Intelligent preparation system and method for large-diameter basalt fiber composite material

Abstract

The invention discloses an intelligent preparation system and method for a large-diameter basalt fiber composite material, and belongs to the technical field of fiber composite material production equipment. A storage tank unit of the system comprises a plurality of independent storage tanks, a temperature control device is arranged in each storage tank, the storage tanks are connected in parallel through pipelines and then communicated with a primary mixing unit, and the primary mixing unit is sequentially connected with a spectrum analyzer, a rheometer and a nano dispersion unit through pipelines; the intelligent control center is respectively connected with the storage tank unit, the primary mixing unit and the nano dispersion unit through lines, and is used for receiving sensor data of each unit, issuing a control instruction, recording a historical formula, environmental parameters and performance indexes, and supporting formula input, parameter visualization and alarm reminding. The device has the advantages that multi-source data fusion control is achieved, nano dispersion is precisely regulated and controlled, continuous production is supported, the device is adaptive to a multi-layer winding process of pipelines with the diameter of 1.2-3 m, and the production efficiency is improved by 30%.

Description

Technical Field

[0001] The present invention belongs to the technical field of fiber composite material production equipment, and particularly relates to an intelligent preparation system and method for large-diameter basalt fiber composite materials. Background Art

[0002] The performance of basalt fiber composite pipes highly depends on the formulation accuracy and process stability of the sizing agent. However, the traditional configuration system has the following defects: (1) Strong dependence on manual labor: The proportioning of sizing agent components (such as film-forming agent, coupling agent, toughening agent) relies on manual experience, and the weighing error is >5%, resulting in performance fluctuations between batches; (2) Lack of dynamic regulation: It is unable to monitor the influence of environmental parameters (temperature, humidity) on the mixing process in real time. For example, epoxy resin emulsion is prone to agglomeration at low temperature (<15°C), causing uneven sizing; (3) Poor coordination among multiple processes: Processes such as mixing, ultrasonic dispersion, and quality inspection are independently operated in segments, and it is difficult to meet the timeliness requirements of the continuous winding process for large-diameter pipes (requiring continuous supply of sizing agent for >8 hours).

[0003] Although the fiber sizing agent production equipment disclosed in the prior art realizes basic automation, it does not solve the problems of dynamic optimization of the formulation, multi-scale dispersion control (uniformity of nano-toughening agent), and adaptability to large-diameter processes. Summary of the Invention

[0004] The purpose of the present invention is to overcome the defects in the prior art and provide an intelligent preparation system and method for large-diameter basalt fiber composite materials that integrates precise metering, multi-process coordination, and intelligent feedback control, realizing unmanned production of the sizing agent dedicated to large-diameter pipes and performance consistency control.

[0005] The specific technical solutions adopted by the present invention are as follows:

[0006] In the first aspect, the present invention provides an intelligent preparation system for large-diameter basalt fiber composite materials, including a storage tank unit, a primary mixing unit, a nano-dispersion unit, and an intelligent control center;

[0007] The storage tank unit includes multiple independent storage tanks for storing different raw materials respectively. Each storage tank is equipped with a temperature control device. The storage tanks are connected in parallel through pipelines and communicated with the primary mixing unit. The primary mixing unit is sequentially connected to a spectral analyzer, a rheometer, and the nano-dispersion unit through pipelines;

[0008] The intelligent control center is respectively connected to the storage tank unit, the primary mixing unit, and the nano-dispersion unit through lines, and is responsible for receiving sensor data of each unit and issuing control instructions, recording historical formulations, environmental parameters, and performance indicators, and supporting formula input, parameter visualization, and alarm reminder.

[0009] Preferably, the storage tank unit includes a film-forming agent storage tank, a deionized water storage tank, a toughening agent storage tank, a coupling agent storage tank, a lubricant storage tank, and an antistatic agent storage tank. Each storage tank is integrated with an electric heating device and a cooling coil for temperature control.

[0010] Furthermore, high-precision metering pumps are respectively installed on the outlet pipelines of the film-forming agent storage tank, the deionized water storage tank, the toughening agent storage tank, the coupling agent storage tank, the lubricant storage tank, and the antistatic agent storage tank; the high-precision metering pumps are gear pumps driven by servo motors, with a flow error < 0.5%, and an on-line viscosity sensor is installed at the inlet end.

[0011] Preferably, the primary mixing unit is a round tank structure, with a jacket provided circumferentially on the outer side wall for introducing circulating water to control the temperature, and a paddle-type stirrer for evenly stirring the raw materials is provided in the inner cavity.

[0012] Furthermore, the paddle-type stirrer is a six-blade turbine paddle and is speed-controlled by electrode frequency conversion.

[0013] Preferably, the nano-dispersion unit includes an ultrasonic emitter and a high-pressure microfluidization device; the top of the ultrasonic emitter is connected to a rheometer through a pipeline, and an ultrasonic emitter is provided at the bottom.

[0014] Furthermore, the ultrasonic emitter is a piezoelectric ceramic transducer array.

[0015] Preferably, the rheometer is a rotary concentric cylinder structure with a built-in torque sensor.

[0016] In a second aspect, the present invention provides a control method for using the large-diameter basalt fiber composite material intelligent formulation system according to any one of the first aspect, specifically as follows:

[0017] Input the target formula into the storage tank unit through the intelligent control center to control the liquid discharge amounts of the film-forming agent storage tank, the deionized water storage tank, the toughening agent storage tank, the coupling agent storage tank, the lubricant storage tank, and the antistatic agent storage tank. Each raw material flows out from the corresponding storage tank and enters the primary mixing unit. The intelligent control center controls the stirring speed and stirring time of the paddle-type stirrer to evenly mix the raw materials; the mixed liquid then enters the spectral analyzer, which can scan the chemical composition of the sizing agent in real time and transmit the signal to the intelligent control center, and the intelligent control center can adjust the storage tank unit according to the signal feedback; the mixed liquid then enters the rheometer, which can dynamically monitor the viscosity change of the mixed liquid and transmit the signal to the intelligent control center, and the intelligent control center can adjust the ultrasonic emitter according to the signal feedback; after the mixed liquid passes through the spectral analyzer and the rheometer in sequence, it enters the high-pressure microfluidization device, and the ultrasonic emitter makes the mixed liquid more evenly dispersed; the qualified product is transported to the pipe winding production line, and at the same time, the intelligent control center generates a batch quality report.

[0018] The present invention has the following beneficial effects compared with the prior art:

[0019] (1) Multi-source data fusion control: Integrate environmental sensors, on-line detection devices and historical process data, and realize dynamic optimization of the formula through an adaptive algorithm, so that the fluctuation of the interfacial shear strength (IFSS) between batches < 3%; (2) Precise regulation of nano-dispersion: The synergistic effect of ultrasonic-microjet breaks through the limitations of traditional single dispersion methods, reduces the agglomeration rate of nano-toughening agents to < 5%, and increases the impact strength of the pipeline by 15-20%; (3) The system supports continuous production (≥12h uninterrupted feeding), adapts to the multi-level winding process of pipelines with a diameter of 1.2-3m, and improves the production efficiency by 30%. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 It is a schematic structural diagram of the device of the present invention.

[0021] The reference numerals in the figure are: film-forming agent storage tank 1, deionized water storage tank 2, toughening agent storage tank 3, coupling agent storage tank 4, lubricant storage tank 5, antistatic agent storage tank 6, high-precision metering pump 7, paddle stirrer 8, primary mixing unit 9, spectral analyzer 10, rheometer 11, ultrasonic emitter 12, high-pressure microjet device 13, nano-dispersion unit 14, intelligent control center 15. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0022] The present invention will be further described and explained below in conjunction with the drawings and specific embodiments. The technical features of each embodiment in the present invention can be combined correspondingly without conflict.

[0023] As Figure 1 shown, a large-diameter basalt fiber composite intelligent formulation system provided by the present invention mainly includes a storage tank unit, a primary mixing unit 9, a nano-dispersion unit 14 and an intelligent control center 15.

[0024] The structure and connection method of each unit will be specifically described below.

[0025] In the device of the present invention, the storage tank unit includes a plurality of independent storage tanks, which can store different raw materials respectively. A temperature control device 16 is provided in each storage tank. The storage tanks are connected in parallel through pipelines and communicated with the primary mixing unit 9. The primary mixing unit 9 is sequentially connected to a spectral analyzer 10, a rheometer 11 and a nano-dispersion unit 14 through pipelines.

[0026] As a preferred embodiment of the present invention, the storage tank unit has a multi-compartment storage tank, namely a film-forming agent storage tank 1, a deionized water storage tank 2, a toughening agent storage tank 3, a coupling agent storage tank 4, a lubricant storage tank 5 and an antistatic agent storage tank 6. Each storage tank can be made of stainless steel and can independently store raw materials such as epoxy resin emulsion, waterborne polyurethane, and silane / titanate coupling agent. Each storage tank is integrated with an electric heating device and a cooling coil for temperature control, and the temperature control accuracy is ±1°C to ensure the stability of the raw material temperature. High-precision metering pumps 7 are provided on the outlet pipelines of the film-forming agent storage tank 1, the deionized water storage tank 2, the toughening agent storage tank 3, the coupling agent storage tank 4, the lubricant storage tank 5 and the antistatic agent storage tank 6. The high-precision metering pump 7 is a gear pump driven by a servo motor, with a flow error <0.5%. An on-line viscosity sensor is installed at the inlet end to monitor the fluidity of the raw material in real time to prevent pipeline blockage. The high-precision metering pump 7 can dynamically adjust the flow rate based on the formulation ratio (error <0.5%), and the detection range of the viscosity sensor is 10 - 5000 mPa·s.

[0027] As a preferred embodiment of the present invention, the primary mixing unit 9 has a circular tank structure, and a jacket is provided circumferentially on the outer side wall. Circulating water can be introduced into the jacket to control the temperature. A paddle-type stirrer 8 is provided in the inner cavity of the primary mixing unit 9. The rotation speed of the paddle-type stirrer 8 is adjustable from 0 to 500 rpm, which can stir the raw materials evenly to achieve the macroscopic mixing of the raw materials. The paddle-type stirrer 8 can adopt a six-blade turbine paddle and is speed-controlled by electrode frequency conversion.

[0028] As a preferred embodiment of the present invention, the nano-dispersion unit 14 mainly includes an ultrasonic emitter 12 and a high-pressure microfluidization device 13. The top of the ultrasonic emitter 12 is connected to the rheometer 11 through a pipeline, and the ultrasonic emitter 12 is provided at the bottom. The ultrasonic emitter 12 can adopt a piezoelectric ceramic transducer array with a frequency of 20 - 40 kHz. The pressure of the high-pressure microfluidization device 13 is 50 - 200 MPa, which can ensure the uniform dispersion of the mixed liquid (especially nano-silica modified acrylate) again, so that the particle size D90 of each substance in the mixed liquid ≤ 100 nm.

[0029] As a preferred embodiment of the present invention, the spectral analyzer can detect the chemical composition of the sizing agent in real time (such as the residual amount of the coupling agent <0.1%). The rheometer 11 has a rotary concentric cylinder structure, with a built-in torque sensor, which is directly connected in series in the conveying pipeline to dynamically monitor the viscosity change. The rheometer 11 can monitor the viscosity change in real time (target value 80 - 120 mPa·s) and feed the data back to the intelligent control center 15.

[0030] In the device of the present invention, the intelligent control center 15 is respectively connected to the storage tank unit, the primary mixing unit 9 and the nano-dispersion unit 14 through lines, and is responsible for receiving the sensor data of each unit and issuing control instructions, recording historical formulas, environmental parameters and performance indicators, and supporting formula input, parameter visualization and alarm reminder.

[0031] As a preferred embodiment of the present invention, the intelligent control center 15 has a process database and a dynamic optimization algorithm. Among them, the process database can store historical formulas, environmental parameters (temperature, humidity, air pressure) and performance data (IFSS, viscosity); the dynamic optimization algorithm can predict the optimal process parameters (such as ultrasonic time, stirring rate) based on a machine learning model (such as an LSTM neural network), and the response time < 1 s.

[0032] Using the control method of any of the above large-diameter basalt fiber composite material intelligent preparation systems, the control method is specifically as follows:

[0033] Input the target formula into the storage tank unit through the intelligent control center 15 to control the liquid output of the film-forming agent storage tank 1, deionized water storage tank 2, toughening agent storage tank 3, coupling agent storage tank 4, lubricant storage tank 5 and antistatic agent storage tank 6. Each raw material flows out of the corresponding storage tank and enters the primary mixing unit 9. The intelligent control center 15 controls the stirring speed and stirring time of the paddle stirrer 8 to make each raw material mix evenly. The mixed liquid then enters the spectral analyzer 10. The spectral analyzer 10 can scan the chemical composition of the sizing agent in real time and transmit the signal to the intelligent control center 15. The intelligent control center 15 can adjust the storage tank unit according to the signal feedback. The mixed liquid then enters the rheometer 11. The rheometer 11 can dynamically monitor the viscosity change of the mixed liquid and transmit the signal to the intelligent control center 15. The intelligent control center 15 can adjust the ultrasonic emitter 12 according to the signal feedback. If it deviates from the threshold, trigger parameter self-adjustment (such as increasing the ultrasonic power by 10%). After the mixed liquid passes through the spectral analyzer 10 and the rheometer 11 in sequence, it enters the high-pressure microfluidic device 13, and the ultrasonic emitter 12 makes the mixed liquid disperse more evenly. The qualified products are transported to the pipeline winding production line, and at the same time, the intelligent control center 15 generates a batch quality report.

[0034] During the above process, the intelligent control center 15 can feedback and adjust the temperature control device (16) according to the signals of the temperature sensors arranged in each storage tank, so that the temperature control device (16) can automatically correct the raw material preheating temperature according to the environmental temperature and humidity (for example, when the temperature is 25°C and the humidity is 60%, the epoxy resin is preheated to 35°C).

[0035] The embodiments described above are only a preferred solution of the present invention, but they are not intended to limit the present invention. Those of ordinary skill in the relevant technical field can still make various changes and modifications without departing from the spirit and scope of the present invention. Therefore, all technical solutions obtained by means of equivalent substitution or equivalent transformation fall within the protection scope of the present invention.

Claims

1. An intelligent preparation system for large-caliber basalt fiber composite materials, characterized in that: It includes a storage tank unit, a primary mixing unit (9), a nano-dispersion unit (14) and an intelligent control center (15); The storage tank unit includes a plurality of independent storage tanks for storing different raw materials respectively. Each storage tank is provided with a temperature control device (16). The storage tanks are connected in parallel through pipelines and are connected to the primary mixing unit (9). The primary mixing unit (9) is connected in sequence to a spectrometer (10), a rheometer (11) and a nano-dispersion unit (14) through pipelines. The intelligent control center (15) is respectively connected to the storage tank unit, the primary mixing unit (9) and the nano-dispersion unit (14) through lines, and is responsible for receiving sensor data from each unit and issuing control instructions, recording historical formulas, environmental parameters and performance indicators, and supporting formula input, parameter visualization and alarm reminders.

2. The large-caliber basalt fiber composite material intelligent preparation system according to claim 1, characterized in that: The storage tank unit comprises a film-forming agent storage tank (1), a deionized water storage tank (2), a toughening agent storage tank (3), a coupling agent storage tank (4), a lubricant storage tank (5) and an antistatic agent storage tank (6), and each storage tank is integrated with an electric heating device and a cooling coil for temperature control.

3. The large-caliber basalt fiber composite material intelligent preparation system according to claim 2, characterized in that: The outlet pipelines of the film-forming agent storage tank (1), the deionized water storage tank (2), the toughening agent storage tank (3), the coupling agent storage tank (4), the lubricant storage tank (5) and the antistatic agent storage tank (6) are respectively provided with high-precision metering pumps (7); the high-precision metering pump (7) adopts a gear pump driven by a servo motor, with a flow error of less than 0.5%, and an online viscosity sensor is installed at the inlet end.

4. The large-caliber basalt fiber composite material intelligent preparation system according to claim 1, characterized in that: The primary mixing unit (9) is a round tank structure, with a jacket provided around the outer wall for introducing circulating water to control the temperature, and a paddle stirrer (8) provided in the inner cavity for stirring the raw materials evenly.

5. The large-caliber basalt fiber composite material intelligent preparation system according to claim 4, characterized in that: The paddle-type stirrer (8) adopts a six-blade turbine propeller, and its speed is adjusted by electrode frequency conversion.

6. The large-caliber basalt fiber composite material intelligent preparation system according to claim 1, characterized in that: The nano-dispersion unit (14) comprises an ultrasonic transmitter (12) and a high-pressure microfluidic device (13); the top of the ultrasonic transmitter (12) is connected to the rheometer (11) through a pipeline, and the bottom is provided with an ultrasonic transmitter (12).

7. The large-caliber basalt fiber composite material intelligent preparation system according to claim 6, characterized in that: The ultrasonic transmitter (12) is a piezoelectric ceramic transducer array.

8. The large-caliber basalt fiber composite material intelligent preparation system according to claim 1, characterized in that: The rheometer (11) is a rotating concentric cylinder structure with a built-in torque sensor.

9. A control method using the large-caliber basalt fiber composite material intelligent preparation system according to any one of claims 1 to 8, characterized in that: The details are as follows: The target formula is input into the storage tank unit through the intelligent control center (15) to control the liquid output of the film-forming agent storage tank (1), the deionized water storage tank (2), the toughening agent storage tank (3), the coupling agent storage tank (4), the lubricant storage tank (5) and the antistatic agent storage tank (6). Each raw material flows out from the corresponding storage tank and enters the primary mixing unit (9). The intelligent control center (15) controls the stirring speed and stirring time of the paddle stirrer (8) to make the raw materials mixed evenly. The mixed liquid then enters the spectrometer (10), which can scan the chemical composition of the wetting agent in real time and transmit the signal to the intelligent control center (15). ), the intelligent control center (15) can adjust the storage tank unit according to the signal feedback; the mixed liquid then enters the rheometer (11), the rheometer (11) can dynamically monitor the viscosity change of the mixed liquid and transmit the signal to the intelligent control center (15), and the intelligent control center (15) can adjust the ultrasonic transmitter (12) according to the signal feedback; the mixed liquid passes through the spectrometer (10) and the rheometer (11) in turn, and then enters the high-pressure microfluidic device (13), and the ultrasonic transmitter (12) makes the mixed liquid dispersed more evenly; the qualified products are transported to the pipe winding production line, and the intelligent control center (15) generates a batch quality report.

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