Method and equipment for automatic batching and safety inspection of aqueous phase preparation tanks for emulsion explosives

Abstract

This invention discloses a method and equipment for automatic batching safety inspection of emulsion explosive aqueous phase preparation tanks. The method relates to the field of safety inspection data management technology and includes the following steps: collecting and processing automatic batching data from the emulsion explosive aqueous phase preparation tank; analyzing and optimizing the data. This invention improves the stability of the safety inspection method by collecting and processing the automatic batching data from the emulsion explosive aqueous phase preparation tank, analyzing the data to obtain evaluation values ​​for mixing uniformity and energy efficiency, and evaluation values ​​for PID control response timeliness. Comprehensive analysis and optimization improve the stability of the safety inspection method and solve the problem of low stability in existing safety inspection methods.

Description

Technical Field

[0001] This invention relates to the field of safety inspection data management technology, and in particular to a method and equipment for automatic batching safety inspection of aqueous phase preparation tanks for emulsion explosives. Background Technology

[0002] With the urgent need for safe production in the civil explosives industry, the risks of traditional manual operations, and the rapid development of industrial automation and intelligent technologies, the proposal of an automated batching and safety inspection method for aqueous phase preparation tanks of emulsion explosives is essentially an inevitable choice driven by the triple forces of process safety, regulatory compliance, and technological empowerment within the civil explosives industry. By deeply integrating the industrial internet, AI algorithms, and explosion-proof robots, not only can the risk of human-caused accidents be reduced by more than 90%, but it can also promote the transformation and upgrading of civil explosives manufacturing from "experience-driven" to "data-driven." In the future, with the further penetration of technologies such as digital twins and 5G private networks, the inherent safety level of high-risk chemical production will continue to improve.

[0003] Existing automated batching and safety inspection methods for emulsion explosive aqueous phase preparation tanks monitor data in real time using sensor equipment; fully automated batching is achieved through an automated control system, reducing human error and preventing local viscosity increases caused by insufficient stirring.

[0004] For example, the invention patent with publication number CN116882899A discloses a safety inspection system and its scoring criteria for a production line and warehouse of hazardous emulsion explosives. The system includes: an oil-water phase preparation process, a pharmaceutical process, a steel belt cooling process, a belt conveyor, a loading process, a packaging process, a loading process, and a hazardous materials warehouse. It includes a sensing and detection system and an automatic control system, a density sensor installed on the discharge pipe of the water phase preparation tank in the oil-water phase preparation process to detect the water phase ratio, a first vision sensor installed on the steel belt in the steel belt cooling process to monitor the steel belt's operating status in real time, and a second vision sensor installed in the steel belt cooling process to detect the personnel configuration in the steel belt cooling process.

[0005] For example, the invention patent announcement CN115619298B discloses an intelligent control method and system for emulsion explosives, which includes: locating the corresponding vibration relationship time period based on vibration signals at each monitoring location; obtaining a set of monitoring locations associated with the temperature gradient of the monitoring location within the vibration relationship time period as a monitoring domain; calculating the hazard analysis value of each monitoring domain; and issuing an early warning and adjusting the environment if the hazard analysis value of any monitoring domain is greater than the hazard threshold. This method can accurately locate the time periods between discrete oscillations caused by intermittent falls, rolling, collisions, and friction of the emulsion explosive, significantly reducing false alarms and distortions in subsequent steps.

[0006] However, in the process of implementing the inventive technical solution in the embodiments of this application, it was found that the above-mentioned technology has at least the following technical problems:

[0007] This method is applied in the automatic batching application scenario of emulsion explosive aqueous phase preparation tanks. The viscosity change of the emulsion explosive solution affects the uniformity of temperature distribution. High viscosity areas form local high temperature zones. Traditional temperature sensors are sparsely distributed in the aqueous phase preparation tank and cannot capture local high and low temperature areas, resulting in large temperature differences. Under high temperature and high pressure environments, the oxidation of the sensor metal film causes drift errors, leading to inaccurate local temperature control. When the viscosity of the emulsion explosive solution changes abruptly, it is accompanied by temperature changes. The PID control responds to local temperature changes with a delay, causing the steam valve to lag and fail to adjust in time, resulting in temperature runaway. In high viscosity solutions, a fixed rotation speed creates a stirring dead zone, increasing the mixing uniformity. When the viscosity changes abruptly, the rotation speed is not dynamically adjusted, increasing energy consumption. When the temperature exceeds the preset temperature, the ammonium nitrate decomposition reaction accelerates, releasing gas and causing a sudden increase in tank pressure. The change in liquid viscosity affects heat distribution and conduction, resulting in insufficient stability of the safety inspection method. Summary of the Invention

[0008] This application provides an automatic batching safety inspection method and equipment for aqueous phase preparation tanks of emulsion explosives, which solves the problem of low stability of existing safety inspection methods and improves the stability of safety inspection methods.

[0009] This application provides a method for automatic batching safety inspection of an emulsion explosive aqueous phase preparation tank, comprising the following steps: collecting and processing automatic batching data of the emulsion explosive aqueous phase preparation tank; analyzing the automatic batching data of the emulsion explosive aqueous phase preparation tank to obtain evaluation values ​​for mixing uniformity and energy consumption efficiency, and evaluation values ​​for PID control response timeliness; comprehensively analyzing to obtain a stability evaluation value for the automatic batching safety inspection of the aqueous phase preparation tank; and optimizing and adjusting the method for automatic batching safety inspection of emulsion explosive aqueous phase preparation tank based on the evaluation value and a preset threshold from the database.

[0010] Furthermore, the specific steps for collecting and processing the automatic batching data of the emulsion explosive aqueous phase preparation tank are as follows: Sensor data is transmitted in real time to the central control system via IoT technology to collect the raw data of the automatic batching of the emulsion explosive aqueous phase preparation tank; the raw data of the automatic batching of the emulsion explosive aqueous phase preparation tank is cleaned and denoised to obtain the automatic batching data of the emulsion explosive aqueous phase preparation tank; the automatic batching data of the emulsion explosive aqueous phase preparation tank includes mixing uniformity and energy efficiency data, PID control response timeliness data, and temperature runaway frequency.

[0011] Furthermore, the specific steps for obtaining the mixing uniformity and energy efficiency evaluation values ​​are as follows: the mixing uniformity and energy efficiency data include the stirring dead zone area, PID control response time, maximum temperature inside the aqueous phase preparation tank, minimum temperature inside the aqueous phase preparation tank, maximum viscosity change amplitude of the emulsion explosive solution, minimum viscosity change amplitude of the emulsion explosive solution, and mixing uniformity; the stirring dead zone area threshold, PID control response time threshold, standard value of temperature difference inside the aqueous phase preparation tank, standard value of viscosity change amplitude difference of emulsion explosive, mixing uniformity threshold, weighting factor of stirring dead zone area, and mixing efficiency are obtained from the aqueous phase preparation tank safety inspection database. The weighting factors for uniformity, PID control response time, temperature difference coefficient, and viscosity mutation coefficient of the emulsion explosive solution are calculated. The ratio of the mixing dead zone area to the mixing dead zone area threshold is analyzed, and the results are averaged. The weighting factor of the mixing dead zone area is then used to correct the averaged results, which is denoted as the first component of the mixing uniformity and energy efficiency evaluation value. The ratio of PID control response time to the PID control response time threshold is also analyzed, and the weighting factor of the PID control response time is used to correct the results, which is denoted as the mixing uniformity. The second component of the evaluation value for temperature and energy consumption efficiency; the deviation between the maximum and minimum temperatures in the aqueous phase preparation tank is analyzed relative to the standard value of the temperature difference in the aqueous phase preparation tank, and the results of the ratio analysis are corrected using the weighting factor of the temperature difference coefficient, denoted as the temperature difference coefficient; the deviation between the maximum and minimum viscosity changes of the emulsion explosive solution is analyzed relative to the standard value of the difference in viscosity change amplitude, and the results of the ratio analysis are corrected using the weighting factor of the viscosity change coefficient of the emulsion explosive solution, denoted as the viscosity change coefficient of the emulsion explosive solution; the mixing uniformity and mixing efficiency are analyzed relative to the standard value of the temperature difference coefficient. A proportion analysis is performed on the uniformity threshold, and the results of the proportion analysis are averaged. The weighting factor of mixing uniformity is used to correct the averaged results, which is denoted as the third component of the mixing uniformity and energy efficiency evaluation value. The coupling results of the first component, the second component, the temperature difference coefficient, and the viscosity mutation coefficient of the emulsion explosive solution are combined with the third component of the mixing uniformity and energy efficiency evaluation value to obtain the mixing uniformity and energy efficiency evaluation value. The mixing uniformity and energy efficiency evaluation value represents the quantitative data of dynamically adjusting the stirring speed.

[0012] Further, the specific steps for obtaining the PID control response timeliness evaluation value are as follows: The PID control response timeliness data includes PID control response time, steam valve adjustment lag time, maximum stirring power in the aqueous phase preparation tank, minimum stirring power in the aqueous phase preparation tank, maximum amplitude of viscosity change in the emulsion explosive solution, and minimum amplitude of viscosity change in the emulsion explosive solution; the PID control response time threshold, steam valve adjustment lag time threshold, standard value of stirring power difference in the aqueous phase preparation tank, standard value of viscosity change amplitude difference in the emulsion explosive, weighting factor of PID control response time, weighting factor of steam valve adjustment lag time, weighting factor of energy consumption change coefficient, and weighting factor of viscosity change coefficient of emulsion explosive solution are obtained from the aqueous phase preparation tank safety inspection database; the PID control response time threshold and PID control response time are analyzed in proportion, and the results of the proportion analysis are corrected using the weighting factor of PID control response time, which is recorded as the first component of the PID control response timeliness evaluation value; the steam valve adjustment lag time threshold and steam valve adjustment lag time are analyzed in proportion. The results of the proportion analysis are corrected using a weighting factor for the steam valve adjustment lag time, and this is denoted as the second component of the PID control response timeliness evaluation value. The deviation between the maximum and minimum stirring power in the aqueous phase preparation tank is compared with the standard value of the stirring power difference in the aqueous phase preparation tank. The results of the proportion analysis are corrected using a weighting factor for the energy consumption variation coefficient, and this is denoted as the energy consumption variation coefficient. The deviation between the maximum and minimum viscosity change of the emulsion explosive solution is compared with the standard value of the viscosity change amplitude difference of the emulsion explosive solution. The results of the proportion analysis are corrected using a weighting factor for the viscosity change coefficient of the emulsion explosive solution, and this is denoted as the viscosity change coefficient of the emulsion explosive solution. The coupling results of the first and second components of the PID control response timeliness evaluation value are compared with the coupling results of the energy consumption variation coefficient and the viscosity change coefficient of the emulsion explosive solution to obtain the PID control response timeliness evaluation value. The PID control response timeliness evaluation value represents the response speed of the control system, reflecting its ability to cope with emergencies.

[0013] Furthermore, the specific steps for obtaining the stability assessment value of the automatic batching safety inspection of the aqueous phase preparation tank through comprehensive analysis are as follows: Obtain the temperature runaway frequency threshold, the weighting factor of the PID control response timeliness assessment value, the weighting factor of the mixing uniformity and energy efficiency assessment value, and the weighting factor of the temperature runaway frequency from the aqueous phase preparation tank safety inspection database; Average the PID control response timeliness assessment value, and correct the averaged result using the weighting factor of the PID control response timeliness assessment value, denoted as the first component of the stability assessment value of the automatic batching safety inspection of the aqueous phase preparation tank; Average the mixing uniformity and energy efficiency assessment values, and correct the averaged result using the weighting factor of the mixing uniformity and energy efficiency assessment values, denoted as the automatic batching value of the aqueous phase preparation tank. The second component of the safety inspection stability assessment value is calculated as follows: The ratio of temperature runaway frequency to temperature runaway frequency threshold is analyzed, and the results of the ratio analysis are averaged. The averaged results are then corrected using a weighting factor for temperature runaway frequency, and this is denoted as the third component of the safety inspection stability assessment value for the automatic batching of the aqueous phase preparation tank. The coupling results of the first, second, and third components of the safety inspection stability assessment value for the automatic batching of the aqueous phase preparation tank are analyzed, and a comprehensive analysis is performed to obtain the final safety inspection stability assessment value for the automatic batching of the aqueous phase preparation tank. The safety inspection stability assessment value for the automatic batching of the aqueous phase preparation tank represents the quantitative data of the stability of the aqueous phase preparation tank during the automatic batching process.

[0014] Furthermore, the specific steps for optimizing and adjusting the automatic batching safety inspection method for aqueous phase preparation tanks of emulsion explosives are as follows: Obtain from the database a first threshold for PID control response timeliness evaluation, a second threshold for mixing uniformity and energy efficiency evaluation, and a comprehensive threshold for the stability evaluation of automatic batching safety inspection of aqueous phase preparation tanks; compare and analyze the PID control response timeliness evaluation, mixing uniformity and energy efficiency evaluation, and the stability evaluation of automatic batching safety inspection of aqueous phase preparation tanks with the first threshold for PID control response timeliness evaluation, the second threshold for mixing uniformity and energy efficiency evaluation, and the comprehensive threshold for the stability evaluation of automatic batching safety inspection of aqueous phase preparation tanks to obtain the optimized and adjusted method for automatic batching safety inspection of emulsion explosives; the optimized and adjusted method for automatic batching safety inspection of aqueous phase preparation tanks of emulsion explosives includes a PID control response timeliness optimization method, a mixing uniformity and energy efficiency optimization method, and a stability optimization method for automatic batching safety inspection of aqueous phase preparation tanks.

[0015] Furthermore, the specific steps of the PID control response timeliness optimization method are as follows: if the PID control response timeliness evaluation value is greater than or equal to the first threshold of the PID control response timeliness evaluation value, then the PID control response timeliness optimization method is not required; if the PID control response timeliness evaluation value is less than the first threshold of the PID control response timeliness evaluation value, then the PID parameters are adjusted to improve the response speed to sudden changes in temperature and viscosity; emergency stop logic is designed, and the highest and lowest threshold triggering conditions for temperature, pressure, and viscosity are set.

[0016] Furthermore, the specific steps of the mixing uniformity and energy efficiency optimization method are as follows: if the evaluation values ​​of mixing uniformity and energy efficiency are lower than or equal to the second threshold of the evaluation values ​​of mixing uniformity and energy efficiency, then the mixing uniformity and energy efficiency optimization method is not required; if the evaluation values ​​of mixing uniformity and energy efficiency are higher than the second threshold of the evaluation values ​​of mixing uniformity and energy efficiency, then the automatic batching process of the emulsion explosive aqueous phase preparation tank is simulated using CFD software, and parameters are set according to the actual safety inspection; by analyzing the fused data, dead zones and high-temperature points in the automatic batching process of the emulsion explosive aqueous phase preparation tank are identified; and the output frequency of the frequency converter is adjusted in real time according to the output of the PID control algorithm to control the speed of the stirring equipment.

[0017] Furthermore, the specific steps of the automatic batching safety inspection stability optimization method for the aqueous phase preparation tank are as follows: if the stability evaluation value of the automatic batching safety inspection of the aqueous phase preparation tank is greater than or equal to the comprehensive threshold value of the stability evaluation value of the automatic batching safety inspection of the aqueous phase preparation tank, then the stability optimization method for the automatic batching safety inspection of the aqueous phase preparation tank is not required; if the stability evaluation value of the automatic batching safety inspection of the aqueous phase preparation tank is less than the comprehensive threshold value of the stability evaluation value of the automatic batching safety inspection of the aqueous phase preparation tank, then the temperature and viscosity of each area are monitored in real time to locate the anomaly; the automatic batching safety inspection data of the aqueous phase preparation tank is corrected by model prediction control; and the automatic batching safety inspection path of the aqueous phase preparation tank is dynamically adjusted by correcting the automatic batching safety inspection data of the aqueous phase preparation tank.

[0018] This application provides an automatic batching and safety inspection device for an aqueous phase preparation tank of emulsion explosives, comprising: recording time-series data of temperature and control signals through a data logger; acquiring the temperature inside the aqueous phase preparation tank through a temperature sensor; measuring the viscosity of the emulsion explosive solution through a capillary viscometer; and acquiring the stirring power inside the aqueous phase preparation tank through a power sensor.

[0019] One or more technical solutions provided in the embodiments of this application have at least the following technical effects or advantages:

[0020] 1. By collecting and processing the automatic batching data of the emulsion explosive aqueous phase preparation tank, the automatic batching data of the emulsion explosive aqueous phase preparation tank is analyzed to obtain the evaluation values ​​of mixing uniformity, energy consumption efficiency and PID control response timeliness. Comprehensive analysis and optimization adjustment improve the stability of the safety inspection method and solve the problem of low stability of the existing safety inspection method.

[0021] 2. By analyzing the automatic batching data of the aqueous phase preparation tank of emulsion explosive, the evaluation values ​​of mixing uniformity and energy consumption efficiency, as well as the evaluation value of PID control response timeliness, are obtained. This ensures that the components of the aqueous phase solution are evenly distributed, avoids performance instability caused by excessively high or low local concentrations, and thus reduces energy consumption and production costs.

[0022] 3. Through comprehensive analysis, the stability assessment value of the automatic batching safety inspection of the aqueous phase preparation tank is obtained, and the safety inspection method of the automatic batching for the aqueous phase preparation tank of emulsion explosive is optimized and adjusted. Potential safety hazards, such as abnormal temperature and pressure fluctuations, are discovered, and preventive measures are taken to reduce the risk of accidents. Attached Figure Description

[0023] Figure 1 This is a flowchart of an automatic batching and safety inspection method for an aqueous phase preparation tank of emulsion explosives, provided in an embodiment of this application.

[0024] Figure 2 This is a schematic diagram of the viscosity-time change curve of the emulsion explosive solution provided in the embodiments of this application. Detailed Implementation

[0025] This application provides an automatic batching safety inspection method and equipment for emulsion explosive aqueous phase preparation tanks, which solves the problem of low stability in existing safety inspection methods. By collecting and processing automatic batching data from emulsion explosive aqueous phase preparation tanks, analyzing the automatic batching data, and obtaining evaluation values ​​for mixing uniformity, energy consumption efficiency, and PID control response timeliness, the stability of the safety inspection method is improved through comprehensive analysis and optimization.

[0026] The technical solution in this application embodiment aims to address the aforementioned problem of low stability in the safety inspection method. The overall approach is as follows:

[0027] By collecting and processing the automatic batching data of the emulsion explosive aqueous phase preparation tank, and analyzing the automatic batching data of the emulsion explosive aqueous phase preparation tank, we can obtain evaluation values ​​of mixing uniformity and energy consumption efficiency, as well as evaluation values ​​of PID control response timeliness. Through comprehensive analysis and optimization, the stability of the safety inspection method has been improved.

[0028] To better understand the above technical solutions, the following will provide a detailed explanation of the technical solutions in conjunction with the accompanying drawings and specific implementation methods.

[0029] like Figure 1 The diagram shown is a flowchart of an automatic batching safety inspection method for an aqueous phase preparation tank of emulsion explosives provided in this application embodiment. This method is applied to an automatic batching safety inspection method and equipment for an aqueous phase preparation tank of emulsion explosives. The method includes the following steps: collecting and processing automatic batching data from the aqueous phase preparation tank of emulsion explosives; analyzing the automatic batching data to obtain evaluation values ​​for mixing uniformity and energy efficiency, and evaluation values ​​for PID control response timeliness; comprehensively analyzing to obtain a stability evaluation value for the automatic batching safety inspection of the aqueous phase preparation tank; and optimizing and adjusting the automatic batching safety inspection method for an aqueous phase preparation tank of emulsion explosives based on a comparison of the evaluation value with a preset threshold from the database.

[0030] In this embodiment, during the automatic batching process in the aqueous phase preparation tank of the emulsion explosive, the core objective of the central control system in dynamically adjusting the amount of raw materials is to control the viscosity of the emulsion explosive within a preset threshold by compensating for the effects of temperature and time in real time. This avoids emulsion stratification or uneven sensitization caused by abnormal emulsion explosive viscosity, as shown in Table 1. Figure 2 As shown, the horizontal axis (X-axis) represents time (minutes), ranging from 0 to 60 minutes, and is divided into three stages according to the process: 0-20 minutes: raw material dissolution stage; 20-40 minutes: heating stage; 40-60 minutes: emulsification stage; the vertical axis (Y-axis) represents the viscosity (cP) of the emulsion explosive solution, with a logarithmic scale (accommodating a wide viscosity range), ranging from 0 to 10,000 cP.

[0031] Table 1. Viscosity Changes of Emulsion Explosive Solution

[0032]

[0033] Furthermore, the specific steps for collecting and processing the automatic batching data of the emulsion explosive aqueous phase preparation tank are as follows: Sensor data is transmitted in real time to the central control system via IoT technology to collect the raw data of the automatic batching of the emulsion explosive aqueous phase preparation tank; the raw data of the automatic batching of the emulsion explosive aqueous phase preparation tank is cleaned and denoised to obtain the automatic batching data of the emulsion explosive aqueous phase preparation tank; the automatic batching data of the emulsion explosive aqueous phase preparation tank includes mixing uniformity and energy efficiency data, PID control response timeliness data, and temperature runaway frequency.

[0034] Further, the specific steps for obtaining the mixing uniformity and energy efficiency evaluation values ​​are as follows: The mixing uniformity and energy efficiency data include the stirring dead zone area, PID control response time, maximum temperature inside the aqueous phase preparation tank, minimum temperature inside the aqueous phase preparation tank, maximum viscosity change amplitude of the emulsion explosive solution, minimum viscosity change amplitude of the emulsion explosive solution, and mixing uniformity; The stirring dead zone area threshold, PID control response time threshold, standard value of temperature difference inside the aqueous phase preparation tank, standard value of viscosity change amplitude difference of the emulsion explosive, mixing uniformity threshold, weighting factor of stirring dead zone area, and mixing efficiency are obtained from the aqueous phase preparation tank safety inspection database. The weighting factors for uniformity, PID control response time, temperature difference coefficient, and viscosity mutation coefficient of the emulsion explosive solution are calculated. A ratio analysis is performed between the stirring dead zone area and its threshold value. The results of this ratio analysis are then averaged, and the weighting factor for the stirring dead zone area is used to correct the averaged results. This is denoted as the first component of the mixing uniformity and energy efficiency evaluation value. A ratio analysis is also performed between the PID control response time and its threshold value. The weighting factor for the PID control response time is used to correct the ratio analysis results. This is denoted as the mixing uniformity. The second component of the energy efficiency assessment value; the deviation between the maximum and minimum temperatures in the aqueous phase preparation tank and the standard value of the temperature difference in the aqueous phase preparation tank are analyzed as a proportion, and the results of the proportion analysis are corrected using the weighting factor of the temperature difference coefficient, which is denoted as the temperature difference coefficient; the deviation between the maximum and minimum viscosity changes of the emulsion explosive solution and the standard value of the difference in viscosity change amplitude are analyzed as a proportion, and the results of the proportion analysis are corrected using the weighting factor of the viscosity change coefficient of the emulsion explosive solution, which is denoted as the viscosity change coefficient of the emulsion explosive solution; the mixing uniformity and mixing efficiency are analyzed as a proportion. A proportion analysis is performed on the uniformity threshold, and the results of the proportion analysis are averaged. The weighting factor of mixing uniformity is used to correct the averaged results, which is denoted as the third component of the mixing uniformity and energy efficiency evaluation value. The coupling results of the first component, the second component, the temperature difference coefficient, and the viscosity mutation coefficient of the emulsion explosive solution are combined with the third component of the mixing uniformity and energy efficiency evaluation value to obtain the mixing uniformity and energy efficiency evaluation value. The mixing uniformity and energy efficiency evaluation value represents the quantitative data of dynamically adjusting the stirring speed.

[0035] In this embodiment, the specific method for obtaining the mixing uniformity and energy efficiency evaluation values ​​is as follows:

[0036]

[0037]

[0038] The preset mixing uniformity and energy efficiency detection points are numbered sequentially. S0 represents the number of the mixing uniformity and energy efficiency detection point under the T0th mixing uniformity and energy efficiency detection segment. S0 = 1, 2, ..., S, where S represents the total number of mixing uniformity and energy efficiency detection points.

[0039] The preset mixing uniformity and energy efficiency time is divided into mixing uniformity and energy efficiency detection segments of equal length. T0 represents the number of the mixing uniformity and energy efficiency detection segment, T0 = 1, 2, ..., T, and T represents the total number of mixing uniformity and energy efficiency detection segments.

[0040] This represents the evaluation values ​​of mixing uniformity and energy efficiency in the T0th mixing uniformity and energy efficiency detection segment.

[0041] The area of ​​the stirring dead zone at the S0th mixing uniformity and energy efficiency detection point represents the area of ​​the region that was not fully mixed during the stirring process. Fluid visualization technology is used to observe and measure the flow of fluid in the aqueous preparation tank, generating a flow field image. The dead zone area is extracted using image processing software, the number of pixels is calculated, and then converted into the actual area according to the scale to determine the stirring dead zone area.

[0042] G0 represents the stirring dead zone area threshold, which is a preset stirring dead zone area threshold obtained from the safety inspection database of the aqueous phase preparation tank. It can be the average stirring dead zone area under preset historical mixing uniformity and energy consumption efficiency detection points in the safety inspection database of the aqueous phase preparation tank.

[0043] This represents the PID control response time under the T0th mixing uniformity and energy efficiency detection segment, which is the time delay from the temperature change to the start of the PID controller response. The time series data of temperature and control signal are recorded by a data logger.

[0044] Z0 represents the PID control response time threshold, which is a preset PID control response time threshold obtained from the safety inspection database of the aqueous phase preparation tank. It can be the average value of the PID control response time under the preset historical mixing uniformity and energy consumption efficiency detection segments in the safety inspection database of the aqueous phase preparation tank.

[0045] This represents the temperature difference coefficient under the T0th mixing uniformity and energy efficiency detection segment.

[0046] It represents the viscosity mutation coefficient of the emulsion explosive solution under the T0th mixing uniformity and energy consumption efficiency detection segment.

[0047] The maximum temperature inside the aqueous phase preparation tank during the T0th mixing uniformity and energy efficiency detection segment is obtained through a temperature sensor.

[0048] This represents the minimum temperature inside the aqueous phase preparation tank during the T0th mixing uniformity and energy efficiency detection segment.

[0049] ΔW represents the standard value of temperature difference inside the aqueous phase preparation tank, which is a preset standard value of temperature difference inside the aqueous phase preparation tank obtained from the safety inspection database of the aqueous phase preparation tank. It can be the average value of temperature difference inside the aqueous phase preparation tank under the preset historical mixing uniformity and energy consumption efficiency detection sections in the safety inspection database of the aqueous phase preparation tank.

[0050] This represents the maximum amplitude of viscosity change in the emulsion explosive solution under the T0th mixing uniformity and energy consumption efficiency detection segment, and the viscosity of the emulsion explosive solution is measured by a capillary viscometer.

[0051] This represents the minimum amplitude of viscosity change in the emulsion explosive solution under the T0th mixing uniformity and energy consumption efficiency detection segment.

[0052] ΔF represents the standard value of the viscosity variation amplitude difference of emulsion explosive, which is a preset standard value of the viscosity variation amplitude difference of emulsion explosive obtained from the safety inspection database of aqueous preparation tank. It can be the average value of the viscosity variation amplitude difference of emulsion explosive under the preset historical mixing uniformity and energy consumption efficiency detection section in the safety inspection database of aqueous preparation tank.

[0053] This represents the mixing uniformity at the S0th mixing uniformity and energy efficiency detection point, obtained through chemical analysis instruments such as high performance liquid chromatography.

[0054] D0 represents the mixing uniformity threshold, which is a preset mixing uniformity threshold obtained from the safety inspection database of the aqueous phase preparation tank. It can be the average mixing uniformity under the preset historical mixing uniformity and energy consumption efficiency detection segments from the safety inspection database of the aqueous phase preparation tank.

[0055] This is a preset stirring dead zone area weighting factor obtained from the safety inspection database of the aqueous phase preparation tank.

[0056] This is a preset mixing uniformity weighting factor obtained from the safety inspection database of the aqueous preparation tank.

[0057] The preset PID control response time weighting factor is obtained from the safety inspection database of the aqueous preparation tank.

[0058] The preset temperature difference coefficient weighting factor is obtained from the safety inspection database of the aqueous preparation tank.

[0059] This is a weighting factor for the viscosity mutation coefficient of the pre-set emulsion explosive solution, obtained from the safety inspection database of the aqueous preparation tank.

[0060] By retrieving a mapping table of weighting factors from a database, the system can quickly extract corresponding weighting factors based on the current stirring dead zone area, mixing uniformity, PID control response time, temperature difference coefficient, and viscosity mutation coefficient of the emulsion explosive solution. Examples include weighting factors for the stirring dead zone area, mixing uniformity, PID control response time, temperature difference coefficient, and viscosity mutation coefficient of the emulsion explosive solution. For instance, this mapping table defines a clear set of association rules that converts the specific values ​​of the stirring dead zone area, mixing uniformity, PID control response time, temperature difference coefficient, and viscosity mutation coefficient of the emulsion explosive solution into their corresponding weighting factors. This mechanism effectively enables dynamic acquisition of weighting factors, whether achieving precise one-to-one matching or a many-to-one relationship where multiple parameters converge into a single weight.

[0061] A larger dead zone area indicates more areas that are not fully mixed during the mixing process, leading to a decrease in mixing uniformity. Mixing uniformity is affected by the control of the mixing process. The shorter the PID control response time, the faster and more accurate the temperature control, which helps maintain stable mixing conditions and thus improves mixing uniformity. The greater the difference between the maximum and minimum temperatures in the aqueous phase preparation tank, the more likely it is to cause local overheating or undercooling, affecting the dissolution and dispersion of components and thus reducing mixing uniformity. The greater the difference between the maximum and minimum temperatures in the aqueous phase preparation tank, the greater the difference between the maximum and minimum viscosity changes of the emulsion explosive solution, because temperature affects the viscosity of the solution; as temperature increases, viscosity decreases, and as temperature decreases, viscosity increases. A shorter PID control response time helps to quickly adjust the temperature and maintain the stability of the temperature in the aqueous phase preparation tank.

[0062] The area of ​​the stirring dead zone is positively correlated with the mixing uniformity and energy efficiency assessment values. A larger dead zone area indicates lower mixing uniformity, but also higher mixing uniformity and energy efficiency assessment values. Conversely, mixing uniformity is negatively correlated with these assessment values. Higher uniformity indicates more effective stirring, but also lower mixing uniformity and energy efficiency assessment values. The PID control response time is positively correlated with mixing uniformity and energy efficiency assessment values. An excessively long PID control response time leads to inaccurate temperature control, causing temperature fluctuations during mixing and reducing the PID control response time. The longer the reaction time, the higher the evaluation values ​​for mixing uniformity and energy efficiency. The temperature difference coefficient is positively correlated with the evaluation values ​​for mixing uniformity and energy efficiency; a larger temperature difference coefficient indicates a greater temperature difference within the aqueous phase preparation tank, and thus, a higher evaluation value for mixing uniformity and energy efficiency. The viscosity mutation coefficient of the emulsion explosive solution is also positively correlated with the evaluation values ​​for mixing uniformity and energy efficiency; a larger viscosity mutation coefficient indicates unstable solution properties, increasing the load on the stirring equipment and mixing inhomogeneity, and thus, a higher evaluation value for mixing uniformity and energy efficiency.

[0063] Further, the specific steps for obtaining the PID control response timeliness evaluation value are as follows: The PID control response timeliness data includes PID control response time, steam valve regulation lag time, maximum stirring power in the aqueous phase preparation tank, minimum stirring power in the aqueous phase preparation tank, maximum amplitude of viscosity change in the emulsion explosive solution, and minimum amplitude of viscosity change in the emulsion explosive solution; the PID control response time threshold, steam valve regulation lag time threshold, standard value of stirring power difference in the aqueous phase preparation tank, standard value of viscosity change amplitude difference in the emulsion explosive, weighting factor of PID control response time, weighting factor of steam valve regulation lag time, weighting factor of energy consumption change coefficient, and weighting factor of viscosity change coefficient of emulsion explosive solution are obtained from the aqueous phase preparation tank safety inspection database; the PID control response time threshold and PID control response time are analyzed in proportion, and the results of the proportion analysis are corrected using the weighting factor of PID control response time, which is recorded as the first component of the PID control response timeliness evaluation value; the steam valve regulation lag time threshold and steam valve regulation lag time are analyzed in proportion, making... The results of the proportion analysis are corrected using a weighting factor for the lag time of steam valve adjustment, and this is denoted as the second component of the PID control response timeliness evaluation value. A proportion analysis is performed on the deviation between the maximum and minimum stirring power in the aqueous phase preparation tank and the standard value of the difference in stirring power within the aqueous phase preparation tank. The results of the proportion analysis are corrected using a weighting factor for the energy consumption variation coefficient, and this is denoted as the energy consumption variation coefficient. A proportion analysis is performed on the deviation between the maximum and minimum viscosity mutation amplitudes of the emulsion explosive solution and the standard value of the difference in viscosity mutation amplitudes. The results of the proportion analysis are corrected using a weighting factor for the viscosity mutation coefficient of the emulsion explosive solution, and this is denoted as the viscosity mutation coefficient of the emulsion explosive solution. A proportion analysis is performed on the coupling results of the first and second components of the PID control response timeliness evaluation value and the coupling results of the energy consumption variation coefficient and the viscosity mutation coefficient of the emulsion explosive solution to obtain the PID control response timeliness evaluation value. The PID control response timeliness evaluation value represents the response speed of the control system, reflecting its ability to cope with emergencies.

[0064] In this embodiment, the specific method for obtaining the PID control response timeliness evaluation value is as follows:

[0065]

[0066] ρ1+ρ2+ρ3+ρ4=1;

[0067] The preset PID control response timeliness detection segments are numbered sequentially, where N0 represents the number of the PID control response timeliness detection segment, N0 = 1, 2, ..., N, and N represents the total number of PID control response timeliness detection segments.

[0068] This represents the PID control response timeliness evaluation value of the N0th PID control response timeliness detection segment.

[0069] Q0 represents the PID control response time threshold, which is a preset PID control response time threshold obtained from the safety inspection database of the aqueous preparation tank. It can be the average value of the PID control response time under the preset historical PID control response time detection segment from the safety inspection database of the aqueous preparation tank.

[0070] This represents the PID control response time under the N0th PID control response timeliness detection segment.

[0071] P0 represents the steam valve regulation lag time threshold, which is a preset steam valve regulation lag time threshold obtained from the safety inspection database of the aqueous phase preparation tank. It can be the average steam valve regulation lag time under the preset historical PID control response and timeliness detection segment from the safety inspection database of the aqueous phase preparation tank.

[0072] This represents the steam valve regulation lag time under the N0th PID control response time detection segment, which is obtained through the system log.

[0073] This represents the energy consumption change coefficient under the timeliness detection segment of the N0th PID control response.

[0074] This represents the viscosity mutation coefficient of the emulsion explosive solution under the timeliness detection segment of the N0th PID control response.

[0075] This represents the maximum stirring power inside the aqueous phase preparation tank under the N0th PID control response and timeliness detection segment, which is obtained through real-time monitoring and acquisition by a power sensor.

[0076] This represents the minimum stirring power in the aqueous phase preparation tank under the timeliness detection segment of the N0th PID control response.

[0077] ΔR represents the standard value of the stirring power difference in the aqueous phase preparation tank. It is a preset standard value of the stirring power difference in the aqueous phase preparation tank obtained from the safety inspection database of the aqueous phase preparation tank. It can be the average value of the stirring power difference in the aqueous phase preparation tank under the preset historical PID control response timeliness detection segment in the safety inspection database of the aqueous phase preparation tank.

[0078] This represents the maximum amplitude of the viscosity change of the emulsion explosive solution under the timeliness detection segment of the N0th PID control response.

[0079] This represents the minimum amplitude of the viscosity change of the emulsion explosive solution under the timeliness detection segment of the N0th PID control response.

[0080] ΔH represents the standard value of the viscosity variation amplitude difference of emulsion explosive, which is a preset standard value of the viscosity variation amplitude difference of emulsion explosive obtained from the safety inspection database of aqueous preparation tank. It can be the average value of the viscosity variation amplitude difference of emulsion explosive under the preset historical PID control response and timeliness detection segment in the safety inspection database of aqueous preparation tank.

[0081] ρ1 is a preset PID control response time weighting factor obtained from the safety inspection database of the aqueous preparation tank.

[0082] ρ2 is a preset steam valve regulation lag time weighting factor obtained from the safety inspection database of the aqueous preparation tank.

[0083] ρ3 is a preset energy consumption variation coefficient weighting factor obtained from the safety inspection database of the aqueous preparation tank.

[0084] ρ4 is a preset viscosity mutation coefficient weighting factor for emulsion explosive solution obtained from the safety inspection database of aqueous preparation tank.

[0085] By retrieving a mapping table of weighting factors from a database, the system can quickly extract corresponding weighting factors based on the current PID control response time, steam valve regulation lag time, energy consumption variation coefficient, and viscosity mutation coefficient of the emulsion explosive solution. Examples include weighting factors for PID control response time, steam valve regulation lag time, energy consumption variation coefficient, and viscosity mutation coefficient of the emulsion explosive solution. For instance, this mapping table defines a clear set of association rules that converts the specific values ​​of PID control response time, steam valve regulation lag time, energy consumption variation coefficient, and viscosity mutation coefficient of the emulsion explosive solution into their corresponding weighting factors. This mechanism effectively enables dynamic acquisition of weighting factors, whether achieving precise one-to-one matching or a many-to-one relationship where multiple parameters converge into a single weight.

[0086] A longer steam valve regulation lag time means a shorter time interval between the valve receiving the control signal and the valve actually starting to move, resulting in a longer PID control response time. The energy consumption variation coefficient reflects the degree of energy consumption fluctuation during the process. A shorter PID control response time means faster temperature control, reducing additional energy consumption caused by temperature fluctuations, thus lowering the energy consumption variation coefficient. A longer steam valve regulation lag time leads to untimely temperature control, causing temperatures to be too high or too low, requiring additional energy to correct, thus increasing the energy consumption variation coefficient. A larger viscosity mutation coefficient of the emulsion explosive solution indicates greater viscosity fluctuations, affecting the load of the stirring equipment, leading to energy consumption fluctuations, and thus increasing the energy consumption variation coefficient.

[0087] There is a negative correlation between PID control response time and PID control response timeliness evaluation value. A shorter PID control response time indicates a faster response of the controller to changes in the setpoint; a longer PID control response time results in a lower PID control response timeliness evaluation value. Similarly, there is a negative correlation between steam valve regulation lag time and PID control response timeliness evaluation value. A shorter steam valve regulation lag time indicates a faster response of the valve to the control signal; a longer steam valve regulation lag time results in a lower PID control response timeliness evaluation value. Furthermore, there is a negative correlation between the energy consumption variation coefficient and PID control response timeliness evaluation value. A smaller energy consumption variation coefficient indicates smaller energy consumption fluctuations during the process, generally meaning a stable and timely control system; a larger energy consumption variation coefficient results in a lower PID control response timeliness evaluation value. Finally, there is a negative correlation between the energy consumption variation coefficient and PID control response timeliness evaluation value. A smaller viscosity change coefficient indicates stable solution viscosity, meaning the control system adjusts to viscosity changes promptly and effectively; a larger energy consumption change coefficient results in a lower PID control response timeliness evaluation value.

[0088] Further, the specific steps for obtaining the stability assessment value of the automatic batching safety inspection of the aqueous phase preparation tank through comprehensive analysis are as follows: Obtain the temperature runaway frequency threshold, the weighting factor of the PID control response timeliness assessment value, the weighting factor of the mixing uniformity and energy efficiency assessment value, and the weighting factor of the temperature runaway frequency from the aqueous phase preparation tank safety inspection database; Average the PID control response timeliness assessment value, and correct the averaged result using the weighting factor of the PID control response timeliness assessment value, denoted as the first component of the stability assessment value of the automatic batching safety inspection of the aqueous phase preparation tank; Average the mixing uniformity and energy efficiency assessment values, and correct the averaged result using the weighting factor of the mixing uniformity and energy efficiency assessment values, denoted as the first component of the stability assessment value of the automatic batching safety inspection of the aqueous phase preparation tank. The second component of the overall inspection stability assessment value is calculated. A ratio analysis is performed on the temperature runaway frequency and its threshold, and the results are averaged. The averaged result is then corrected using a weighting factor for the temperature runaway frequency, and this is denoted as the third component of the automatic batching safety inspection stability assessment value for the aqueous phase preparation tank. A ratio analysis is then performed on the coupling results of the first, second, and third components of the automatic batching safety inspection stability assessment value for the aqueous phase preparation tank. A comprehensive analysis yields the final automatic batching safety inspection stability assessment value for the aqueous phase preparation tank. This value represents the quantitative data on the stability of the aqueous phase preparation tank during the automatic batching process.

[0089] In this embodiment, the specific method for obtaining the mixing uniformity and energy efficiency evaluation values ​​is as follows:

[0090]

[0091] The preset automatic batching safety inspection stability test points of the aqueous phase preparation tank are numbered sequentially. K0 represents the number of the automatic batching safety inspection stability test point of the aqueous phase preparation tank. K0 = 1, 2, ..., K, where K represents the total number of the automatic batching safety inspection stability test points of the aqueous phase preparation tank.

[0092] δ represents the stability assessment value of the automatic batching safety inspection of the aqueous phase preparation tank.

[0093] This represents the PID control response timeliness evaluation value of the N0th PID control response timeliness detection segment.

[0094] This represents the evaluation values ​​of mixing uniformity and energy efficiency in the T0th mixing uniformity and energy efficiency detection segment.

[0095] The frequency of temperature runaway is represented at the stability detection point of the automatic batching safety inspection of the K0th aqueous phase preparation tank, which is obtained by collecting the temperature runaway frequency through an infrared temperature sensor.

[0096] φ0 represents the temperature runaway frequency threshold, which is a preset temperature runaway frequency threshold obtained from the safety inspection database of the aqueous phase preparation tank. It can be the average temperature runaway frequency at preset historical stability detection points of automatic batching safety inspection of the aqueous phase preparation tank from the safety inspection database of the aqueous phase preparation tank.

[0097] The weighting factor is the preset PID control response timeliness evaluation value obtained from the safety inspection database of the aqueous preparation tank.

[0098] The weighting factors are the preset mixing uniformity and energy efficiency evaluation values ​​obtained from the safety inspection database of the aqueous preparation tank.

[0099] This is a preset temperature runaway frequency weighting factor obtained from the safety inspection database of the aqueous preparation tank.

[0100] By retrieving a mapping table of weighting factors from a database, the system can quickly extract the corresponding weighting factors based on the current PID control response timeliness assessment value, mixing uniformity and energy efficiency assessment value, and temperature runaway frequency. For example, this mapping table defines a clear set of association rules that converts the specific values ​​of the PID control response timeliness assessment value, mixing uniformity and energy efficiency assessment value, and temperature runaway frequency into their corresponding weighting factors. Under this mechanism, whether achieving precise one-to-one matching or a many-to-one relationship where multiple parameters converge into a single weight, the dynamic acquisition of weighting factors can be effectively achieved.

[0101] A higher PID control response timeliness evaluation value indicates that parameters such as stirring speed and temperature can be adjusted quickly to adapt to changes in the mixing process, thereby helping to improve mixing uniformity. The lower the evaluation values ​​for mixing uniformity and energy efficiency, the better. A lower temperature runaway frequency indicates stable temperature control, which is beneficial for maintaining constant mixing conditions, thereby improving mixing uniformity. The lower the evaluation values ​​for mixing uniformity and energy efficiency, the better. A higher PID control response timeliness evaluation value indicates that temperature deviations can be corrected quickly, reducing the frequency of temperature runaway. The lower the temperature runaway frequency, the better.

[0102] There is a positive correlation between the PID control response timeliness assessment value and the automatic batching safety inspection stability assessment value of the aqueous phase preparation tank. A higher PID control response timeliness assessment value indicates that process parameters can be adjusted quickly to maintain the stability of the batching process and reduce safety risks caused by untimely control. A higher PID control response timeliness assessment value also indicates a higher automatic batching safety inspection stability assessment value of the aqueous phase preparation tank. There is a negative correlation between the mixing uniformity and energy efficiency assessment values ​​and the automatic batching safety inspection stability assessment value of the aqueous phase preparation tank. A higher mixing uniformity and energy efficiency assessment value indicates uneven distribution during the batching process, increasing the potential safety risks caused by uneven mixing. Higher mixing uniformity and energy efficiency assessment values ​​also indicate a lower automatic batching safety inspection stability assessment value of the aqueous phase preparation tank. There is a negative correlation between the temperature runaway frequency and the automatic batching safety inspection stability assessment value of the aqueous phase preparation tank. A higher temperature runaway frequency indicates unstable temperature control, which may lead to changes in material properties during the batching process. A higher temperature runaway frequency also indicates a lower automatic batching safety inspection stability assessment value of the aqueous phase preparation tank.

[0103] Further, the specific steps for optimizing and adjusting the automatic batching safety inspection method for aqueous phase preparation tanks of emulsion explosives are as follows: Obtain the first threshold value for PID control response timeliness evaluation, the second threshold value for mixing uniformity and energy efficiency evaluation, and the comprehensive threshold value for the stability evaluation of automatic batching safety inspection of aqueous phase preparation tanks from the database; compare and analyze the PID control response timeliness evaluation value, mixing uniformity and energy efficiency evaluation value, and the stability evaluation value of automatic batching safety inspection of aqueous phase preparation tanks with the first threshold value, the second threshold value, and the comprehensive threshold value of automatic batching safety inspection of aqueous phase preparation tanks to obtain the optimized and adjusted method for automatic batching safety inspection of emulsion explosives; the optimized and adjusted method for automatic batching safety inspection of aqueous phase preparation tanks of emulsion explosives includes a PID control response timeliness optimization method, a mixing uniformity and energy efficiency optimization method, and a stability optimization method for automatic batching safety inspection of aqueous phase preparation tanks.

[0104] Furthermore, the specific steps of the PID control response timeliness optimization method are as follows: if the PID control response timeliness evaluation value is greater than or equal to the first threshold of the PID control response timeliness evaluation value, then the PID control response timeliness optimization method is not required; if the PID control response timeliness evaluation value is less than the first threshold of the PID control response timeliness evaluation value, then the PID parameters are adjusted to improve the response speed to sudden changes in temperature and viscosity; emergency stop logic is designed, and the highest and lowest threshold trigger conditions for temperature, pressure, and viscosity are set.

[0105] In this embodiment, a PID controller is a common industrial control system used to regulate the response speed to sudden changes in temperature and viscosity of emulsion explosive solutions. Based on the deviation between a preset threshold and the actual value, it controls the output through three stages: proportional (P), integral (I), and derivative (D), thereby controlling the process. The goal of adjusting the PID parameters is to improve the system's response speed to sudden changes in temperature and viscosity of the emulsion explosive solution, enabling it to quickly adjust the output to make the actual value equal to the preset threshold. By gradually adjusting the P, I, and D parameters of the PID controller, the optimal combination of PID parameters is found, allowing the system to respond quickly to sudden changes in temperature and viscosity of the emulsion explosive solution and maintain stable operation. Adjusting the PID parameters can improve the system's response speed to sudden changes in temperature and viscosity of the emulsion explosive solution. This system allows it to react before parameters approach thresholds, reducing the likelihood of emergency shutdowns. Simultaneously, the emergency shutdown logic serves as a last line of defense, preventing accidents from escalating. Based on the automatic batching process of the emulsion explosive aqueous phase preparation tank, it determines the maximum and minimum safe thresholds for temperature, pressure, and emulsion explosive solution viscosity. If any two of these parameters exceed the maximum safe threshold or fall below the minimum safe threshold, the emergency shutdown logic is triggered directly, first stopping heating, then stopping stirring, and finally closing the valves. If any one of these parameters exceeds the maximum safe threshold or falls below the minimum safe threshold, an alarm is triggered to alert the operator. Continuous monitoring of abnormal situations ensures that the system can be safely restarted once the anomaly is resolved.

[0106] Furthermore, the specific steps of the mixing uniformity and energy efficiency optimization method are as follows: If the evaluation values ​​of mixing uniformity and energy efficiency are lower than or equal to the second threshold of the evaluation values ​​of mixing uniformity and energy efficiency, then the mixing uniformity and energy efficiency optimization method is not required; if the evaluation values ​​of mixing uniformity and energy efficiency are higher than the second threshold of the evaluation values ​​of mixing uniformity and energy efficiency, then the automatic batching process of the emulsion explosive aqueous phase preparation tank is simulated using CFD software, and parameters are set according to the actual safety inspection; by analyzing the fused data, dead zones and high-temperature points in the automatic batching process of the emulsion explosive aqueous phase preparation tank are identified; based on the output of the PID control algorithm, the output frequency of the frequency converter is adjusted in real time to control the speed of the stirring equipment.

[0107] In this embodiment, computational fluid dynamics (CFD) software is used to simulate the mixing process, analyze the flow state of the fluid within the container, and set appropriate fluid properties, boundary conditions, initial conditions, and other parameters according to actual working conditions. The simulation area is meshed to ensure computational accuracy and efficiency. Sensor data, including key parameters such as temperature, flow rate, and viscosity, is collected in real time. Data fusion technology is used to integrate multi-sensor data into a unified data format, providing a foundation for subsequent analysis. By analyzing the fused data, dead zones (areas with poor flow) and high-temperature points in the mixing process are identified. Using CFD simulation results and sensor data, the location and range of dead zones and high-temperature points are accurately located. A temperature prediction model for the mixing process is established, considering the relationship between input variables (such as heating power and cooling rate) and output variables (such as temperature). Temperature control objectives are set, such as maintaining a constant temperature or rapid heating. Based on the real-time collected temperature data and the prediction model, the optimal control strategy is calculated, and the operating state of the heating or cooling equipment is adjusted. The parameters of the frequency converter are set according to actual needs, such as frequency range and start-up mode. Based on the output of the PID control algorithm, the output frequency of the frequency converter inside the stirring equipment is adjusted in real time to control the rotation speed of the stirring equipment.

[0108] Furthermore, the specific steps of the stability optimization method for the automatic batching safety inspection of the aqueous phase preparation tank are as follows: If the stability assessment value of the automatic batching safety inspection of the aqueous phase preparation tank is greater than or equal to the comprehensive threshold value of the stability assessment value of the automatic batching safety inspection of the aqueous phase preparation tank, then the stability optimization method for the automatic batching safety inspection of the aqueous phase preparation tank is not required; if the stability assessment value of the automatic batching safety inspection of the aqueous phase preparation tank is less than the comprehensive threshold value of the stability assessment value of the automatic batching safety inspection of the aqueous phase preparation tank, then the temperature and viscosity of each area are monitored in real time to locate the anomaly; the safety inspection data of the automatic batching of the aqueous phase preparation tank is corrected by model predictive control; and the safety inspection path of the automatic batching of the aqueous phase preparation tank is dynamically adjusted by correcting the safety inspection data of the automatic batching of the aqueous phase preparation tank.

[0109] In this embodiment, temperature and viscosity changes in each area are monitored in real time. When the temperature in a certain area of ​​the aqueous phase preparation tank exceeds a preset temperature or the viscosity change exceeds a preset viscosity change, that area is automatically marked as a high-risk area. Through real-time monitoring and automatic marking, problematic areas are quickly identified, providing clear targets for subsequent inspections and handling, and prioritizing them. ΔT represents the degree of temperature deviation, and Δμ represents the degree of viscosity deviation. The system assesses the risk level of each area based on the degree of deviation of these two parameters. Inspection paths are dynamically generated based on the risk level of each area, ensuring that high-risk areas are inspected first. The purpose of prioritization is to ensure reasonable resource allocation and improve the efficiency and accuracy of inspections. Model Predictive Control (MPC) uses real-time inspection data, such as temperature field and viscosity distribution, as the initial state input for MPC. Historical inspection records, such as local crystallization frequency, are used to correct model parameters and improve prediction accuracy. Data acquired during the inspection process is fed back to the MPC model in real time to update the model status. By combining MPC with inspection feedback, real-time and precise control is achieved to ensure stable system operation. Through the above technical steps, the automatic batching safety inspection data of the aqueous phase preparation tank is corrected, and the automatic batching safety inspection path of the aqueous phase preparation tank is dynamically adjusted. The automatic batching safety inspection data of the aqueous phase preparation tank includes the temperature gradient at the top of the aqueous phase preparation tank, the viscosity of the emulsion explosive solution, and the degree of temperature deviation.If the temperature gradient at the top of the aqueous phase preparation tank exceeds the preset threshold, the MPC will automatically increase the stirring speed and cooling water flow to reduce the temperature gradient. The inspection path will be adjusted to be generated based on real-time data (e.g., bottom → middle → top) to ensure high-risk areas receive focused attention, with extended dwell time in these areas for more detailed inspection and recording. If the viscosity of the local emulsion explosive solution in the aqueous phase preparation tank exceeds the emulsion explosive solution viscosity threshold, a pulse flushing program will be automatically initiated to remove locally high-viscosity substances and restore normal flow. The inspection path will be adjusted to be generated based on real-time data (e.g., bottom → middle → top). The bottom of the tank is prone to accumulating high-viscosity substances and requires close monitoring. If the viscosity at the bottom exceeds the emulsion explosive solution viscosity threshold, the frequency or intensity of the pulse flushing program needs to be increased. The middle section is a critical area for the flow of the emulsion explosive solution and requires further monitoring. To ensure smooth flow, the viscosity of the emulsion explosive solution must be close to the emulsion explosive solution viscosity threshold. While the viscosity of the emulsion explosive solution at the top is relatively low, monitoring is still necessary to ensure there are no areas with high localized emulsion explosive solution viscosity. If the temperature deviation exceeds the preset temperature deviation threshold, the backup cooling system is triggered to quickly reduce the temperature and prevent further heating. Simultaneously, the operator is notified for manual intervention. The inspection path is adjusted to be generated based on real-time data (e.g., high-temperature area of ​​the aqueous phase preparation tank → medium-temperature area of ​​the aqueous phase preparation tank → low-temperature area of ​​the aqueous phase preparation tank). The high-temperature area of ​​the aqueous phase preparation tank is given priority for monitoring, and the backup cooling system is triggered first. The system performs regular automatic inspections, detecting abnormal equipment operating status and parameters, promptly alarming and recording the results. Remote monitoring of the system status via mobile or PC enables remote maintenance and fault diagnosis, and dynamically adjusts the automatic batching safety inspection path for the aqueous phase preparation tank.

[0110] The automatic batching and safety inspection equipment for an aqueous phase preparation tank of emulsion explosives provided in this application includes: recording time-series data of temperature and control signals through a data logger; acquiring the temperature inside the aqueous phase preparation tank through a temperature sensor; measuring the viscosity of the emulsion explosive solution through a capillary viscometer; and acquiring the stirring power inside the aqueous phase preparation tank through a power sensor.

[0111] It will be understood by those skilled in the art that embodiments of the present invention may be provided as methods, systems, or computer program products. Thus, the present invention may take the form of an entirely hardware embodiment, an entirely software embodiment, or an embodiment combining software and hardware. Furthermore, the present invention may take the form of a computer program product implemented on one or more computer-usable storage media (including but not limited to magnetic disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0112] This invention is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowchart illustrations and / or block diagrams. Figure 1 a process or multiple processes and / or boxes Figure 1 A device that provides the functions specified in a block or multiple blocks.

[0113] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 a process or multiple processes and / or boxes Figure 1 The function specified in one or more boxes.

[0114] These computer program instructions may also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process. Figure 1 a process or multiple processes and / or boxes Figure 1 A step that specifies a function in one or more boxes.

[0115] Although the preferred embodiments of the present invention have been described, those skilled in the art may make additional changes and modifications to these embodiments once they have learned the basic creative concept. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments and all changes and modifications that fall within the scope of the present invention.

[0116] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this invention and their equivalents, this invention also intends to include these modifications and variations.

Claims

1. A method for automatic batching and safety inspection of aqueous phase preparation tanks for emulsion explosives, characterized in that, Includes the following steps: Collect and process automatic batching data from the aqueous phase preparation tank of emulsion explosives; The automatic batching data of the emulsion explosive aqueous phase preparation tank were analyzed to obtain the evaluation values ​​of mixing uniformity and energy consumption efficiency, as well as the evaluation value of PID control response timeliness. The automatic batching data of the emulsion explosive aqueous phase preparation tank includes mixing uniformity and energy efficiency data, PID control response timeliness data, and temperature runaway frequency. The mixing uniformity and energy efficiency data include the stirring dead zone area, PID control response time, maximum temperature in the aqueous phase preparation tank, minimum temperature in the aqueous phase preparation tank, maximum amplitude of viscosity change in the emulsion explosive solution, minimum amplitude of viscosity change in the emulsion explosive solution, and mixing uniformity. The PID control response timeliness data includes PID control response time, steam valve adjustment lag time, maximum stirring power in the aqueous phase preparation tank, minimum stirring power in the aqueous phase preparation tank, maximum amplitude of viscosity change in the emulsion explosive solution, and minimum amplitude of viscosity change in the emulsion explosive solution. Comprehensive analysis yielded the stability assessment value for the automatic batching safety inspection of the aqueous phase preparation tank; The specific steps for obtaining the stability assessment value of the automatic batching safety inspection of the aqueous phase preparation tank through comprehensive analysis are as follows: The weighting factors of temperature runaway frequency threshold, PID control response timeliness evaluation value, mixing uniformity and energy efficiency evaluation value, and temperature runaway frequency are obtained from the safety inspection database of aqueous preparation tank. The PID control response timeliness evaluation value is averaged, and the averaged result is corrected using the weighting factor of the PID control response timeliness evaluation value. This is recorded as the first component of the stability evaluation value of the automatic batching safety inspection of the aqueous phase preparation tank. The mixing uniformity and energy efficiency evaluation values ​​are averaged, and the results of the averaged processing are corrected using the weighting factors of the mixing uniformity and energy efficiency evaluation values. This is recorded as the second component of the stability evaluation value of the automatic batching safety inspection of the aqueous phase preparation tank. The frequency of temperature runaway and the threshold of temperature runaway are analyzed in proportion. The results of the proportion analysis are averaged. The weighting factor of the frequency of temperature runaway is used to correct the averaged results. This is recorded as the third component of the stability evaluation value of the automatic batching safety inspection of the aqueous preparation tank. The coupling results of the first component, the second component, and the third component of the stability assessment value of the automatic batching safety inspection of the aqueous phase preparation tank are analyzed by proportion, and the comprehensive analysis is used to obtain the stability assessment value of the automatic batching safety inspection of the aqueous phase preparation tank. The stability assessment value of the automatic batching safety inspection of the aqueous phase preparation tank represents the quantitative data of the stability of the aqueous phase preparation tank during the automatic batching process; Based on the comparison between the evaluated values ​​and the preset thresholds from the database, the safety inspection method for automatic batching of emulsion explosive aqueous phase preparation tanks was optimized and adjusted.

2. The automatic batching and safety inspection method for an aqueous phase preparation tank of emulsion explosives as described in claim 1, characterized in that, The specific steps for collecting and processing the automatic batching data from the aqueous phase preparation tank of emulsion explosives are as follows: Through IoT technology, sensor data is transmitted in real time to the central control system to collect raw data of automatic batching of emulsion explosive aqueous phase preparation tank; The raw data of the automatic batching system for the aqueous phase preparation tank of emulsion explosives is cleaned and noise-reduced to obtain the automatic batching data for the aqueous phase preparation tank of emulsion explosives.

3. The automatic batching and safety inspection method for an aqueous phase preparation tank of emulsion explosives as described in claim 1, characterized in that, The specific steps for obtaining the evaluation values ​​of mixing uniformity and energy efficiency are as follows: The following parameters were obtained from the safety inspection database of the aqueous preparation tank: the threshold of the stirring dead zone area, the threshold of the PID control response time, the standard value of the temperature difference inside the aqueous preparation tank, the standard value of the viscosity change amplitude difference of the emulsion explosive, the threshold of the mixing uniformity, the weighting factor of the stirring dead zone area, the weighting factor of the mixing uniformity, the weighting factor of the PID control response time, the weighting factor of the temperature difference coefficient, and the weighting factor of the viscosity change coefficient of the emulsion explosive solution. The ratio of the mixing dead zone area to the mixing dead zone area threshold is analyzed. The results of the ratio analysis are averaged. The weighting factor of the mixing dead zone area is used to correct the averaged results. This is recorded as the first component of the mixing uniformity and energy efficiency evaluation value. The ratio of PID control response time to PID control response time threshold is analyzed, and the results of the ratio analysis are corrected using the weighting factor of PID control response time. This is recorded as the second component of the mixing uniformity and energy efficiency evaluation value. The deviation between the maximum temperature and the minimum temperature inside the aqueous phase preparation tank is compared with the standard value of the temperature difference inside the aqueous phase preparation tank. The results of the ratio analysis are corrected by the weighting factor of the temperature difference coefficient, which is denoted as the temperature difference coefficient. The deviation between the maximum and minimum viscosity changes of the emulsion explosive solution is compared with the standard value of the difference in viscosity change amplitude. The results of the proportional analysis are corrected using the weighting factor of the viscosity change coefficient of the emulsion explosive solution, and denoted as the viscosity change coefficient of the emulsion explosive solution. The mixing uniformity and the mixing uniformity threshold are analyzed in proportion. The results of the proportion analysis are averaged. The weighting factor of mixing uniformity is used to correct the averaged results. This is recorded as the third component of the mixing uniformity and energy efficiency evaluation value. The coupling results of the first component of the mixing uniformity and energy efficiency evaluation value, the second component of the mixing uniformity and energy efficiency evaluation value, the temperature difference coefficient, and the viscosity change coefficient of the emulsion explosive solution are combined with the third component of the mixing uniformity and energy efficiency evaluation value to obtain the mixing uniformity and energy efficiency evaluation value. The mixing uniformity and energy efficiency assessment values ​​represent quantitative data for dynamically adjusting the stirring speed.

4. The automatic batching and safety inspection method for an aqueous phase preparation tank of emulsion explosives as described in claim 1, characterized in that, The specific steps for obtaining the PID control response timeliness evaluation value are as follows: The following parameters were obtained from the safety inspection database of the aqueous phase preparation tank: PID control response time threshold, steam valve regulation lag time threshold, standard value of stirring power difference in the aqueous phase preparation tank, standard value of viscosity change amplitude difference of emulsion explosive, weighting factor of PID control response time, weighting factor of steam valve regulation lag time, weighting factor of energy consumption change coefficient, and weighting factor of viscosity change coefficient of emulsion explosive solution. The PID control response time threshold and the PID control response time are analyzed as a proportion. The results of the proportion analysis are corrected using the weighting factor of the PID control response time, and this is recorded as the first component of the PID control response timeliness evaluation value. The steam valve regulation lag time threshold and the steam valve regulation lag time are analyzed in proportion. The weighting factor of the steam valve regulation lag time is used to correct the results of the proportion analysis, which is recorded as the second component of the PID control response timeliness evaluation value. The deviation between the maximum and minimum stirring power in the aqueous phase preparation tank is compared with the standard value of the stirring power difference in the aqueous phase preparation tank. The results of the ratio analysis are corrected by the weighting factor of the energy consumption variation coefficient, which is denoted as the energy consumption variation coefficient. The deviation between the maximum and minimum viscosity changes of the emulsion explosive solution is compared with the standard value of the difference in viscosity change amplitude. The results of the proportional analysis are corrected using the weighting factor of the viscosity change coefficient of the emulsion explosive solution, and denoted as the viscosity change coefficient of the emulsion explosive solution. The coupling results of the first and second components of the PID control response timeliness evaluation value are analyzed in proportion to the coupling results of the energy consumption change coefficient and the viscosity change coefficient of the emulsion explosive solution, so as to obtain the PID control response timeliness evaluation value. The PID control response timeliness evaluation value indicates the response speed of the control system, reflecting its ability to cope with unexpected situations.

5. The automatic batching and safety inspection method for an aqueous phase preparation tank of emulsion explosives as described in claim 1, characterized in that, The specific steps for optimizing and adjusting the automatic batching and safety inspection method for aqueous phase preparation tanks of emulsion explosives are as follows: The database is used to obtain the first threshold for PID control response timeliness assessment, the second threshold for mixing uniformity and energy efficiency assessment, and the comprehensive threshold for the stability assessment of automatic batching safety inspection of the aqueous phase preparation tank. By comparing and analyzing the evaluation values ​​of PID control response timeliness, mixing uniformity and energy efficiency, stability evaluation value of automatic batching safety inspection of aqueous phase preparation tank, and the comprehensive threshold values ​​of PID control response timeliness, mixing uniformity and energy efficiency, and stability evaluation value of automatic batching safety inspection of aqueous phase preparation tank, an optimized and adjusted method for safety inspection of automatic batching of emulsion explosives was obtained. The optimized adjustment for the automatic batching safety inspection method of the aqueous phase preparation tank for emulsion explosives includes a PID control response timeliness optimization method, a mixing uniformity and energy consumption efficiency optimization method, and an automatic batching safety inspection stability optimization method for the aqueous phase preparation tank.

6. The automatic batching and safety inspection method for an aqueous phase preparation tank of emulsion explosives as described in claim 5, characterized in that, The specific steps of the PID control response timeliness optimization method are as follows: If the PID control response timeliness evaluation value is greater than or equal to the first threshold of the PID control response timeliness evaluation value, then no PID control response timeliness optimization method is needed. If the PID control response timeliness evaluation value is less than the first threshold of the PID control response timeliness evaluation value, the PID parameters are adjusted to improve the response speed to sudden changes in temperature and viscosity; emergency stop logic is designed, and the highest and lowest threshold trigger conditions for temperature, pressure, and viscosity are set.

7. The automatic batching and safety inspection method for an aqueous phase preparation tank of emulsion explosives as described in claim 5, characterized in that, The specific steps of the method for optimizing mixing uniformity and energy efficiency are as follows: If the evaluation values ​​of mixing uniformity and energy efficiency are lower than or equal to the second threshold of the evaluation values ​​of mixing uniformity and energy efficiency, then no optimization method for mixing uniformity and energy efficiency is required. If the evaluation values ​​of mixing uniformity and energy efficiency are higher than the second threshold of mixing uniformity and energy efficiency, the automatic batching process of the emulsion explosive aqueous phase preparation tank is simulated using CFD software, and parameters are set according to actual safety inspections. By analyzing the fused data, dead zones and high-temperature points in the automatic batching process of the emulsion explosive aqueous phase preparation tank are identified. Based on the output of the PID control algorithm, the output frequency of the frequency converter is adjusted in real time to control the speed of the stirring equipment.

8. The automatic batching and safety inspection method for an aqueous phase preparation tank of emulsion explosives as described in claim 5, characterized in that, The specific steps of the method for optimizing the stability of automatic batching safety inspection of the aqueous phase preparation tank are as follows: If the stability assessment value of the automatic batching safety inspection of the aqueous phase preparation tank is greater than or equal to the comprehensive threshold of the stability assessment value of the automatic batching safety inspection of the aqueous phase preparation tank, then there is no need to optimize the stability of the automatic batching safety inspection of the aqueous phase preparation tank. If the stability assessment value of the automatic batching safety inspection of the aqueous phase preparation tank is less than the comprehensive threshold value of the automatic batching safety inspection of the aqueous phase preparation tank, the temperature and viscosity of each area are monitored in real time to locate the anomaly; the automatic batching safety inspection data of the aqueous phase preparation tank is corrected by model prediction control; and the automatic batching safety inspection path of the aqueous phase preparation tank is dynamically adjusted by correcting the automatic batching safety inspection data of the aqueous phase preparation tank.

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