Pesticide water dispersible granule production system based on DCS control

Abstract

The invention provides a pesticide water dispersible granule production system based on DCS control, and relates to the technical field of granule production, the pesticide water dispersible granule production system comprises a production module and a DCS control module, the production module is used for processing pesticide water dispersible granules; the DCS control module comprises a PLC control cabinet, a DCS controller and a communication network. The PLC control cabinet is used for realizing localized control of each production section equipment in the production module; the DCS controller is used for executing PID (Proportion Integration Differentiation) adjustment, sequence control and interlocking protection logic; and the communication network realizes real-time data interaction of each production section device in the production module. By using the DCS control system, remote control is achieved, and key production parameters such as pressure and temperature are monitored in real time; continuous production is achieved, the productivity and the automation degree are improved, manpower is saved, the stability of the production process is improved, and the risk that workers make contact with harmful substances is reduced.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of granular agent production, and particularly relates to a pesticide water dispersible granule production system based on DCS control. BACKGROUND

[0002] Water dispersible granule (WG) is an advanced solid pesticide formulation with low dust, high content, convenient use, excellent suspension dispersion performance and environmental friendliness. It is processed by wet granulation (extrusion / fluidized bed / spray drying) or dry granulation process to form particles that can quickly disintegrate in water and form stable suspensions. Its excellent performance makes it an important choice to replace traditional wettable powder (WP) and in some cases to replace suspension concentrate (SC), especially in modern agriculture that focuses on operation safety, environmental protection and convenient use.

[0003] The existing water dispersible granule production line has the following problems: low production efficiency, intermittent production mode as the main mode, unable to realize continuous production; low automation degree, high labor cost, product quality is greatly affected by human factors, batch consistency is poor; dust pollution, harm to the health of operators.

[0004] In order to solve the defects in the prior art, the present application provides a pesticide water dispersible granule production system based on DCS control. SUMMARY

[0005] The present application provides a pesticide water dispersible granule production system based on DCS control to solve the defects in the prior art.

[0006] In one aspect, the present application provides a pesticide water dispersible granule production system based on DCS control, comprising: The production module is used for processing pesticide water dispersible granules, and the DCS control module is used for centralized monitoring and decentralized control of the operation of the production module; the DCS control module comprises a PLC control cabinet, a DCS controller and a communication network; the PLC control cabinet is used for realizing the localized control of the devices in each production section of the production module; the DCS controller is used for receiving sensor signals in the production module, and based on the sensor signals, executing PID adjustment, sequence control and interlocking protection logic; the communication network adopts an industrial Ethernet ring network and a DCS-PLC special communication link to realize the real-time interaction of data of the devices in each production section of the production module.

[0007] According to the pesticide water dispersible granule production system based on DCS control provided by the present application, the production module comprises: Dust-free feeding and raw material storage module, for storing raw materials, fillers and additives through the raw material bin arranged in the warehouse, combining with the feeding instruction issued to the PLC control cabinet through the communication network, controlling the opening and closing rhythm of the feeding valve, cooperating with the dust-free feeding station to receive the material feeding; Automatic batching module, for automatically issuing the batching instruction of each raw material based on the preset formula data received by the DCS controller through the batching scale and the online automatic batching system, automatically weighing each raw material to obtain the proportioning completed batch; Multi-section mixing and kneading module, for mixing and kneading the proportioning completed batch and the material through the double-shaft paddle mixer to obtain the kneaded material; Pulverization and dust separation module, for pulverizing the kneaded material through the ultrafine pulverizer or the air flow pulverizer, and conveying the pulverized material to the cyclone separator through the pneumatic pipeline for preliminary separation of the material and the dust to obtain the primary granular material; Granulation, drying and screening module, for granulating the primary granular material through the rotary extrusion granulator, conveying the wet granules into the boiling fluidized bed dryer, and screening the dried granules through the vibrating screen to obtain the screened qualified granular material; Closed conveying and finished product storage module, for conveying the screened qualified granular material to the finished product bin through the closed conveyor belt; Multi-stage dust prevention and control module, for reducing the exhaust dust concentration, and monitoring in real time through the dust concentration sensor, and triggering the bag-type dust collector high-frequency dust removal when the dust concentration exceeds the standard.

[0008] According to the pesticide water dispersible granule production system based on DCS control provided by the application, the step of obtaining the proportioning completed batch by the automatic batching module comprises: The DCS controller calls the stored raw material formula database to obtain the target formula data of the current production batch; Based on the target formula data, the DCS controller sends the batching start instruction to the PLC control cabinet through the communication network, the PLC control cabinet triggers the batching scale calibration program, and confirms that the weighing sensor accuracy meets the process requirements and feeds back the calibration completion signal; Based on the calibration completion signal, the DCS controller sends the discharging instruction to each raw material storage bin according to the formula sequence, first opens the feeding valve of the main bin, controls the discharging speed through the frequency conversion speed regulation, and the batching scale collects the discharging weight data in real time and uploads it to the DCS controller; When the main material weighing reaches the preset weight interval, the DCS controller reduces the frequency of the feeding valve to the low speed interval, and closes the main material valve when the main material weight reaches the target value; The step of obtaining the proportioning completed batch by the automatic batching module comprises:

[0009] The application provides a pesticide water dispersible granule production system based on DCS control. The DCS controller calls preset multi-stage mixing process parameters according to the water dispersible granule type of the target formula data; Start the double-shaft paddle mixer and set low-speed mixing, so that different raw materials are uniformly contacted and preliminarily dispersed; The DCS controller monitors the material temperature in the mixer, if the temperature exceeds the preset temperature threshold due to frictional heat, automatically triggers the cooling water valve to open, and the cooling water is cooled to the first temperature through jacket circulating water and then the cooling water is closed; Increase the rotating speed of the mixer, and at the same time, pass steam into the paddle jacket to adjust the temperature to the second temperature, so that the raw materials are fully kneaded to form uniform granules, and the kneaded materials are obtained.

[0010] The application provides a pesticide water dispersible granule production system based on DCS control. The DCS controller receives the flow signal of the kneaded materials, and adjusts the rotating speed of the feeding screw of the ultrafine grinder in linkage, and outputs the rotating speed instruction; Based on the rotating speed instruction, the grinder main shaft motor is started, the rotating speed is adjusted through the frequency converter, and the crushed materials are output; The crushed materials are conveyed to the cyclone separator through the pneumatic pipeline, the DCS controller controls the opening degree of the cyclone separator inlet air valve, so that the separation efficiency is maintained at 95%-98%, and the primary granules are obtained; the dust-containing gas at the top enters the bag-type dust collector, and the DCS controller adjusts the pulse dust removal frequency according to the real-time data of the dust concentration sensor.

[0011] The application provides a pesticide water dispersible granule production system based on DCS control. The DCS controller receives the flow signal of the primary granules, adjusts the pressure roller gap and rotating speed of the rotary extrusion granulator in linkage, and obtains wet particles; The wet particles fall into the boiling fluidized bed dryer, and the DCS controller sets the drying parameters according to the initial moisture content of the wet particles; Based on the drying parameters, the DCS controller monitors the moisture content of the particles in real time through the online moisture meter, and obtains the dried qualified granules; The dried qualified particles are conveyed into the vibrating screen, the DCS controller sets the mesh number of the screen according to the product specification, adjusts the vibration frequency and amplitude, separates large particles and fine powder, and the middle-sized particles are taken as the screened qualified granules.

[0012] The application provides a pesticide water dispersible granule production system based on DCS control. The application provides a pesticide water dispersible granule production system based on DCS control. The start and stop of the closed conveying belt is controlled by the DCS controller, and the conveying speed is adjusted by the frequency converter; A gas collection hood is arranged above the conveying belt, and the DCS controller adjusts the frequency of the gas collection fan according to the dust concentration sensor signal; The conveying belt conveys the sieved qualified bulk particles to the finished product bin, and the DCS controller triggers the bag dust collector at the top of the bin to start, and simultaneously opens the nitrogen protection device in the bin to control the oxygen concentration in the bin within a preset concentration range; A radar level gauge is arranged in the bin, and the DCS controller controls the start and stop of the conveying belt according to the level signal: the conveying is started when the level is below the low limit; the conveying is paused and an alarm is triggered when the level is above the high limit; The temperature and humidity in the bin are monitored in real time by the DCS controller, and if the temperature and humidity exceed the preset standard, the bin ventilation system is started.

[0013] According to the pesticide water dispersible granule production system based on DCS control provided by the application, the multi-stage dust prevention and control module reduces the exhaust dust concentration strategy, which comprises: A dust concentration sensor is arranged at the dust generating point, and three-stage prevention and control thresholds are set, including a warning value, an intervention value and a shutdown value; When the dust concentration at a certain point reaches the warning value, an audible and visual alarm is triggered by the DCS controller, and the specific position and real-time concentration data are displayed on the HMI interface; If the concentration continues to rise to the intervention value, the DCS controller automatically increases the frequency of the corresponding gas collection fan, triggers the high-frequency dust removal of the corresponding dust removal equipment, and closes the unnecessary dust generating equipment feed valve; If the concentration reaches the shutdown value, the DCS controller immediately triggers the emergency shutdown program of the whole system, including stopping the operation of all dust generating equipment, closing all material conveying valves, fully opening the emergency exhaust valve, and sending a short message to the operator, and sounding and lighting alarm.

[0014] According to the pesticide water dispersible granule production system based on DCS control provided by the application, the DCS controller comprises a process parameter self-optimization module, which is used for training historical production data by a machine learning algorithm, and establishing an optimal process parameter model corresponding to different formulations.

[0015] According to the pesticide water dispersible granule production system based on DCS control provided by the application, the DCS control module further comprises a man-machine interactive operation station, which is used for providing one-key start function, real-time parameter monitoring interface, historical data query and production report generation.

[0016] The application provides a pesticide water dispersible granule production system based on DCS control, which realizes remote control and real-time monitoring of key production parameters such as pressure and temperature by using a DCS control system; realizes continuous production, greatly improves production capacity compared with a traditional batch production mode, and has high automation degree, saves manpower, improves production process stability and reduces the risk of workers contacting harmful substances. The DCS system accurately coordinates the material balance and energy matching of each process, greatly improves the utilization rate of equipment. Through actual production verification, the production capacity of the same scale production line is greatly improved compared with the traditional mode, and the consistency deviation of the products between batches is reduced, and the waste of raw materials and time cost caused by start-stop loss are significantly reduced. Through the collaborative control of PLC and DCS, automatic operation of the production link is realized, from automatic weighing and proportioning of raw materials, closed pipeline transportation, to intelligent speed regulation of the granulator, automatic classification of the particle size of the screening machine, to weighing, counting and code spraying and labeling of the packaging line, the manual intervention link in the whole process is reduced, the production process stability is improved, and the risk of workers contacting harmful substances is reduced. The quality early warning module built in the DCS can compare the online near-infrared spectrum detection data with the standard process curve in real time, and once the indicators such as the dispersion degree of active ingredients and the moisture content are abnormal, the system will automatically trigger the process to pause and start the traceability mechanism. BRIEF DESCRIPTION OF DRAWINGS

[0017] In order to more clearly illustrate the technical solutions in the present application or prior art, below will briefly introduce the drawings needed to be used in the embodiments or prior art description. Obviously, the drawings in the following description are some embodiments of the present application, and other drawings can be obtained by those skilled in the art without creative effort.

[0018] Fig. 1 is a structural schematic diagram of a pesticide water dispersible granule production system based on DCS control provided by an embodiment of the present application; Fig. 2 is a strategy diagram for reducing exhaust dust concentration by a multi-stage dust prevention and control module provided by an embodiment of the present application. DETAILED DESCRIPTION

[0019] In order to make the purpose, technical solutions and advantages of the present application clearer, below will combine the drawings in the present application to clearly and completely describe the technical solutions in the present application. Obviously, the described embodiments are some embodiments of the present application, not all embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative effort belong to the protection scope of the present application.

[0020] Embodiment one: Below will combine Figs. 1-2The application discloses a pesticide water dispersible granule production system based on DCS control.

[0021] As shown in the figure, the pesticide water dispersible granule production system based on DCS control provided by the embodiment of the application comprises: Fig. 1 The production module is used for processing pesticide water dispersible granules, and the production module is connected through sealed pipelines or closed conveying belts between sections to reduce the exposure risk of materials. The DCS control module is used for centralized monitoring and decentralized control of the operation of the production module. The DCS control module adopts an industrial-grade redundant design, and key devices are all equipped with backup units to ensure the stability of 24-hour continuous operation of the system. The DCS control module comprises a PLC control cabinet, a DCS controller and a communication network. The PLC control cabinet is used for realizing the localized control of devices in each production section of the production module. The PLC control cabinet is usually integrated with a programmable controller (such as a Siemens S7-1500 series), supports multi-task parallel processing, and the response time is less than or equal to 50 ms. The DCS controller is used for receiving sensor signals in the production module and executing PID adjustment, sequence control and interlocking protection logic based on the sensor signals. The communication network adopts an industrial Ethernet ring network and a DCS-PLC special communication link to realize the real-time interaction of data of devices in each production section of the production module. The industrial Ethernet ring network adopts a redundant double-network structure, and the switching time is less than or equal to 20 ms when a single network fails. The DCS-PLC special link adopts a Profibus-DP protocol, and the communication rate is up to 12 Mbps. The production module comprises a dust-free feeding and raw material storage module, an automatic batching module, a multi-section mixing and kneading module, a crushing and dust separation module, a granulation, drying and screening module, a closed conveying and finished product storage module and a multi-stage dust prevention and control module.

[0022] The dust-free feeding and raw material storage module is used for storing raw pesticides, fillers and additives through raw material bins arranged in warehouses. The raw material bin is made of 304 stainless steel, the inner wall is polished, and a weighing sensor (accuracy 0.1% FS) is arranged to monitor the material level in real time. In combination with the feeding instruction issued to the PLC control cabinet by the communication network, the opening and closing rhythm of the feeding valve is controlled, and the dust-free feeding station receives the material. The dust-free feeding station adopts a negative pressure design and is equipped with a pulse back-blowing dust collector. The dust overflow concentration during feeding is.

[0023] The automatic batching module is used for automatically issuing the batching instructions of each raw and auxiliary material in sequence based on the preset formula data received by the DCS controller through the batching scale and the online automatic batching system, automatically weighing each raw and auxiliary material, obtaining the batching ratio and completing the batching. The specific steps comprise:

[0024] The DCS controller calls the stored raw and auxiliary material formula database to obtain the target formula data of the current production batch.

[0025] ​Based on the target formula data, a batching start instruction is issued to the PLC control cabinet through a communication network, the PLC control cabinet triggers the batching scale calibration program, and after confirming that the weighing sensor accuracy meets the process requirements, a calibration completion signal is fed back.

[0026] Based on the calibration completion signal, the DCS controller sends a discharging instruction to each raw material storage bin according to the formula sequence, first opens the feeding valve of the main material bin, controls the discharging speed through frequency conversion, and the feeding valve adopts an electric gate valve + star feeder combined structure, the frequency conversion speed range is 5-50 Hz, the batching scale collects real-time discharging weight data and uploads it to the DCS controller.

[0027] When the main material weighing reaches the preset weight interval, the DCS controller reduces the frequency of the feeding valve to the low speed interval, and closes the main material valve until the main material weight reaches the target value, the low speed interval frequency range is 5-10 Hz, and the weight error is controlled within ±0.5 kg.

[0028] The target formula data is sequentially completed according to the formula sequence of each raw material, and after all the raw materials are weighed, the proportioning is completed, and the step-by-step weighing follows the principle of "first large and then small", and the weighing error of small materials is ≤±0.1 kg.

[0029] The multi-section mixing and kneading module is used to mix and knead the proportioning completed material and the material by a double-shaft paddle mixer to obtain a kneaded material, and the specific steps include: The DCS controller calls the preset multi-section mixing process parameters according to the water dispersible granule type of the target formula data. The process parameter library contains standard parameter templates of 5 common water dispersible granules (such as suspension type, wettable powder type, etc.).

[0030] Start the double-shaft paddle mixer, set the low-speed mixing, make different raw materials uniformly contact and preliminarily disperse. The paddle angle of the double-shaft paddle mixer is usually 45°, the low-speed rotating speed is 30 r / min, and the mixing time is 5 min.

[0031] The DCS controller monitors the temperature of the material in the mixer, if the temperature exceeds the preset temperature threshold due to friction, the cooling water valve is automatically triggered to open, and the jacket circulating water is cooled to the first temperature and then the cooling water is closed. The jacket circulating water uses softened water, the water temperature is controlled at 15-25℃, and the flow is 5 m 3 / h.

[0032] Increase the rotating speed of the mixer, and at the same time, pass steam into the paddle jacket to adjust the temperature to the second temperature, so that the raw materials are fully kneaded to form uniform granules, and the kneaded material is obtained. The high-speed rotating speed is 120 r / min, the steam pressure is 0.3-0.5 MPa, and the kneading time is 15 min.

[0033] The crushing and dust separation module is used to crush the kneaded material by a super micro crusher or an air flow crusher. The super micro crusher adopts a hammer type structure, and the crushing fineness D90 is less than or equal to 100 μm. The air flow crusher adopts a flat nozzle, and the crushing fineness D90 is less than or equal to 50 μm. After crushing, the material is transported to a cyclone separator through a pneumatic pipeline for preliminary separation of the material and dust, and primary granules are obtained. The specific steps include: The DCS controller receives the flow signal of the kneaded material, and the speed of the feeding screw of the super micro crusher is adjusted in linkage to output the speed instruction. The speed of the feeding screw ranges from 50 rpm to 200 rpm, and is linearly and positively correlated with the flow of the kneaded material (R 2 ≥ 0.95).

[0034] Based on the speed instruction, the main shaft motor of the crusher is started, and the speed is adjusted by a frequency converter to output the crushed material. The power of the main shaft motor is usually 75 kW, and the frequency converter adjusts the range of 30-75 Hz.

[0035] The crushed material is transported to the cyclone separator through the pneumatic pipeline, and the DCS controller controls the opening degree of the inlet air valve of the cyclone separator to maintain the separation efficiency at 95%-98% to obtain the primary granules. The dust-containing gas at the top enters the bag dust collector, and the DCS controller adjusts the pulse cleaning frequency according to the real-time data of the dust concentration sensor.

[0036] The granulation, drying and screening module is used to granulate the primary granules by a rotary extrusion granulator. The surface of the compression roller of the rotary extrusion granulator is specially treated, and the gap adjustment range is adapted to the granulation requirements of different materials. The wet granules after granulation enter the fluidized bed dryer, the inlet air parameters of the fluidized bed are adapted to the drying requirements, and the dried granules are sent to the vibrating screen for screening. The vibration parameters of the vibrating screen are adapted to the screening efficiency requirements, and the screened qualified granules are obtained. The specific steps include: The DCS controller receives the flow signal of the primary granules, and the gap and speed of the compression roller of the rotary extrusion granulator are adjusted in linkage to obtain the wet granules. The speed and gap adjustment are adapted to the flow change to ensure the quality of the wet granules.

[0037] The wet granules fall into the fluidized bed dryer, and the DCS controller sets the drying parameters according to the initial moisture content of the wet granules. The drying parameters include the inlet air temperature, air speed, residence time, etc., which are adapted to the drying requirements of different materials.

[0038] Based on the drying parameters, the DCS controller monitors the moisture content of the granules in real time through the online moisture meter to obtain the dried qualified granules.

[0039] The dried qualified granules are transported into the vibrating screen, the DCS controller sets the mesh size according to the product specifications, adjusts the vibration frequency and amplitude, separates the large particles and fine powder, and the middle size particles are taken as the screened qualified granules.

[0040] The closed conveying and finished product storage module is used for conveying the screened qualified bulk particles to the finished product bin through the closed conveyor belt, the closed conveyor belt adopts a sealing structure design, and anti-dust devices are additionally arranged on both sides, and the specific steps include: The start and stop of the closed conveying belt are controlled by the DCS controller, and the conveying speed is adjusted by the frequency converter.

[0041] A gas collecting hood is arranged above the conveying belt, and the DCS controller adjusts the frequency of the gas collecting fan according to the dust concentration sensor signal.

[0042] Before the conveying belt conveys the screened qualified bulk particles to the finished product bin, the DCS controller triggers the bag dust collector at the top of the bin to start, and simultaneously opens the nitrogen protection device in the bin, so as to control the oxygen concentration in the bin within a preset concentration range.

[0043] A radar level gauge is arranged in the bin, and the DCS controller controls the start and stop of the conveying belt according to the level signal: when the level is lower than the low limit, the conveying is started. When the level is higher than the high limit, the conveying is paused and an alarm is triggered.

[0044] The DCS controller is used for monitoring the temperature and humidity in the bin in real time, and if the temperature and humidity exceed the preset standard, the bin ventilation system is started in linkage.

[0045] The multi-stage dust prevention and control module is used for reducing the exhaust dust concentration, and the dust concentration sensor is used for monitoring in real time, and when the dust concentration exceeds the standard, the bag dust collector is triggered to high-frequency dust removal.

[0046] As shown in Fig. 2 , the strategy of the multi-stage dust prevention and control module for reducing the exhaust dust concentration includes: A dust concentration sensor is arranged at the dust generation point, and three-stage prevention and control threshold values are set, including a warning value, an intervention value and a shutdown value.

[0047] When the dust concentration at a certain point reaches the warning value, the DCS controller triggers an audible and visual alarm, and the specific position and real-time concentration data are displayed on the HMI interface.

[0048] If the concentration continues to rise to the intervention value, the DCS controller automatically increases the frequency of the corresponding gas collecting fan, triggers the high-frequency dust removal of the corresponding dust removal equipment, and closes the unnecessary dust generation equipment feed valve. After the feed valve is closed, the system automatically records the interruption time, and manual confirmation is required after recovery.

[0049] If the concentration reaches the shutdown value, the DCS controller immediately triggers the emergency shutdown program of the whole system, including stopping the operation of all dust generation equipment, closing all material conveying valves, fully opening the emergency exhaust valve, and sending a short message to the operator, and triggering an audible and visual alarm.

[0050] The DCS controller further comprises a process parameter self-optimization module, which is used to train historical production data by a machine learning algorithm, establish an optimal process parameter model corresponding to different formulations, and the steps include: Through the historical database of the DCS control system, complete production data of different formulations in batches are collected and standardized to obtain standard production data.

[0051] Based on the production characteristics of the pesticide water dispersible granule, key feature variables are extracted from the standard production data.

[0052] A gradient boosting regression tree algorithm is used as a basic model, the key feature variables and initial process parameters are used as input layers, and the product quality index compliance rate and production energy consumption are used as output layers for model training. The model hyperparameters are optimized by a Bayesian optimization algorithm to minimize the quality prediction error of the validation set.

[0053] In combination with the pesticide production process constraints, a constraint layer is implanted in the model. When the process parameters output by the model exceed the equipment safety threshold, the parameter correction mechanism is automatically triggered.

[0054] The trained optimal process parameter model is integrated into the real-time database of the DCS controller. When a new formulation is input, the model automatically calls the optimal parameters of the similar historical formulation as the initial solution, and combines the current production environment parameters for real-time correction to output the recommended process parameters of each section.

[0055] The DCS control module further comprises a human-computer interaction operation station, which is used to provide one-key start function, real-time parameter monitoring interface, historical data query and production report generation. The one-key start function supports multiple start modes, automatically performs device self-checking before starting, and prompts the specific fault point when an exception occurs; the real-time parameter monitoring interface displays the key data points of each section, supports trend curve viewing; the historical data query supports multi-dimensional screening and can be exported in standard format; the production report generation includes various statistical reports and supports custom templates.

[0056] In summary, the present application provides a pesticide water dispersible granule production system based on DCS control, which realizes remote control and real-time monitoring of key production parameters such as pressure and temperature by using a DCS control system; realizes continuous production, greatly improves production capacity compared with traditional batch production mode, and at the same time has high automation degree, saves manpower, improves production process stability, and reduces the risk of workers contacting harmful substances. The DCS system precisely coordinates the material balance and energy matching of each process, greatly improving the utilization rate of equipment. Actual production verification shows that the production capacity of the same scale production line is greatly improved compared with the traditional mode, and the consistency deviation of the product between batches is reduced, and the waste of raw materials and time cost caused by start-stop loss is significantly reduced. Through the cooperative control of PLC and DCS, the automation operation of the production link is realized, from the automatic weighing and proportioning of raw materials, closed pipeline transportation, to the intelligent speed regulation of the granulator, the automatic grading of the particle size of the screening machine, and the weighing counting and code spraying of the packaging line. The manual intervention link is reduced, the production process stability is improved, and the risk of workers contacting harmful substances is reduced. The quality warning module built in the DCS can compare the online near-infrared spectrum detection data with the standard process curve in real time. Once the indicators such as effective component dispersion and moisture content are abnormal, the system will automatically trigger the process to pause and start the traceability mechanism.

[0057] Through the description of the above embodiments, those skilled in the art can clearly understand that the embodiments can be realized by means of software and necessary general hardware platforms, and of course, can also be realized by hardware. Based on such understanding, the above technical solutions can be embodied in the form of a software product, which can be stored in a computer readable storage medium, such as ROM / RAM, magnetic disk, optical disk, etc., and includes a plurality of instructions for causing a computer device (which can be a personal computer, a server, or a network device, etc.) to execute the method of each embodiment or some parts of the embodiment.

[0058] Finally, it should be noted that: the above embodiments are only used to illustrate the technical solutions of the present application, and not to limit them; although the present application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that: it can still modify the technical solutions recorded in the foregoing embodiments, or make equivalent replacement for some technical features; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the spirit and scope of the technical solutions of the embodiments of the present application.

Claims

1. A pesticide water dispersible granule production system based on DCS control, characterized by, The application relates to a pesticide water dispersible granule production system. The production module is used for processing pesticide water dispersible granules, and the DCS control module is used for centralized monitoring and decentralized control of the operation of the production module; the DCS control module comprises a PLC control cabinet, a DCS controller and a communication network; the PLC control cabinet is used for realizing localized control of equipment in each production section of the production module; the DCS controller is used for receiving sensor signals in the production module, and performing PID adjustment, sequence control and interlocking protection logic based on the sensor signals; the communication network adopts an industrial Ethernet ring network and a DCS-PLC special communication link, so as to realize real-time interaction of data of the equipment in each production section of the production module.

2. The pesticide water dispersible granule production system based on DCS control according to claim 1, characterized in that, The production module comprises: A dust-free feeding and raw material storage module is used for storing raw materials, fillers and additives through raw material bins arranged in warehouses, and controls the opening and closing rhythm of feeding valves in combination with feeding instructions issued to the PLC control cabinet through the communication network, so as to receive materials in cooperation with a dust-free feeding station; An automatic batching module is used for automatically issuing batching instructions of each raw and auxiliary material in sequence based on preset formula data received by the DCS controller through a batching scale and an online automatic batching system, automatically weighing each raw and auxiliary material, and obtaining a batching completed material through proportioning; A multi-section mixing and kneading module is used for mixing and kneading the batching completed material and the material through a double-shaft paddle mixer, so as to obtain kneaded material; A crushing and dust separation module is used for crushing the kneaded material through a super-micro pulverizer or an air flow pulverizer, and conveying the crushed material to a cyclone separator through a pneumatic pipeline for preliminary separation of the material and dust, so as to obtain primary particles; A granulating, drying and screening module is used for granulating the primary particles through a rotary extrusion granulator, conveying the wet granules into a boiling fluidized bed dryer, conveying the dried granules to a vibrating screen for screening, and obtaining screened qualified particles; A closed conveying and finished product storage module is used for conveying the screened qualified particles to a finished product bin through a closed conveying belt; A multi-stage dust prevention and control module is used for reducing exhaust dust concentration, and monitoring in real time through a dust concentration sensor, and triggering a bag-type dust collector high-frequency dust removal when the dust concentration exceeds a standard.

3. The pesticide water dispersible granule production system based on DCS control according to claim 2, characterized in that, The step of obtaining the batching completed material by the automatic batching module comprises the following steps: The DCS controller calls a stored raw and auxiliary material formula database to obtain target formula data of a current production batch; Based on the target formula data, a batching start instruction is issued to the PLC control cabinet through a communication network, the PLC control cabinet triggers a batching scale calibration program, and a calibration completion signal is fed back after confirming that the accuracy of a weighing sensor meets process requirements; Based on the calibration completion signal, the DCS controller sends a discharging instruction to each raw and auxiliary material storage bin in a formula sequence, opens a feeding valve of a main material bin first, controls the discharging speed through frequency conversion speed regulation, and the batching scale collects discharging weight data in real time and uploads the data to the DCS controller; When the main material weighing reaches a preset weight interval, the DCS controller reduces the frequency of the feeding valve to a low speed interval, and closes the main material valve after the main material weight reaches a target value. The step of obtaining the kneaded material by the multi-section mixing and kneading module includes:

4. The pesticide water dispersible granule production system based on DCS control according to claim 3, characterized in that, The step of obtaining the kneaded material by the multi-section mixing and kneading module includes: The DCS controller calls preset multi-section mixing process parameters according to the water dispersible granule type of the target formula data; Start the double-shaft paddle mixer and set the low-speed mixing to make different raw and auxiliary materials uniformly contact and preliminarily disperse; The DCS controller monitors the material temperature in the mixer, and if the temperature exceeds the preset temperature threshold due to frictional heat, automatically triggers the cooling water valve to open, and through the jacket circulating water cooling to the first temperature, the cooling water is closed; Increase the mixing speed, and at the same time, adjust the temperature to the second temperature by passing steam into the paddle jacket, so that the raw and auxiliary materials are fully kneaded to form uniform granules, and the kneaded material is obtained.

5. The pesticide water dispersible granule production system based on DCS control according to claim 2, characterized in that, The step of obtaining the primary granules by the crushing and dust separation module includes: The DCS controller receives the flow signal of the kneaded material, and adjusts the feed screw speed of the ultrafine crusher in linkage to output the speed instruction; Based on the speed instruction, the crusher main shaft motor is started, and the speed is adjusted through the frequency converter to output the crushed material; The crushed material is transported to the cyclone separator through the pneumatic pipeline, and the DCS controller controls the opening degree of the cyclone separator inlet air valve to maintain the separation efficiency at 95%-98%, and the primary granules are obtained; the dust-containing gas at the top enters the bag dust collector, and the DCS controller adjusts the pulse cleaning frequency according to the real-time data of the dust concentration sensor.

6. The pesticide water dispersible granule production system based on DCS control according to claim 2, characterized in that, The step of obtaining the screened qualified granules by the granulation, drying and screening module includes: The DCS controller receives the flow signal of the primary granules, and adjusts the pressure roller gap and speed of the rotary extrusion granulator in linkage to obtain wet particles; The wet particles fall into the fluidized bed dryer, and the DCS controller sets the drying parameters according to the initial moisture content of the wet particles; Based on the drying parameters, the DCS controller monitors the moisture content of the particles in real time through the online moisture meter to obtain the dried qualified granules; The dried qualified granules are transported into the vibrating screen, the DCS controller sets the mesh number of the screen according to the product specification, adjusts the vibration frequency and amplitude, separates the large particles and fine powder, and the intermediate specification particles are taken as the screened qualified granules.

7. The pesticide water dispersible granule production system based on DCS control according to claim 2, characterized in that, The step of transporting the screened qualified granules to the finished product bin by the closed conveying and finished product storage module includes: The DCS controller controls the start and stop of the closed conveying belt, and adjusts the conveying speed through the frequency converter; A gas collecting hood is arranged above the conveying belt, and the DCS controller adjusts the frequency of the gas collecting fan according to the dust concentration sensor signal; Before the conveying belt transports the screened qualified granules to the finished product bin, the DCS controller triggers the bag dust collector at the top of the bin to start, and at the same time, the nitrogen protection device in the bin is started, so that the oxygen concentration in the bin is controlled within the preset concentration range; A radar level gauge is arranged in the bin, and the DCS controller controls the start and stop of the conveying belt according to the level signal: the conveying belt is started when the level is below the low limit, and the conveying belt is stopped and an alarm is triggered when the level is above the high limit; The DCS controller monitors the temperature and humidity in the bin in real time, and if the temperature and humidity exceed the preset standard, the bin ventilation system is started in linkage.

8. The pesticide water dispersible granule production system based on DCS control according to claim 2, characterized in that, The strategies employed by the multi-level dust control module to reduce exhaust dust concentration include: Dust concentration sensors are installed at dust generation points, and three levels of prevention and control thresholds are set, including warning values, intervention values, and shutdown values; When the dust concentration at a certain point reaches the warning value, the DCS controller will trigger an audible and visual alarm and display the specific location and real-time concentration data on the HMI interface. If the concentration continues to rise to the intervention value, the DCS controller will automatically increase the frequency of the corresponding area's air collection fan, trigger the high-frequency cleaning of the corresponding dust removal equipment, and close the feed valve of unnecessary dust-generating equipment. If the concentration reaches the shutdown threshold, the DCS controller will immediately trigger the emergency shutdown procedure for the entire system, including stopping all dust-generating equipment, closing all material conveying valves, fully opening the emergency exhaust valves, and sending text messages and audible and visual alarms to the operators.

9. The pesticide water dispersible granule production system based on DCS control according to claim 1, characterized by, The DCS controller includes a process parameter self-optimization module, which is used to train historical production data through machine learning algorithms to establish optimal process parameter models corresponding to different formulas.

10. The pesticide water dispersible granule production system based on DCS control according to claim 1, characterized by, The DCS control module also includes a human-machine interface station, which provides one-click start function, real-time parameter monitoring interface, historical data query and production report generation.

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