Method for measuring soybean soaking weight gain ratio in real time, soybean soaking system and application of soybean soaking system

Abstract

The invention belongs to the field of soybean sauce brewing, and discloses a method for measuring the soybean soaking weight gain ratio in real time, a soybean soaking system and application of the soybean soaking system. Comprising the following steps: weighing dry soybeans before soaking the soybeans to obtain the weight W of the dry soybeans; before soaking the beans, metering the bean soaking water to obtain the weight W (soaking) of the bean soaking water; after soaking the beans, draining water, and weighing the drained bean soaking water to obtain the drained water weight W row; and S, calculating the foaming weight gain ratio K according to a formula K = (W foam-W row + W) / W. According to the method, the soybean weight gain ratio can be rapidly measured in real time, the difference rate of the measured weight gain ratio to the actual weight gain ratio obtained through weighing of a belt scale is within 2%, the method is reliable, the difference is small, the stability of material proportion control in the soy sauce production process is improved, the cost is low, the equipment transformation difficulty is small, and the method is suitable for popularization and application. Wide application prospects and economic values are realized.

Description

Technical Field

[0001] The invention belongs to the field of soybean sauce brewing, and particularly relates to a method for real-time measuring soybean soaking weight gain ratio, a soybean soaking system and applications thereof. Background Art

[0002] During the soy sauce production process, soybeans must undergo processes such as impurity removal, soaking, cooking, mixing with powder, inoculation, koji making, and fermentation before the delicious fermented crude oil can be produced. During this process, the ratio of the powder to be mixed and the amount of bacterial strain inoculated directly affect the quality of the fermentation. Therefore, the ratio and inoculation of the powder to be mixed need to be strictly controlled during the production process, and the deviation needs to be controlled within 5%. However, after soaking, the volume and weight of soybeans change. If the change in weight of the soybeans after soaking is not accurately assessed, the subsequent inoculation amount of bacterial strain and the amount of wheat flour to be mixed will fluctuate, thereby affecting the stability of production. In traditional production models, the soaking of soybeans is mainly evaluated by the operator's experience, and the amount of bacterial strain and wheat flour used is constantly adjusted during the production process. This requires a high degree of dependence on personnel. If the soybean material quality fluctuates greatly (such as the change between old and new beans) or the temperature fluctuates greatly, it still takes some time to explore the soaking rules of the soybeans, which has a significant impact on the stability of soy sauce fermentation.

[0003] In recent years, with the upgrading of production equipment, more companies have adopted weighing methods to evaluate the quality of soaked soybeans. For example, patent CN105547900A "A method and system for online measurement of water absorption rate of soybeans" uses a belt scale to measure the weight of soaked beans. After production is completed, the measured weight gain ratio (the weight gain ratio refers to the ratio of soaked soybeans to dry soybeans, and other materials also use "water absorption rate" to express it) can be used to guide subsequent production. However, the weight gain ratio measured by this method has a lag, and the weight gain ratio of the day cannot be obtained until the end of production. It can only be used to guide the production of the next batch. However, when the fluctuation between raw material batches is large, the reliability of this method is still insufficient. Another more reliable method is to add a weighing module to each soybean soaking tank. This method can accurately and timely determine the weight gain ratio of each tank, but it also has significant disadvantages. First, adding a weighing module to existing equipment is a large and difficult project. Second, the weighing module is expensive. A weighing module for a 30-ton storage tank costs 100,000 to 150,000 yuan. In a large-scale production enterprise that processes more than 200 tons of soybean raw materials daily, it needs to weigh more than 25 soybean soaking tanks weighing more than 30 tons, and the investment in weighing modules is approximately 2.5 to 3.8 million yuan. Therefore, it is urgent to provide a real-time, rapid, and accurate method for measuring soybean weight gain ratio to achieve refined control of the soy sauce production process and stable and controllable soy sauce brewing process. Summary of the Invention

[0004] In order to overcome the shortcomings and deficiencies of the prior art, the primary purpose of the present invention is to provide a method for quickly measuring the weight gain ratio of soybeans, which can immediately obtain the weight gain ratio of a single bean soaking tank after the beans are soaked and drained.

[0005] Another object of the present invention is to provide a bean soaking system for measuring the weight gain ratio of soaked beans.

[0006] Another object of the present invention is to provide application of the above method and system in soy sauce brewing.

[0007] The purpose of the present invention is achieved through the following technical solutions:

[0008] A method for real-time measurement of soybean soaking weight gain ratio comprises the following steps:

[0009] S1: Weigh the dry soybeans before soaking to obtain the dry soybean weight W;

[0010] S2: Measure the soaking water before soaking the beans to obtain the weight of the soaking water W 泡 ;

[0011] S3: After soaking the beans, drain the water and weigh the drained water to obtain the drained water weight W. 排 ;

[0012] S4: Using the weights obtained in steps S1 to S3, calculate the foaming weight gain ratio K according to formula (1):

[0013] K=(W 泡 -W 排 +W) / W formula (1).

[0014] Preferably, in steps S2 and S3, the weight of the bean soaking water is W 泡 and drainage weight W 排 All are calculated based on the flow count value, and the calculation formula is W 泡 = bean soaking water flow rate × density, W 排 = drainage flow × density.

[0015] Preferably, the density is water density, generally the density of water at 25°C, and it is assumed that the density of the bean soaking water is equal to the density of the discharged bean soaking water; the bean soaking water flow rate and the drainage flow rate are recorded by the bean soaking water flow meter and the drainage flow meter respectively.

[0016] A soybean soaking system for real-time measurement of soybean soaking weight gain ratio, comprising:

[0017] A buffer tank (2) is used to store dry soybeans and has a bean outlet at the bottom;

[0018] A bean soaking tank (3) includes one or more bean soaking tanks, and the bean soaking tanks are connected to the bean outlet of the buffer tank via a bean inlet pipeline;

[0019] A water inlet unit, comprising a water storage tank (1) and a water inlet pipeline, for injecting water into the bean soaking tank, wherein a flow meter 1 (4) is provided on the water inlet pipeline for recording the flow rate of the bean soaking water;

[0020] A drainage unit, comprising a drainage pipeline and a drainage tank (8), for draining excess water from the bean soaking tank, wherein a flow meter 2 (5) is provided on the drainage pipeline for recording drainage flow;

[0021] A wet bean conveying device, the feeding end of which is connected to the bottom of the bean soaking tank through a bean discharge pipeline, and the discharging end is connected to a wet bean belt scale (7);

[0022] The control system (6) is used to control the speed of bean feeding, water addition, drainage, bean discharge and the conveying speed of the wet bean belt scale, and the control system is provided with a calculation formula (1) according to the weight of dry soybeans W and the weight of bean soaking water W. 泡 , drainage weight W 排 , calculate the weight gain ratio K of a single can of soybeans.

[0023] Preferably, in the bean soaking system, the soybean conveying path is: buffer tank → bean inlet pipeline → bean soaking tank → bean discharge pipeline → wet bean belt scale;

[0024] The bean soaking water transportation path is: water storage tank → water inlet pipe → bean soaking tank → water outlet pipe → water storage tank.

[0025] Preferably, the buffer tank is provided with a weighing module, and the weighing module is connected to a control system.

[0026] Preferably, the bottom of the bean soaking tank is conical, and a drainage outlet is provided at the conical bottom.

[0027] Preferably, the dry buffer tank has a weighing function and can transport dry soybeans in a quantitative manner.

[0028] The weighing module of the buffer tank is connected to the control system and can display the accumulated weight.

[0029] The flowmeter 1 and the flowmeter 2 are both connected to the control system.

[0030] The application of the above method in soy sauce brewing.

[0031] The application of the above-mentioned bean soaking system in soy sauce brewing.

[0032] Preferably, the above application includes the following steps: inputting the processing speed V of dry soybeans into the control system 干 The control system adjusts the conveying speed V of the belt scale according to the weight gain ratio K. 泡 , the calculation formula is:

[0033] V 泡 =K×V干 Formula (2).

[0034] Compared with the prior art, the present invention has the following advantages and beneficial effects:

[0035] (1) The present invention provides a method and system for measuring the weight gain ratio of soybeans in real time. This method can immediately determine the weight gain ratio of the soaked beans in a single soaking tank after the beans are soaked, solving the problem of lagging weight gain ratio that has not been solved in the prior art. The method can quickly and in real time measure the weight gain ratio of soybeans and, based on the weight gain ratio of soybeans, regulate the subsequent dosage of wheat, bacterial strains, and brine, thereby achieving refined control of the production process, which is beneficial to improving the stability of material ratio control in the soy sauce production process and thus ensuring the stability of the quality of fermented soy sauce.

[0036] (2) The difference between the weight gain measured by the method of the present invention and the actual weight gain ratio obtained by weighing on a belt scale is within 2%. In actual operation, by setting a correction value, the difference can be stably maintained within 1%. The measurement accuracy can meet actual production needs and can be used to guide the adjustment of the soaking process of the next day to improve the quality stability of the soaked beans.

[0037] (3) By rationally scheduling the operation sequence of multiple bean soaking tanks and making full use of the idle time between tanks for material transfer, the production process can be parallelized and optimized, thereby improving overall equipment utilization and production efficiency. This operation model effectively breaks through the timing limitations of traditional single-tank operations and transforms discontinuous production links into continuous production output through process overlap technology.

[0038] (4) The method of the present invention has the characteristics of low cost, low difficulty in equipment modification, and high stability, and has broad application prospects and economic value. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] Figure 1 Schematic diagram of the structure for measuring the weight gain ratio of soybeans after soaking.

[0040] In the figure: 1-water storage tank; 2-dry soybean buffer tank; 3-bean soaking tank, 4-flow meter 1; 5-flow meter 2; 6-control system; 7-belt scale, 8-drainage tank; 3-bean soaking tanks (31-bean soaking tank A; 32-bean soaking tank B; 33-bean soaking tank C; 34-bean soaking tank D). DETAILED DESCRIPTION

[0041] The present invention will be described in further detail below with reference to specific examples, but the embodiments of the present invention are not limited thereto. For process parameters not particularly noted, conventional techniques may be used.

[0042] See also Figure 1A bean soaking system for real-time measurement of the weight gain ratio of soaked beans includes a water storage tank, a dry soybean buffer tank 2, a bean soaking tank 3 (bean soaking tanks 31 to 34), a bean soaking water flow meter 4, a drainage flow meter 5, a control system 6, a wet bean belt scale 7, and a drainage tank 8, and also includes a bean inlet pipeline, a bean outlet pipeline, a water inlet pipeline, and a water outlet pipeline.

[0043] The bean soaking water flow meter 4 (i.e., flow meter 1) and the drainage flow meter 5 (i.e., flow meter 2) can both record the accumulated drainage volume and transmit the recorded data values to the control system 6.

[0044] The bottoms of the bean soaking tanks A31 to D34 are conical, and a drainage port is provided at the bottom of the cone, and the discharged water passes through a drainage flow meter.

[0045] A method for calculating the weight gain ratio of soaked beans, the steps are as follows:

[0046] Step S1: When soaking soybeans, equal weights of dry soybeans are put into the soaking tank A31, soaking tank B32, soaking tank C33 and soaking tank D34 through the dry soybean buffer tank 2, and the weights are respectively calculated as W 干1 、W 干2 、W 干3 、W 干4 .

[0047] Step S2: Soaking water is injected into the four bean soaking tanks through the water storage tank 1. The soaking water passes through a pipe equipped with a soaking water flow meter 4. Soaking water is injected into only one bean soaking tank at a time. The four bean soaking tanks work alternately without affecting each other. The water intake into the four bean soaking tanks is recorded separately, and the water intake is recorded as W. j1 、W j2 、W j3 、W j4 .

[0048] Step S3: After the beans are soaked, the excess soaking water is drained from the drain holes at the bottom of the soaking tanks A to D. Only one soaking tank is drained at a time. The drained soaking water is counted by the drainage flow meter 5. The drainage volume of the four soaking tanks is recorded as W. p1 、W p2 、W p3 、W p4 .

[0049] Step S4: Based on the statistical values obtained in the above three steps, the weight gain ratio K of the four bean soaking cans can be directly calculated in the control system 6. Taking the bean soaking can A31 as an example, the calculation formula is: K1 = (W j1 -W p1 +W1) / W1, K2, K3, and K4 can be calculated in the same way.

[0050] In actual application, the processing speed V of dry soybeans is input into the control system 6. 干 The control system can adjust the conveying speed V of the belt scale 7 for soaking and fermenting beans according to the weight gain ratios K1 to K4 obtained in step 4. 泡1 ~V 泡4 The calculation formula of the soaked bean conveying speed V1 is: V 泡1 =K1×V 干1 Similarly, the conveying speed V of the other three bean soaking tanks can be obtained in turn. 泡2 、V 泡3 、V 泡4 .

[0051] In order to further verify the reliability of the method provided by the present invention, the present invention uses the cumulative weight of the belt scale to calculate the actual weight gain ratio after the production is completed, and compares it with the weight gain ratio measured by the method of the present invention. The comparison results are shown in Table 1 below. According to the comparison results, the theoretical weight gain measured by the present invention is 0.02 to 0.04 larger than the actual weight gain ratio obtained by weighing the belt scale, and the difference rate is within 2%. Since the theoretical weight gain ratio is always too large (the main reason for the large difference is that the density of the soaking water increases during the soaking of soybeans, and the statistical method of the present invention is based on the constant density of water, the statistical drainage volume is less than the actual drainage volume, which causes the theoretical weight gain to be larger than the actual value). In actual operation, the difference rate can be reduced by setting a correction value. The correction value (about 1%) can be subtracted from the theoretical weight gain ratio to make it closer to the actual value. After correction, the difference rate can be stably maintained within 1%.

[0052] Table 1

[0053]

[0054] Note: ① Actual weight gain ratio: total weight of soaked soybeans on belt scale / total weight of dry soybeans

[0055] ②Theoretical weight gain ratio: (water intake - drainage + total weight of dry soybeans) / total weight of dry soybeans

[0056] The above embodiments are preferred implementations of the present invention, but the implementations of the present invention are not limited to the above embodiments. Any other changes, modifications, substitutions, combinations, and simplifications that do not deviate from the spirit and principles of the present invention should be considered equivalent replacement methods and are included in the scope of protection of the present invention.

Claims

1. A method for real-time measurement of soybean soaking weight gain ratio, characterized in that: The steps include: S1: Weigh the dry soybeans before soaking to obtain the dry soybean weight W; S2: Measure the soaking water before soaking the beans to obtain the weight of the soaking water W 泡 ; S3: After soaking the beans, drain the water and weigh the drained water to obtain the drained water weight W. 排 ; S4: Using the weights obtained in steps S1 to S3, calculate the foaming weight gain ratio K according to formula (1): K = (W 泡 -W 排 +W) / W formula (1).

2. The method for real-time measurement of soybean soaking weight gain ratio according to claim 1, characterized in that: In steps S2 and S3, the weight of the bean soaking water is W 泡 and drainage weight W 排 All are calculated based on the flow count value, and the calculation formula is W 泡 = bean soaking water flow rate × density, W 排 = drainage flow × density.

3. The method for real-time measurement of soybean soaking weight gain ratio according to claim 2, characterized in that: The density is the water density, and the bean soaking water flow rate and drainage flow rate are recorded by flow meters respectively.

4. A bean soaking system for the method according to any one of claims 1 to 3, characterized in that: include: Buffer tank, used to store dry soybeans, with a bean outlet at the bottom; The bean soaking tank includes one or more bean soaking tanks, which are connected to the bean outlet of the buffer tank through a bean inlet pipe; The water inlet unit includes a water storage tank and a water inlet pipeline, which is used to inject water into the bean soaking tank. A flow meter 1 is provided on the water inlet pipeline to record the flow rate of the bean soaking water. The drainage unit includes a drainage pipe and a drainage tank, which is used to drain excess water from the bean soaking tank. A flow meter 2 is provided on the drainage pipe to record the drainage flow rate; A wet bean conveying device, the feeding end of which is connected to the bottom of the bean soaking tank through a bean discharge pipeline, and the discharging end is connected to a wet bean belt scale; The control system is used to control the speed of bean feeding, water addition, drainage, bean discharge and wet bean belt scale, and the control system has a calculation formula (1) according to the weight of dry soybeans W and the weight of bean soaking water W. 泡 , drainage weight W 排 , calculate the weight gain ratio K of a single can of soybeans.

5. The bean soaking system according to claim 4, characterized in that: In the bean soaking system, The soybean conveying path is: buffer tank → bean inlet pipe → bean soaking tank → bean discharge pipe → wet bean belt scale; The bean soaking water transportation path is: water storage tank → water inlet pipe → bean soaking tank → water outlet pipe → water storage tank.

6. The bean soaking system according to claim 4, characterized in that: The buffer tank is provided with a weighing module, and the weighing module is connected to a control system.

7. The bean soaking system according to claim 4, characterized in that: The bottom of the bean soaking tank is conical, and a drainage outlet is provided at the conical bottom.

8. Use of the method according to any one of claims 1 to 3 in soy sauce brewing.

9. Use of the bean soaking system according to any one of claims 4 to 7 in soy sauce brewing.

10. The use according to claim 9, characterized in that The steps include: Input the processing speed V of dry soybeans into the control system 干 The control system adjusts the conveying speed V of the belt scale according to the weight gain ratio K. 泡 , the calculation formula is: V 泡 =K×V 干 Formula (2).

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