusing on analyzing the changes in the relative position of the container on the conveyor belt when the conveyor belt speed decreases. The data obtained through these analyses can be used to find the maximum deceleration that will not cause the container to shift under different liquid capacities, and provide a basis for selecting the appropriate deceleration when no failure occurs; the advantage of this measure is that it can ensure that the container remains in a stable state when the conveyor belt needs to decelerate, prevent the container from shifting on the conveyor belt, avoid the risk of splashing and dumping, and improve the safety of the production process.

[0076] 2. By implementing secondary anti-contamination risk control during the filling process, the leakage or splashing of chemical solutions can effectively avoid harm to the surrounding environment and operators; by controlling the depth of the filling rod inserted into the container and the distance from the bottom of the container, as well as ensuring the distance between the liquid outlet and the liquid surface, the possibility of the chemical solution injected into the filling process impacting the liquid surface and causing the chemical solution to splash onto the filling rod is reduced; in addition, by strictly controlling the liquid level rising speed, the distance between the filling rod and the liquid surface can be effectively controlled to avoid contact between the liquid surface and the filling rod, further improving the safety and accuracy of the entire process, and avoiding the risk of the chemical solution contaminating the filling rod and being carried out of the container by the filling rod.

[0077] 3. In the simulation experiment, the deceleration of the conveyor belt is controlled to decrease gradually from the maximum simulated deceleration. This decreasing method can make the optimal deceleration obtained in the final experiment meet the conditions that the container does not shift and the liquid level is not higher than the inner wall. Therefore, when selecting the appropriate deceleration in the future, there is an accurate reference value of the optimal deceleration, so that the selected deceleration can be less than or equal to the optimal deceleration, providing accurate data support for subsequent operations.

[0078] 4. Through simulation experiments, we can obtain the changes in the liquid level of the chemical solution inside the container at different capacities and decelerations, providing the necessary basis for anti-contamination control measures. By predicting the highest and lowest points of the liquid level changes, we can formulate targeted anti-contamination strategies to ensure that during the filling process, the liquid level fluctuations will not cause contamination and splash onto the filling rod. This control method based on experimental data can minimize the risk of leakage of chemical solutions and ensure the cleanliness and safety of the production environment through prediction and optimization of operations.

[0079] 5. In the simulation experiment, by comparing the highest point of the liquid surface after deceleration with the height of the inner wall of the container, it is determined whether the deceleration is the optimal deceleration under the current chemical solution capacity of the container. This method ensures that when the conveyor belt decelerates at the optimal deceleration finally screened out, the liquid level of the chemical solution in the container will not approach the top of the container, thereby minimizing the risk of the chemical solution in the container splashing out from the top of the container after deceleration.

[0080] 6. By obtaining the symmetrical simulation slope, all areas involved in the fluctuation of the liquid level of the chemical solution in the container after deceleration can be basically predicted. The emergency simulation slope represents the liquid level fluctuation caused by the chemical solution in the container moving in the conveying direction of the conveyor belt at the moment of deceleration, while the symmetrical simulation slope represents the liquid level fluctuation caused by the chemical solution in the container moving in the opposite direction of the conveying direction. Through the two slopes, all areas involved in the liquid level fluctuation of the chemical solution in the container are basically represented, providing data support for the subsequent implementation of anti-contamination risk management.

[0081] 7. By obtaining the minimum distance and the maximum distance, the maximum distance and the minimum distance between the liquid outlet point of the filling rod and the liquid surface can be known after the conveyor belt is decelerated. By comparing the maximum distance and the minimum distance with the upper limit and the lower limit of the spacing respectively, it is determined whether the filling rod can continue to fill without changing the position of the filling rod. This method ensures that the distance between the liquid outlet point of the filling rod and the liquid surface is within an appropriate range after the conveyor belt is decelerated, preventing the chemical liquid sprayed from the liquid outlet of the filling rod from impacting the liquid surface and causing splashing due to excessive distance, and preventing the liquid surface of the chemical solution from contacting the filling rod due to excessive distance, thereby avoiding the risk of the chemical solution contaminating the filling rod.

[0082] 8. By moving the filling rod horizontally in the opposite direction of the conveying direction by the maximum adjustment distance and lowering it downward, the distance between the liquid outlet point of the filling rod and the emergency simulation slope is equal to the lower limit of the spacing. When the filling rod is in this position, it is the minimum distance between the liquid outlet point of the filling rod and the emergency simulation slope. If in this position, the distance between the liquid outlet point of the filling rod and the symmetrical simulation slope does not meet the requirement of being less than or equal to the upper limit of the spacing, it means that there is no other position in the container that meets the conditions for continuing to pour the chemical solution, and filling cannot be continued. In this way, the system can timely determine whether there is a position in the container for continuing filling, and then choose whether to continue filling, to ensure that continued filling will not cause the risk of contamination to the filling rod.

[0083] 9. In the event of an emergency stop of the conveyor belt, immediate anti-dumping control measures should be taken to prevent the container from tipping over due to the emergency stop, especially when there is a chemical solution in the container, as the tipping over of the container may cause leakage or contamination of the solution. By controlling the filling rod to stop filling and move horizontally in the opposite direction of the conveying direction for the maximum adjustment distance, the filling rod will come into contact with the opening of the product container, and then when the conveyor belt stops suddenly, the filling rod will provide a certain support to the container, ensuring that the container can still be placed stably after the emergency stop to avoid the risk of tipping. BRIEF DESCRIPTION OF THE DRAWINGS

[0084] Figure 1 It is a schematic diagram of a container for storing chemical solutions according to the present invention.

[0085] Figure 2 It is a schematic diagram of the state of the container of the present invention on the conveyor belt.

[0086] Figure 3 It is a schematic diagram of the emergency simulated slope of the present invention.

[0087] Figure 4 It is a schematic diagram of the symmetrical simulated inclined plane of the present invention. DETAILED DESCRIPTION

[0088] 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.

[0089] Embodiment, a risk classification intelligent management and control method for safe production, comprising:

[0090] Reference Figure 1 and Figure 2 In this embodiment, the container is a rectangular container. When the container is transported on the conveyor belt, the bottom surface of the container contacts the conveyor belt. Among the four vertical surfaces of the container perpendicular to the bottom surface, two vertical surfaces parallel to each other are parallel to the conveying direction of the conveyor belt. A risk simulation experiment is conducted on the running state of containers with different capacities of chemical solutions on the conveyor belt to form a risk simulation experiment model, including:

[0091] Add chemical solutions to the simulation container piece by piece;

[0092] After each filling, the simulated container is placed on the conveyor belt to start the transport;

[0093] Set the deceleration position and start deceleration at this position;

[0094] During the deceleration process, the deceleration of the conveyor belt is controlled to decrease gradually from the maximum deceleration;

[0095] And monitor the position change of the container and the liquid level change in the container after deceleration; test the operating status of the container when containing chemical solutions of different capacities through simulation experiments, and focus on analyzing the change of the relative position of the container on the conveyor belt when the conveyor belt speed decreases. Through the data obtained from these analyses, it is possible to find out the maximum deceleration that will not cause the container to shift under different liquid capacities, and provide a basis for selecting the appropriate deceleration when no failure occurs; the advantage of this measure is that it can ensure that the container remains in a stable state when the conveyor belt needs to decelerate, prevent the container from shifting on the conveyor belt, avoid the risk of splashing and dumping, and improve the safety of the production process.

[0096] The secondary anti-contamination risk control is performed in the process of using the filling rod to fill the chemical solution into the container; in this embodiment, when the filling rod fills the chemical solution into the container, it moves simultaneously with the container, and the two remain relatively still;

[0097] The secondary anti-contamination risk control is specifically as follows:

[0098] When the container is transported by the conveyor belt, the liquid level growth rate in the container is obtained when the filling rod fills the chemical solution into the container, which is recorded as the liquid level rising speed;

[0099] When the filling rod is set to fill the chemical solution into the container, the distance between the liquid outlet of the filling rod and the liquid surface is recorded as H;

[0100] After the filling rod is extended into the container, the distance between it and the bottom of the container is equal to H;

[0101] When the filling rod starts to fill the chemical solution, the filling rod is controlled to rise at the speed of the liquid level rising, and the chemical solution is continuously poured into the container during the rising process; wherein, when the liquid outlet of the filling rod reaches the opening of the container, the filling rod stops rising and continues to pour the chemical solution into the container until the filling of the chemical solution is completed; by implementing secondary anti-contamination risk control during the filling process, the harm to the surrounding environment and operators caused by leakage or splashing of the chemical solution is effectively avoided; by controlling the depth of the filling rod extending into the container and the distance from the bottom of the container, as well as ensuring the distance between the liquid outlet and the liquid surface, the possibility of the chemical solution poured into the filling process impacting the liquid surface and causing the chemical solution to splash onto the filling rod is reduced; in addition, by strictly controlling the liquid level rising speed, the distance between the filling rod and the liquid surface can be effectively controlled to avoid contact between the liquid surface and the filling rod, further improving the safety and accuracy of the entire process, and avoiding the risk of the chemical solution contaminating the filling rod and then being taken out of the container by the filling rod.

[0102] When a temporary failure occurs and the conveying speed of the conveyor belt needs to be reduced, according to the risk simulation experimental model, anti-shift and anti-splash risk control is implemented in the process of using the conveyor belt to transport containers; at the same time, the first-level anti-contamination risk control is implemented in the process of the filling rod pouring the chemical solution into the container;

[0103] When a temporary failure occurs and the conveyor belt needs to be controlled to stop urgently, anti-dumping risk control is implemented.

[0104] The risk simulation experiment is conducted on the operating state of containers with different volumes of chemical solutions on the conveyor line to form a risk simulation experiment model, which specifically includes:

[0105] Place a container on the conveyor belt, which is referred to as the simulated container;

[0106] Set the volume of chemical solution poured into the container in each simulation experiment, and record it as the pouring increment;

[0107] In each simulation experiment, a deceleration difference is set to control the deceleration of the conveyor belt speed to gradually decrease, and it is recorded as the deceleration decrease amount;

[0108] Conduct simulation experiments on simulated containers:

[0109] Add chemical solution in a volume equal to the injection increment into the simulation container step by step;

[0110] After the simulation container is filled with the chemical solution each time, the simulation container is placed on the conveyor belt, and the conveyor belt is controlled to transport the simulation container.

[0111] The risk simulation experiment is conducted on the running state of containers with different volumes of chemical solutions on the conveying line to form a risk simulation experiment model, and further includes:

[0112] Setting a deceleration position on the conveyor belt for starting deceleration;

[0113] When the simulated container is transported to the deceleration position by the conveyor belt, the conveyor belt is controlled to decelerate at different deceleration rates, specifically:

[0114] Set the maximum simulated deceleration;

[0115] Each time the conveyor belt is controlled to transport the simulated container from the starting point of the conveyor belt to the deceleration position, the deceleration of the conveyor belt is controlled to decrease gradually from the maximum simulated deceleration, so that the difference of the successively decreasing decelerations is equal to the deceleration decrease amount; in the simulation experiment, the deceleration of the conveyor belt is controlled to decrease gradually from the maximum simulated deceleration. This decreasing method can make the optimal deceleration obtained in the final experiment meet the conditions that the container does not shift and the liquid level is not higher than the inner wall, so that when selecting the appropriate deceleration later, there is an accurate reference value of the preferred deceleration, so that the selected deceleration can be less than or equal to the preferred deceleration, providing accurate data support for subsequent operations.

[0116] When the simulated container is transported by the conveyor belt, the state of the simulated container on the conveyor belt after passing the deceleration position is obtained.

[0117] The obtaining of the state of the simulated container on the conveyor belt after passing the deceleration position specifically includes:

[0118] In each simulation:

[0119] Obtaining the relative position of the simulated container on the conveyor belt of the conveyor when the conveyor belt is started, and recording it as the initial position;

[0120] Obtaining the relative position of the simulated container on the conveyor belt of the conveyor belt after the simulated container passes through the deceleration position on the conveyor belt, and recording it as the position after deceleration;

[0121] After the simulated container passes the deceleration position on the conveyor belt, the highest point and the lowest point of the liquid level in the simulated container are obtained, and the capacity of the chemical solution in the simulated container and the deceleration of the conveyor belt at this time are obtained. The highest point of the liquid level is recorded as the highest point of the liquid level under the capacity and deceleration, and the lowest point of the liquid level is recorded as the lowest point of the liquid level under the capacity and conveying speed. By conducting simulation experiments, the liquid level changes of the chemical solution inside the container at different capacities and decelerations can be obtained, which provides the necessary basis for anti-contamination control measures. By predicting the highest and lowest points of the liquid level changes, targeted anti-contamination strategies can be formulated to ensure that during the filling process, the liquid level fluctuation will not cause contamination and splashing onto the filling rod. This control method based on experimental data can minimize the risk of leakage of chemical solutions and ensure the cleanliness and safety of the production environment through prediction and optimization of operations.

[0122] Reference Figure 1 , obtain the height of the inner wall of the container, recorded as the inner wall height;

[0123] If the position after deceleration is different from the initial position or the highest point of the liquid surface is equal to the inner wall height, then record the volume of the chemical solution in the simulated container, and record the deceleration of the conveyor belt after the simulated container passes the deceleration position, and record the deceleration as the removal deceleration under the volume;

[0124] If the position after deceleration is the same as the initial position and the highest point of the liquid surface is less than the inner wall height, the capacity of the chemical solution in the simulated container is recorded, and the deceleration of the conveyor belt after the simulated container passes the deceleration position is recorded, and the speed is recorded as the preferred deceleration under the capacity. In the simulation experiment, by comparing the highest point of the liquid surface after deceleration with the inner wall height of the container, it is determined whether the deceleration is the preferred deceleration under the current chemical solution capacity of the container. This method ensures that when the conveyor belt decelerates at the preferred deceleration finally selected, the liquid surface of the chemical solution in the container will not approach the top of the container, and the risk of the chemical solution in the container splashing out from the top of the container after deceleration is avoided as much as possible.

[0125] The implementation of anti-displacement and anti-splash risk management includes:

[0126] When a temporary failure occurs, the container currently in the filling state is obtained, and the volume of the chemical solution in the container is obtained, which is recorded as the current volume;

[0127] According to the simulation experiment, the optimal deceleration when the capacity of the chemical solution in the container is the current capacity is obtained;

[0128] When a temporary fault occurs, the deceleration of the conveyor belt is controlled to be less than or equal to the preferred deceleration.

[0129] The first-level anti-contamination risk control is implemented during the process of the filling rod filling the chemical solution into the container, including:

[0130] When a temporary fault occurs and the conveying speed of the conveyor belt needs to be controlled to decrease, the deceleration of the conveyor belt is obtained and recorded as the fault deceleration, and the capacity of the chemical solution in the current container is obtained and recorded as the fault capacity;

[0131] Reference Figure 3 , according to the simulation experiment, the liquid level extreme low point and liquid level extreme high point under the fault capacity and fault deceleration are obtained, which are recorded as the emergency liquid level extreme low point and the emergency liquid level extreme high point respectively;

[0132] Set the maximum and minimum distances between the liquid outlet of the filling rod and the liquid level of the chemical solution in the container, which are recorded as the upper and lower limits of the distance respectively;

[0133] The four faces of the container on the conveyor belt that are perpendicular to the bottom of the container are recorded as four container vertical faces;

[0134] Among the four container elevations, two container elevations parallel to the conveying direction of the conveyor belt are obtained and recorded as marked container elevations;

[0135] Reference Figure 3 , make a plane passing through the lowest point and the highest point of the emergency liquid level and perpendicular to the vertical surface of the marked container, and record it as the emergency simulation inclined plane;

[0136] Reference Figure 4 , make a plane passing through the center point of the bottom surface of the container and perpendicular to the vertical surface of the marked container, and record it as the marking reference surface;

[0137] Taking the marked reference plane as the symmetry reference plane, the symmetry plane of the emergency simulation slope is obtained and recorded as the symmetric simulation slope. By obtaining the symmetric simulation slope, all areas involved in the fluctuation of the liquid level of the chemical solution in the container after deceleration can be basically predicted. The emergency simulation slope represents the liquid level fluctuation caused by the chemical solution in the container moving in the conveying direction of the conveyor belt at the moment of deceleration, while the symmetric simulation slope represents the liquid level fluctuation caused by the chemical solution in the container moving in the opposite direction of the conveying direction. Through the two slopes, all areas involved in the liquid level fluctuation of the chemical solution in the container are basically represented, providing data support for the subsequent implementation of anti-contamination risk management.

[0138] Get the center point of the plane covered by the liquid outlet of the filling rod and record it as the liquid outlet point.

[0139] The first-level anti-contamination risk control is performed during the process of the filling rod filling the chemical solution into the container, and further includes:

[0140] Reference Figure 4 , draw a straight line perpendicular to the bottom of the container through the discharge point, and record it as the reference vertical line;

[0141] Obtaining the intersection of the reference vertical line and the emergency simulation slope, and obtaining the distance between the intersection and the liquid discharge point, and recording the distance as the minimum distance;

[0142] Obtain the intersection of the reference vertical line and the symmetrical simulated inclined plane, and obtain the distance between the intersection and the liquid outlet point, and record the distance as the maximum distance; by obtaining the minimum distance and the maximum distance, the maximum distance and the minimum distance between the liquid outlet point of the filling rod and the liquid surface can be known after the conveyor belt is decelerated, and by comparing the maximum distance and the minimum distance with the upper limit and the lower limit of the spacing respectively, it is determined whether the filling rod can continue to fill when the position of the filling rod does not change. This method ensures that the distance between the liquid outlet point of the filling rod and the liquid surface is within an appropriate range after the conveyor belt is decelerated, preventing the chemical liquid sprayed from the liquid outlet of the filling rod from impacting the liquid surface and splashing due to excessive distance, and preventing the liquid surface of the chemical solution from contacting the filling rod due to excessive distance, thereby avoiding the risk of the chemical solution contaminating the filling rod.

[0143] The maximum distance and the minimum distance are compared with the upper and lower interval limits respectively;

[0144] If the maximum distance is ≤ the upper limit of the spacing and the minimum distance is ≥ the lower limit of the spacing, no adjustment is made and the filling rod is controlled to continue to fill the chemical solution into the container;

[0145] If the maximum distance is greater than the upper limit of the spacing or the minimum distance is less than the lower limit of the spacing, it is determined whether there is a filling adjustment point.

[0146] The determining whether there is a filling adjustment point includes:

[0147] Obtain the maximum distance that the filling rod moves in the opposite direction of the conveying direction of the conveyor belt after it extends into the container, and record it as the maximum adjustment distance;

[0148] Obtain the maximum adjustment distance of the filling rod moving horizontally in the direction opposite to the conveying direction and descending downward so that the distance between the liquid outlet point of the filling rod and the emergency simulation slope is equal to the lower limit of the spacing, and record it as the distance extreme value;

[0149] Compare the distance extreme value with the spacing upper limit;

[0150] If the distance extreme value is greater than the spacing upper limit, it is determined that there is no filling adjustment point, and when the conveyor belt starts to decelerate, the filling rod is controlled to stop discharging liquid and rise to the container opening of the container;

[0151] If the distance extreme value is ≤ the upper limit of the spacing, it is determined that there is a filling adjustment point, and the filling rod is controlled to move horizontally in the opposite direction of the conveying direction by the maximum adjustment distance and drop downward so that the distance between the liquid outlet point of the filling rod and the emergency simulation slope is equal to the lower limit of the spacing, and the chemical solution continues to be poured into the container. By moving the filling rod horizontally in the opposite direction of the conveying direction by the maximum adjustment distance and dropping it downward so that the distance between the liquid outlet point of the filling rod and the emergency simulation slope is equal to the lower limit of the spacing, when the filling rod is in this position, it is the minimum distance between the liquid outlet point of the filling rod and the emergency simulation slope. If in this position, the distance between the liquid outlet point of the filling rod and the symmetrical simulation slope does not meet the requirement of being less than or equal to the upper limit of the spacing, it means that there is no other position in the container that meets the conditions for continuing to pour the chemical solution, and filling cannot continue. In this way, the system can timely determine whether there is a position in the container for continuing filling, and then choose whether to continue filling, to ensure that continued filling will not cause the risk of contamination on the filling rod.

[0152] When a temporary failure occurs and the conveyor belt needs to be controlled to stop urgently, anti-dumping risk control is implemented, including:

[0153] When the conveyor belt needs to stop urgently, the filling rod is controlled to stop filling;

[0154] After the filling rod stops filling, the filling rod is controlled to move horizontally in the opposite direction of the conveying direction for the maximum adjustment distance. In the event of an emergency stop of the conveyor belt, anti-dumping control measures are immediately taken to prevent the container from tipping over due to the emergency stop, especially when there is a chemical solution in the container, the tipping of the container may cause leakage or contamination of the solution; by controlling the filling rod to stop filling and move horizontally in the opposite direction of the conveying direction for the maximum adjustment distance, the filling rod is brought into contact with the opening of the product container, and then when the conveyor belt stops suddenly, the filling rod plays a certain supporting role on the container, ensuring that the container can still be placed stably after the emergency stop to avoid the risk of tipping.

[0155] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device.

[0156] The above is only a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the technical principles of the present invention. These improvements and modifications should also be regarded as the scope of protection of the present invention.

Claims

1. A risk classification intelligent management and control method for safe production, characterized in that: include: A risk simulation experiment was conducted on the running state of containers with different volumes of chemical solutions on a conveyor belt to form a risk simulation experiment model, including: Add chemical solutions to the simulation container piece by piece; After each filling, the simulated container is placed on the conveyor belt to start the transport; Set the deceleration position and start deceleration at this position; During the deceleration process, the deceleration of the conveyor belt is controlled to decrease gradually from the maximum deceleration; and monitor the position change of the container and the liquid level change in the container after deceleration; Implement secondary contamination risk control when using a filling rod to fill chemical solutions into containers; The secondary anti-contamination risk control is specifically as follows: When the container is transported by the conveyor belt, the liquid level growth rate in the container is obtained when the filling rod fills the chemical solution into the container, which is recorded as the liquid level rising speed; When the filling rod is set to fill the chemical solution into the container, the distance between the liquid outlet of the filling rod and the liquid surface is recorded as H; After the filling rod is extended into the container, the distance between it and the bottom of the container is equal to H; When the filling rod starts to fill the chemical solution, the filling rod is controlled to rise at the speed of the liquid level rising, and the chemical solution is continuously poured into the container during the rising process; When a temporary failure occurs and the conveying speed of the conveyor belt needs to be reduced, according to the risk simulation experimental model, anti-shift and anti-splash risk control is implemented in the process of using the conveyor belt to transport containers; at the same time, the first-level anti-contamination risk control is implemented in the process of the filling rod pouring the chemical solution into the container; When a temporary failure occurs and the conveyor belt needs to be controlled to stop urgently, anti-dumping risk control is implemented.

2. A risk-grading intelligent management and control method for safe production according to claim 1, characterized in that: The risk simulation experiment is conducted on the operating state of containers with different volumes of chemical solutions on the conveyor line to form a risk simulation experiment model, which specifically includes: Place a container on the conveyor belt, which is referred to as the simulated container; Set the volume of chemical solution poured into the container in each simulation experiment, and record it as the filling increment; In each simulation experiment, a deceleration difference is set to control the deceleration of the conveyor belt speed to gradually decrease, and it is recorded as the deceleration decrease amount; Conduct simulation experiments on simulated containers: Add chemical solution in a volume equal to the injection increment into the simulation container step by step; After the simulation container is filled with the chemical solution each time, the simulation container is placed on the conveyor belt, and the conveyor belt is controlled to transport the simulation container.

3. A risk-grading intelligent management and control method for safe production according to claim 2, characterized in that: The risk simulation experiment is conducted on the running state of containers with different volumes of chemical solutions on the conveying line to form a risk simulation experiment model, and further includes: Setting a deceleration position on the conveyor belt for starting deceleration; When the simulated container is transported to the deceleration position by the conveyor belt, the conveyor belt is controlled to decelerate at different deceleration rates, specifically: Set the maximum simulated deceleration; Each time the conveyor belt is controlled to transport the simulated container from the starting point of the conveyor belt to the deceleration position, the deceleration of the conveyor belt is controlled to decrease gradually from the maximum simulated deceleration, so that the difference of the successively decreasing decelerations is equal to the deceleration decreasing amount; When the simulated container is transported by the conveyor belt, the state of the simulated container on the conveyor belt after passing the deceleration position is obtained.

4. A risk-grading intelligent management and control method for safe production according to claim 3, characterized in that: The obtaining of the state of the simulated container on the conveyor belt after passing the deceleration position specifically includes: In each simulation: Obtaining the relative position of the simulated container on the conveyor belt of the conveyor when the conveyor belt is started, and recording it as the initial position; Obtaining the relative position of the simulated container on the conveyor belt of the conveyor belt after the simulated container passes through the deceleration position on the conveyor belt, and recording it as the position after deceleration; After the simulated container passes the deceleration position on the conveyor belt, the highest point and the lowest point of the liquid level in the simulated container are obtained, and the capacity of the chemical solution in the simulated container and the deceleration of the conveyor belt are obtained at this time. The highest point of the liquid level is recorded as the highest point of the liquid level under the capacity and deceleration, and the lowest point of the liquid level is recorded as the lowest point of the liquid level under the capacity and conveying speed; Get the height of the inner wall of the container, recorded as the inner wall height; If the position after deceleration is different from the initial position or the highest point of the liquid surface is equal to the inner wall height, then record the volume of the chemical solution in the simulated container, and record the deceleration of the conveyor belt after the simulated container passes the deceleration position, and record the deceleration as the removal deceleration under the volume; If the position after deceleration is the same as the initial position and the highest point of the liquid surface is less than the inner wall height, record the capacity of the chemical solution in the simulated container, and record the deceleration of the conveyor belt after the simulated container passes the deceleration position, and record this speed as the preferred deceleration under this capacity.

5. The risk-grading intelligent management and control method for safe production according to claim 1 is characterized in that: The implementation of anti-displacement and anti-splash risk management includes: When a temporary failure occurs, the container currently in the filling state is obtained, and the volume of the chemical solution in the container is obtained, which is recorded as the current volume; According to the simulation experiment, the optimal deceleration when the capacity of the chemical solution in the container is the current capacity is obtained; When a temporary fault occurs, the deceleration of the conveyor belt is controlled to be less than or equal to the preferred deceleration.

6. The risk-grading intelligent management and control method for safe production according to claim 1 is characterized in that: The first-level anti-contamination risk control is implemented during the process of the filling rod filling the chemical solution into the container, including: When a temporary fault occurs and the conveying speed of the conveyor belt needs to be controlled to decrease, the deceleration of the conveyor belt is obtained and recorded as the fault deceleration, and the capacity of the chemical solution in the current container is obtained and recorded as the fault capacity; According to the simulation experiment, the lowest point and the highest point of the liquid level under the fault capacity and fault deceleration are obtained, and they are recorded as the emergency lowest point and the emergency highest point of the liquid level respectively; Set the maximum and minimum distances between the liquid outlet of the filling rod and the liquid level of the chemical solution in the container, which are recorded as the upper and lower limits of the distance respectively; The four faces of the container on the conveyor belt that are perpendicular to the bottom of the container are recorded as four container vertical faces; Among the four container elevations, two container elevations parallel to the conveying direction of the conveyor belt are obtained and recorded as marked container elevations; Make a plane passing through the lowest and highest points of the emergency liquid level and perpendicular to the vertical surface of the marked container, and record it as the emergency simulation slope; Draw a plane passing through the center point of the bottom surface of the container and perpendicular to the vertical surface of the marked container, and record it as the marking reference surface; Taking the marked reference surface as the symmetry reference surface, obtaining the symmetry surface of the emergency simulation slope, and recording it as the symmetry simulation slope; Get the center point of the plane covered by the liquid outlet of the filling rod and record it as the liquid outlet point.

7. A risk-grading intelligent management and control method for safe production according to claim 6, characterized in that: The first-level anti-contamination risk control is performed during the process of the filling rod filling the chemical solution into the container, and further includes: Draw a straight line perpendicular to the bottom of the container through the discharge point and record it as the reference vertical line; Obtaining the intersection of the reference vertical line and the emergency simulation slope, and obtaining the distance between the intersection and the liquid discharge point, and recording the distance as the minimum distance; Obtaining the intersection of the reference vertical line and the symmetrical simulated inclined plane, and obtaining the distance between the intersection and the liquid outlet point, and recording the distance as the maximum distance; The maximum distance and the minimum distance are compared with the upper and lower interval limits respectively; If the maximum distance is ≤ the upper limit of the spacing and the minimum distance is ≥ the lower limit of the spacing, no adjustment is made and the filling rod is controlled to continue to fill the chemical solution into the container; If the maximum distance is greater than the upper limit of the spacing or the minimum distance is less than the lower limit of the spacing, it is determined whether there is a filling adjustment point.

8. The risk-grading intelligent management and control method for safe production according to claim 7 is characterized in that: The determining whether there is a filling adjustment point includes: Obtain the maximum distance that the filling rod moves in the opposite direction of the conveying direction of the conveyor belt after it extends into the container, and record it as the maximum adjustment distance; Obtain the maximum adjustment distance of the filling rod moving horizontally in the direction opposite to the conveying direction and descending downward so that the distance between the liquid outlet point of the filling rod and the emergency simulation slope is equal to the lower limit of the spacing, and record it as the distance extreme value; Compare the distance extreme value with the spacing upper limit; If the distance extreme value is greater than the spacing upper limit, it is determined that there is no filling adjustment point, and when the conveyor belt starts to decelerate, the filling rod is controlled to stop discharging liquid and rise to the container opening of the container; If the extreme distance value is ≤ the upper limit of the spacing, it is determined that there is a filling adjustment point, and the filling rod is controlled to move horizontally in the opposite direction of the conveying direction by the maximum adjustment distance and move downward so that the distance between the liquid outlet point of the filling rod and the emergency simulation slope is equal to the lower limit of the spacing, and the chemical solution continues to be poured into the container.

9. A risk-grading intelligent management and control method for safe production according to claim 8, characterized in that: When a temporary failure occurs and the conveyor belt needs to be controlled to stop urgently, anti-dumping risk control is implemented, including: When the conveyor belt needs to stop urgently, the filling rod is controlled to stop filling; After the filling rod stops filling, the filling rod is controlled to move horizontally in the opposite direction of the conveying direction by the maximum adjustment distance.

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