Corn starch explosion-proof stirring system for producing paper tube adhesive

Abstract

The application relates to the technical field of mixing engineering, and discloses a corn starch explosion-proof stirring system for producing paper tube glue, which comprises a mixing cavity, a basic fluidization unit, a dual-mode phased acoustic wave array module, a dynamic control core module and a focused ultrasonic wave deagglomeration module, wherein the basic fluidization unit provides inert gas fluidization to avoid dust explosion; the dual-mode phased acoustic wave array module has a dual function of diagnosis and driving, performs acoustic tomography imaging by emitting a detection acoustic wave, reconstructs real-time density distribution of materials, and generates a controllable rotating acoustic pressure gradient field in the driving mode; the dynamic control core module executes an acoustic tomography algorithm, analyzes material uniformity, and adjusts acoustic field parameters according to adaptive closed-loop control logic to continuously optimize the mixing process. Through the combination of non-contact stirring and fluidization technology of the acoustic field, explosion-proof safety, high uniformity, low energy consumption and intelligent control of the mixing process are realized, and the safety and efficiency of paper tube glue production are improved.

Description

Technical Field

[0001] This invention relates to the field of mixed engineering technology, specifically to a corn starch explosion-proof mixing system for producing paper tube adhesive. Background Technology

[0002] Mixing powdery or granular materials is a common unit operation in industrial production, and its quality directly affects the performance of the final product. In the production of paper tube adhesive, corn starch, as the main raw material, needs to be thoroughly and uniformly mixed with water or other additives. However, existing technologies face many challenges in handling the mixing of such materials.

[0003] Traditional mechanical mixing methods, such as using agitators or screw conveyors, achieve material mixing through physical contact. While effective, this method is problematic when handling flammable and explosive dusts like corn starch. The inherent mechanical friction, shearing, and potential electrostatic sparks can easily trigger dust explosions, posing a significant safety hazard to production. To mitigate this risk, substantial investment in explosion-proof equipment and stringent operating procedures is typically required, undoubtedly increasing production costs and complexity. Furthermore, mechanical mixing can cause excessive shearing of material particles, altering their physical properties and affecting the quality of the final product.

[0004] To improve mixing uniformity, some technologies attempt to increase stirring time or intensity. However, prolonged or high-intensity mechanical stirring not only leads to a significant increase in energy consumption but may also cause localized overheating, further increasing the risk of explosion. More importantly, in some viscous or easily agglomerated material systems, traditional mechanical stirring is ineffective in solving the problem of localized material agglomeration. Once stubborn agglomerates form, even prolonged stirring cannot completely disperse them, resulting in uneven mixing and affecting the bonding strength and stability of the paper tube adhesive.

[0005] Some existing technologies attempt to improve powder mixing uniformity through fluidized bed technology. While fluidized beds can effectively reduce the risk of dust explosions and achieve a certain degree of uniform mixing, they primarily rely on the macroscopic movement of airflow. For materials with significant density differences or those prone to forming viscous agglomerates, a simple fluidized bed often fails to achieve ideal mixing results, especially in areas within the mixing chamber where localized material circulation is easily impaired. Furthermore, fluidized beds require high precision in airflow control; uneven airflow can still lead to insufficient mixing or localized over-fluidization.

[0006] In summary, current technologies for mixing corn starch still have significant room for improvement in terms of safety, mixing uniformity, energy consumption control, and the ability to handle local agglomerates. Summary of the Invention

[0007] To address the shortcomings of existing technologies, this invention provides a corn starch explosion-proof mixing system for producing paper tube adhesive, which solves the problems of high dust explosion risk, difficulty in controlling mixing uniformity, difficulty in handling local agglomerates, and high energy consumption in traditional corn starch mixing processes.

[0008] To achieve the above objectives, the present invention provides the following technical solution:

[0009] The first aspect of the present invention provides a corn starch explosion-proof stirring system for producing paper tube adhesive, comprising:

[0010] The mixing chamber is used to hold corn starch materials;

[0011] A dual-mode phased-array acoustic wave module is disposed outside the hybrid cavity and configured to switch between drive mode and diagnostic mode;

[0012] The dynamic control core module is electrically connected to the dual-mode phased acoustic array module;

[0013] In the driving mode, the dynamic control core module controls the dual-mode phased acoustic array to generate a rotating acoustic pressure gradient field, which is used to drive the corn starch material in the mixing cavity to form a vortex mixing.

[0014] In the diagnostic mode, the dual-mode phased-array acoustic wave array is used to transmit probe acoustic waves and receive echo signals;

[0015] Furthermore, the dynamic control core module is configured to: reconstruct the density distribution of corn starch material in the mixing cavity based on the echo signal using an acoustic tomography algorithm, and dynamically adjust the parameters of the rotating sound pressure gradient field according to the density distribution.

[0016] In one specific embodiment, the system further includes a basic fluidization unit configured to introduce airflow into the bottom of the mixing chamber before the dual-mode phased-array acoustic wave array operates, for forming a dense fluidized bed of corn starch material.

[0017] In one specific embodiment, the dynamic control core module dynamically adjusts the parameters of the rotating sound pressure gradient field according to the density distribution by performing the following steps:

[0018] A quantitative uniformity index is calculated from the density distribution to characterize the current mixing state;

[0019] The quantized uniformity index is compared with a preset uniformity target value to generate a deviation signal;

[0020] Based on the deviation signal, a parameter adjustment amount that can make the uniformity index converge to the target value is determined by a preset control algorithm, and the parameters of the rotating sound pressure gradient field are updated accordingly.

[0021] Preferably, the preset uniformity target value is a parameter that can be configured according to production process requirements. The preset control algorithm is embedded in the dynamic control core module. In a specific embodiment, the preset control algorithm is a gradient descent algorithm. The dynamic control core module defines the quantized uniformity index as the objective function. The adjustable parameters of the rotating sound pressure gradient field are defined as control vectors. The parameter adjustment amount is determined by the following formula:

[0022] ;

[0023] in, For the updated control vector, The control vector at the current moment, For the objective function At the current control vector point The gradient with respect to the control vector. This is a preset learning rate factor used to control the step size of parameter updates.

[0024] Preferably, the quantization uniformity index is the image variance or information entropy of the density distribution.

[0025] Preferably, the parameters of the rotating acoustic pressure gradient field include at least one of the following: rotational angular frequency, topological charge number, or emission amplitude of each transducer unit.

[0026] In one specific embodiment, the dynamic control core controls the spiral shape of the rotating sound pressure gradient field by setting the topological charge number and the phase delay of each transducer unit.

[0027] Preferably, the acoustic tomography algorithm is a filtered back projection algorithm.

[0028] In one specific embodiment, the dual-mode phased acoustic array is composed of multiple transducer units evenly distributed in a ring along the outer wall of the hybrid cavity.

[0029] In one specific embodiment, the system further includes a focused ultrasonic de-agglomeration module, which includes a high-frequency ultrasonic transducer and a movable positioning mechanism for carrying and moving the high-frequency ultrasonic transducer. The movable positioning mechanism is electrically connected to the dynamic control core module. The dynamic control core module is further configured to: identify preset features characterizing the agglomerates from the density distribution and determine the spatial coordinates of the agglomerates; based on the spatial coordinates of the agglomerates, control the movable positioning mechanism to move the high-frequency ultrasonic transducer to the spatial coordinates of the agglomerates and drive the high-frequency ultrasonic transducer to emit ultrasonic waves for targeted de-agglomeration processing.

[0030] Preferably, the high-frequency ultrasonic transducer generates an acoustic cavitation effect at the spatial coordinate position of the agglomerate to microscopically break up the agglomerate.

[0031] This invention provides a corn starch explosion-proof stirring system for producing paper tube adhesive. It has the following beneficial effects:

[0032] This invention utilizes a dual-mode phased-array acoustic wave module located outside the mixing chamber to drive corn starch material through non-contact eddy current mixing using the generated rotating acoustic pressure gradient field. This solves the inherent safety risk of ignition sources generated by friction and impact of mechanical stirring blades in existing technologies, achieving the technical effect of not generating mechanical ignition sources during the mixing process and fundamentally improving the explosion-proof safety level.

[0033] This invention uses the diagnostic mode of a dual-mode phased-array acoustic wave module in conjunction with an acoustic tomography algorithm to reconstruct the density distribution inside the material in real time. It also works in conjunction with a focused ultrasonic de-agglomeration module to perform targeted micro-breakup of the identified agglomerates. This solves the problems of mixing dead zones and the difficulty in eliminating stubborn material agglomerates that exist in traditional stirring methods. It achieves the technical effect of deep and uniform mixing that combines macroscopic material circulation with microscopic particle dispersion.

[0034] This invention, through a dynamic control core module, dynamically adjusts the parameters of the rotating sound pressure gradient field based on the real-time density distribution reconstructed by acoustic tomography. This overcomes the limitations of existing stirring equipment that operates with fixed parameters and cannot adaptively adjust according to the actual mixing state. It achieves the technical effect of closed-loop feedback control of the mixing process and real-time optimization of the mixing strategy based on the mixing uniformity. Attached Figure Description

[0035] Figure 1 This is a schematic diagram of the system structure of the present invention;

[0036] Figure 2 This is a schematic diagram of the system workflow of the present invention;

[0037] Figure 3This is a schematic diagram of the mixing cavity and basic fluidization unit structure of the present invention;

[0038] Figure 4 This is a schematic diagram of the functional block of the dynamic control core module of the present invention;

[0039] Figure 5 This is a schematic diagram of the focused ultrasonic deagglomeration module of the present invention. Detailed Implementation

[0040] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0041] See attached document Figure 1 This invention provides a corn starch explosion-proof mixing system for producing paper tube adhesive. The system may include: a mixing chamber, a dual-mode phased-array acoustic wave module, a dynamic control core module, a basic fluidization unit, and a focused ultrasonic deagglomeration module.

[0042] The mixing chamber is a closed or semi-closed container used to hold the corn starch material to be mixed. The dual-mode phased-array acoustic wave module is located on the outer wall of the mixing chamber and does not directly contact the material inside. The dynamic control core module is electrically connected to the dual-mode phased-array acoustic wave module via a data bus and control lines, used to send control commands to it and receive the data it collects.

[0043] In one embodiment, a basic fluidization unit is disposed at the bottom of the mixing chamber, and includes a gas source and multiple gas outlets distributed at the bottom of the chamber and connected to the gas source. The basic fluidization unit is used to introduce gas at a preset flow rate and pressure into the mixing chamber before the mixing process begins, so that the corn starch material forms a dense fluidized bed.

[0044] In one embodiment, the focused ultrasonic deagglomeration module is disposed on one side or top of the mixing cavity. The focused ultrasonic deagglomeration module is electrically connected to the dynamic control core module and receives positioning commands and drive signals from the dynamic control core module.

[0045] In a complete workflow of this invention, the system is uniformly scheduled by the dynamic control core module, periodically switching between diagnostic mode and drive mode.

[0046] In diagnostic mode, the dynamic control core module instructs the dual-mode phased-array acoustic wave module to emit probe acoustic waves that penetrate the mixing cavity and its internal materials. The transducer unit of the dual-mode phased-array acoustic wave module receives the echo signal after penetration and sends the signal data to the dynamic control core module. Based on the received echo signal data, the dynamic control core module executes an acoustic tomography algorithm to reconstruct the real-time density distribution of the corn starch material inside the mixing cavity at the current moment.

[0047] In drive mode, the dynamic control core module first analyzes the reconstructed density distribution and calculates a quantized uniformity index characterizing the current mixing state. Then, the dynamic control core module determines a set of control parameters for generating a rotating sound pressure gradient field and sends these parameters to the dual-mode phased array acoustic wave module. Based on the received parameters, the dual-mode phased array acoustic wave module drives its multiple transducer units to generate sound waves with specific phase delays, thereby synthesizing a rotating sound pressure gradient field within the mixing cavity. This field drives the corn starch material within the cavity to form macroscopic vortex mixing.

[0048] The generation of the rotating sound pressure gradient field is achieved by dynamically controlling the core module to set the first [module name] in the dual-mode phased-array acoustic wave module. The phase of the drive signal of each transducer unit This is achieved by the following formula, and its phase is determined by:

[0049] ;

[0050] in, For the first Each transducer unit at time... phase, Let be the topological load number, which is an integer. For the first The physical angular coordinates of each transducer unit in the ring array ω is the rotational angular frequency.

[0051] Simultaneously, the dynamic control core module identifies regions with density values ​​exceeding a preset threshold from the density distribution, determines these regions as aggregates, and resolves the spatial coordinates of these aggregates. Based on these spatial coordinates, the dynamic control core module controls the focused ultrasonic deagglomeration module to move to the target location and drives it to perform targeted deagglomeration processing.

[0052] The system forms a closed-loop control system by repeatedly cycling between diagnostic mode and drive mode until the quantized uniformity index calculated from the density distribution reaches the preset uniformity target value, thus completing the entire adaptive mixing process.

[0053] See attached document Figure 2The system provided by this invention first performs a material preparation stage after startup. During this stage, the operator loads corn starch material into the mixing chamber. Subsequently, the basic fluidization unit starts, introducing an airflow with preset parameters into the bottom of the mixing chamber. This airflow, at a fluidization velocity lower than that of pneumatic conveying, elevates the dried corn starch granules into a dense fluidized bed state that is dispersed but still maintains a certain density gradient. This pretreatment step aims to reduce initial dust dispersion and provide a uniform initial distribution for subsequent acoustic mixing, while ensuring that the material can be initially loosened under non-mechanical contact conditions.

[0054] After material preparation is complete, the system enters its core adaptive closed-loop mixing cycle. This cycle is dominated by the dynamic control core module, and its core lies in the periodic switching and iteration of diagnosis and drive. Within each cycle, the system first enters diagnostic mode. In this mode, the dynamic control core module activates the transducer units of the dual-mode phased-array acoustic wave module, enabling them to sequentially or in parallel transmit probe acoustic waves with specific frequencies and pulse widths using time-division multiplexing or frequency-division multiplexing, and to listen for echo signals scattered and reflected from the material within the mixing chamber. These echo signals are received by the same or different groups of transducers in the dual-mode phased-array acoustic wave module and digitally transmitted to the dynamic control core module.

[0055] After receiving the echo signal data, the dynamic control core module executes an acoustic tomography algorithm. This algorithm reconstructs the acoustic impedance or acoustic attenuation distribution inside the material using a backscattering model, and then maps it to a density distribution map of the corn starch material. For example, when using a filtered back projection algorithm, the received echo data from multiple angles and positions are subjected to Fourier transform and filtering, and then superimposed using inverse Fourier transform and back projection to reconstruct a two-dimensional or three-dimensional density distribution image of the mixing cavity. This density distribution image provides precise spatial information on material agglomeration, voids, or non-uniform regions.

[0056] After obtaining the real-time density distribution, the system enters the analysis and decision-making phase. The dynamic control core module first calculates a quantized uniformity index from the density distribution image. For example, this can be done by calculating the statistical variance of the pixel grayscale values ​​(representing density) in the image; a smaller variance indicates higher uniformity. Alternatively, the information entropy of the image can be calculated; a larger entropy value indicates a more chaotic distribution, and vice versa. The calculated current uniformity index is compared with a preset uniformity target value to generate a deviation signal. This deviation signal quantifies the difference between the current mixing state and the ideal target state.

[0057] Next, the dynamic control core module takes this deviation signal as input and uses a pre-defined control algorithm (e.g., gradient descent or proportional-integral-derivative (PID) control algorithm) to calculate and determine a set of parameters for adjusting the rotating sound pressure gradient field. These parameters include, but are not limited to, the rotational angular frequency, topological charge, and the emission amplitude of each transducer unit. For example, if the deviation signal indicates that the uniformity is much lower than the target value, the gradient descent algorithm may suggest increasing the rotational angular frequency to accelerate overall mixing, adjusting the topological charge to change the vortex shape, or even increasing the local emission amplitude to enhance the stirring intensity in a specific area.

[0058] Once the parameters are determined, the system enters drive mode. The dynamic control core module sends the new control parameters to the dual-mode phased-array acoustic wave module. Based on these parameters, the digital signal processor of the dual-mode phased-array acoustic wave module generates and drives its individual transducer units to emit ultrasonic waves with precise phase delay and amplitude. These ultrasonic waves are superimposed within the mixing cavity, forming a sound pressure gradient field with a specific rotational angular frequency and helical shape. This rotating sound pressure gradient field applies a non-contact acoustic radiation force to the corn starch particles within the cavity, driving the particles to form macroscopic vortex motion and circulation, thereby achieving material mixing.

[0059] Furthermore, in each cycle, the dynamic control core module analyzes the density distribution image in parallel, identifying and locating aggregates with diameters or density values ​​exceeding specific thresholds. Once the precise three-dimensional spatial coordinates of the aggregates are determined, the dynamic control core module instructs the movable positioning mechanism of the focused ultrasonic de-agglomeration module to move its high-frequency ultrasonic transducer to the location of the aggregate. Subsequently, the high-frequency ultrasonic transducer is driven to emit focused ultrasonic waves, generating a local acoustic cavitation effect within the aggregate. Through the growth, oscillation, and implosion of microbubbles, the aggregates are microscopically broken up. This targeted de-agglomeration process, combined with macroscopic eddy current mixing, improves mixing efficiency and final homogeneity.

[0060] The aforementioned diagnostic and driving cycle continues until the quantified uniformity index converges and reaches or exceeds the preset uniformity target value. At this point, the dynamic control core module determines that the mixing task is complete, stops the sound field driving and deagglomeration processing, and outputs a mixing completion signal. The entire process achieves explosion-proof, efficient, and uniform corn starch mixing through real-time sensing, intelligent decision-making, and adaptive control.

[0061] See attached document Figure 3This invention relates to a mixing chamber, a sealed container for holding corn starch material to be mixed. The chamber can be made of stainless steel or a high-strength polymer material with good acoustic transmission to ensure structural strength and cleanliness of the internal material. The inner wall of the mixing chamber is polished to reduce material adhesion and friction. The top of the chamber has a material inlet and a sealed cover, while the bottom has a discharge outlet. To accommodate different production batches, the mixing chamber can be designed as a cylinder or have a conical bottom structure to facilitate complete material discharge. The exterior of the mixing chamber may also be fitted with an insulation layer or a heat-insulating layer to maintain a specific temperature for the internal material and prevent the starch from absorbing moisture or experiencing excessive temperature fluctuations.

[0062] The basic fluidization unit is located at the bottom of the mixing chamber. Its core components include a gas source, a flow and pressure control system, and one or more permeable plates or porous distributors. The gas source can be a compressed air source, connected to the flow and pressure control system via piping. This system precisely regulates the flow rate and pressure of the gas introduced into the bottom of the mixing chamber.

[0063] Specifically, a permeable plate or porous distributor evenly covers the bottom area of ​​the mixing chamber. The permeable plate is typically made of sintered metal, porous ceramic, or polymer material with a microporous structure, ensuring that gas is evenly ejected from the small holes rather than forming concentrated airflow channels. When the basic fluidization unit is started, regulated gas (e.g., dry air or an inert gas such as nitrogen to further enhance explosion-proof safety) flows upwards evenly through the corn starch material layer at the bottom of the mixing chamber at a preset, stable flow rate and pressure via the permeable plate or porous distributor.

[0064] The goal of this process is to bring the dried corn starch granules into a dense fluidized bed state under the action of gas. In the dense fluidized bed, the gas velocity is precisely controlled above the initial fluidization velocity of the granules, but much lower than the pneumatic conveying velocity. At this velocity, the material particles are partially supported by gas buoyancy and shear force, increasing the interparticle spacing and reducing the resistance to movement between particles, thus giving the entire material layer a liquid-like fluidity. This state effectively disperses the initially fed material, eliminates stagnant areas formed by material accumulation, and reduces the tendency for particle aggregation.

[0065] The dense fluidized bed formed by the basic fluidizing unit has the following functions: First, it reduces dust generated by violent agitation of materials during mixing startup, improving the cleanliness and explosion-proof safety of the operating environment; Second, it provides an initial uniform and easily flowing material medium for the sound pressure gradient field generated by the subsequent dual-mode phased-array acoustic wave module, enabling the sound field to penetrate and drive the material more effectively, improving the efficiency and final uniformity of acoustic eddy current mixing; Third, it achieves preliminary loosening and premixing of materials under non-mechanical contact conditions, laying the foundation for acoustically driven fine mixing.

[0066] The dual-mode phased-array acoustic wave module of this invention consists of multiple independent transducer units, which are uniformly distributed in a ring along the outer wall of the mixing cavity. Each transducer unit is typically a piezoelectric ceramic transducer (e.g., PZT material), which generates mechanical vibration and emits sound waves when it receives an electrical signal, and vice versa. These transducer units are encapsulated in a housing with a good acoustic matching layer to improve the emission efficiency and reception sensitivity of the sound waves, while ensuring its stability and protection level in industrial environments.

[0067] The key to the dual-mode phased-array acoustic wave module lies in its dual-mode operation capability, namely, switching between drive mode and diagnostic mode. This switching is controlled by commands issued by the dynamic control core module.

[0068] In drive mode, the dynamic control core module sends independent drive electrical signals with precise phase and amplitude control to each transducer unit in the dual-mode phased-array acoustic wave module. The internal digital signal processor (DSP) or field-programmable gate array (FPGA) of the dual-mode phased-array acoustic wave module processes the signals according to the parameters (e.g., topology charge number) issued by the dynamic control core module. Rotational angular frequency ), calculate the specific phase delay required for each transducer unit. and emission amplitude .

[0069] By precisely controlling the phase and amplitude of each transducer unit, the sound waves emitted by these units interfere and superimpose inside the mixing cavity, thereby synthesizing a rotating sound pressure gradient field with a preset topological charge and rotational angular frequency. This sound pressure gradient field applies acoustic radiation force to the corn starch particles inside the cavity, driving the particles to form a non-contact macroscopic vortex motion, thus achieving material mixing.

[0070] In diagnostic mode, the dual-mode phased array acoustic wave module switches its operating state, configuring its internal transducer units into either integrated transmit / receive or time-division receiving mode. In this mode, the dynamic control core module commands one or more transducer units in the array to emit short-pulse probe acoustic waves. These probe acoustic waves pass through the mixing cavity and the cornstarch material inside. When the probe acoustic waves encounter material particles, agglomerates, or areas of uneven density, they are scattered, reflected, and attenuated. Other transducer units in the array (or the transmitting units switch to receiving mode) act as microphones, receiving these scattered and reflected echo signals.

[0071] After pre-amplification, filtering, and digitization, the received echo signal is transmitted back to the dynamic control core module in the form of time-series data, amplitude information, and phase information. The dual-mode phased-array acoustic wave module ensures that the time relationship between the received echo signal and the transmitted pulse is accurately recorded through precise time synchronization and signal acquisition mechanisms. This is the basis for subsequent acoustic tomography algorithms to reconstruct the density distribution.

[0072] Through this dual-mode design, the present invention enables hybrid driving and state diagnosis on the same physical array, reducing system complexity and providing key sensing data for real-time closed-loop control.

[0073] See attached document Figure 4 The dynamic control core module of this invention is the central processing unit of the entire system, responsible for data acquisition, signal processing, algorithm execution, decision-making, and instruction scheduling of other modules. This module typically consists of a high-performance microprocessor (such as an embedded PC, DSP, or FPGA), along with memory, storage units, input / output interfaces, a communication module, and a power management unit. It receives echo signal data from the dual-mode phased-array acoustic wave module, communicates bidirectionally with the focused ultrasonic deagglomeration module, and sends driving parameters to the dual-mode phased-array acoustic wave module.

[0074] One of the core functions of the dynamic control core module is to execute the acoustic tomography algorithm. When it receives echo signal data acquired by the dual-mode phased array acoustic wave module in diagnostic mode, the module initiates the image reconstruction process. In a specific embodiment, the acoustic tomography algorithm employs a filtered back-projection algorithm. The input to this algorithm is echo signals from multiple angles and positions (including sound wave arrival time, amplitude attenuation, and phase change information). The specific steps include: first, preprocessing the received raw echo signal, such as time-domain filtering and denoising, to improve signal quality. Then, processing the preprocessed signal to convert it into projection data corresponding to sound attenuation or sound velocity distributions in different projection directions. These projection data are then subjected to Fourier transform, and a specific filter (e.g., a Ram-Lak filter) is applied in the frequency domain to enhance high-frequency components and correct ambiguity. Finally, through inverse Fourier transform and back-projection superposition operations, the filtered projection data is mapped back to the spatial domain, ultimately reconstructing a two-dimensional or three-dimensional density distribution image of the corn starch material within the mixing cavity. The density distribution image is stored in the form of a digital matrix, where the value of each pixel or voxel represents the material density at the corresponding spatial location.

[0075] Another core function of the dynamic control module is to implement adaptive closed-loop control logic. After reconstructing the density distribution image of the material, this module executes the following series of steps:

[0076] First, a quantization uniformity index is calculated from the reconstructed density distribution image to characterize the current mixing state. In a preferred embodiment, the quantization uniformity index can be either image variance or information entropy. If image variance is used as the quantization uniformity index... The calculation formula is as follows:

[0077] ;

[0078] in, Represents the pixel points in the density distribution image The density value of the material at that location, This represents the average density value of the entire density distribution image. The image variance represents the total number of pixels in the density distribution image. The smaller the value, the more concentrated and uniform the material density distribution.

[0079] If information entropy is used as a quantitative uniformity index The calculation formula is as follows:

[0080] ;

[0081] in, The density value in the density distribution image represents the density value. The proportion (probability) of pixels. The total number of quantization levels representing the density value, information entropy. The larger the value, the more chaotic and uneven the material density distribution. In this invention, the goal is to reduce the information entropy value to achieve a more uniform mixture.

[0082] Secondly, the dynamic control core module compares the calculated quantized uniformity index with a preset uniformity target value to generate a deviation signal. The preset uniformity target value is a configurable value set by the operator according to the specific paper tube adhesive production process requirements. For example, when using image variance, the target value might be set to 0.05; when using information entropy, the target value might be set to 6.0. Deviation signal It is the current uniformity index Compared with the preset target value Functions between, for example Taking image variance as an example, the deviation signal ,when This indicates that the current uniformity is lower than the target, and optimization is needed.

[0083] Finally, based on the deviation signal, the dynamic control core module determines a parameter adjustment amount that can converge the uniformity index to the target value through a preset control algorithm, and updates the parameters of the rotating sound pressure gradient field accordingly. The preset control algorithm is embedded in the software program of the dynamic control core module. In a specific embodiment, the preset control algorithm is a gradient descent algorithm. This algorithm quantizes the uniformity index (e.g., or Consider it as an objective function that needs to be minimized. The parameters of the rotating sound pressure gradient field (including the rotation angular frequency) Topological load and the emission amplitude of each transducer unit The set is viewed as a multidimensional control vector. The algorithm updates the control vector iteratively to improve the objective function. Gradually decrease.

[0084] Control Vector The update formula in each iteration is:

[0085] ;

[0086] in, For the updated control vector, The control vector at the current moment, For the objective function At the current control vector point The gradient with respect to the control vector. This is a preset learning rate factor used to control the step size of parameter updates.

[0087] Through this adaptive control cycle, the dynamic control core module continuously monitors the mixing state and intelligently adjusts the sound field parameters, enabling the mixing process of corn starch materials to be dynamically optimized until the desired uniformity target value is achieved.

[0088] See attached document Figure 5 This invention relates to a focused ultrasonic deagglomeration module for targeted breaking up localized material agglomerates formed within a mixing chamber. The module includes a high-frequency ultrasonic transducer and a movable positioning mechanism for supporting and moving the transducer. The module is typically installed outside the mixing chamber, and its high-frequency ultrasonic transducer focuses sound waves to penetrate the chamber wall and act on specific locations within the chamber.

[0089] High-frequency ultrasonic transducers are typically made of high-performance piezoelectric materials (e.g., titanium lead niobate ceramic) and operate in frequencies ranging from tens to hundreds of kilohertz, such as 20 kHz to 500 kHz. These transducers are designed to generate high-intensity ultrasonic waves and achieve precise focusing of the sound waves through acoustic lensing, curved transducer surfaces, or phased array technology. This focusing capability allows ultrasonic energy to be concentrated in specific small areas within the mixing cavity, achieving localized deagglomeration without excessively affecting the entire mixture.

[0090] The movable positioning mechanism is electrically connected to the dynamic control core module and receives motion commands from it. This mechanism typically consists of a set of precision mechanical components, including linear guides, sliders, stepper motors or servo motors, and position sensors (e.g., encoders). In one embodiment, the mechanism can provide two-dimensional or three-dimensional motion capabilities, such as precisely moving a high-frequency ultrasonic transducer to any specified spatial coordinate position within the hybrid cavity via linear displacement along the XYZ axes. The position sensors feed back the real-time position of the transducer to the dynamic control core module to ensure positioning accuracy.

[0091] The collaborative working mechanism of the focused ultrasonic deagglomeration module is as follows: The dynamic control core module obtains a real-time density distribution image of the corn starch material within the mixing chamber by executing an acoustic tomography algorithm. Subsequently, the core module analyzes and processes this density distribution image to identify preset characteristics representing agglomerates. These characteristics may include, but are not limited to: the density value of a local area is higher than a preset threshold, and the geometric size or shape of the high-density area conforms to the definition of an agglomerate. Once an agglomerate is identified, the dynamic control core module calculates and determines the precise three-dimensional spatial coordinates of the agglomerate.

[0092] Based on the determined spatial coordinates of the aggregate, the dynamic control core module sends a command to the movable positioning mechanism. The movable positioning mechanism drives the high-frequency ultrasonic transducer to move precisely along a preset path until its focal position coincides with the spatial coordinates of the aggregate. Once positioning is complete, the dynamic control core module drives the high-frequency ultrasonic transducer to emit high-intensity focused ultrasonic waves.

[0093] High-frequency ultrasonic transducers utilize acoustic cavitation to break up agglomerates at a microscopic level. Acoustic cavitation relies on localized pressure fluctuations caused by ultrasound waves propagating through liquids or fluidized media. When the negative pressure phase of the ultrasound reaches sufficient intensity, tiny gas nuclei or voids in the medium rapidly expand to form microbubbles. In the subsequent positive pressure phase, these microbubbles suddenly implode, generating localized, instantaneous high pressure (thousands of atmospheres) and high temperature (thousands of Kelvin). This implosion process also generates high-speed microjets and shock waves. These intense physical forces act directly on the surface and interior of the agglomerates, efficiently breaking down van der Waals forces, capillary forces, and other bonds between particles, rapidly decomposing the agglomerates into even finer particles at the microscopic level. This targeted, non-contact micro-breakup capability significantly improves the uniformity and efficiency of mixing, making it particularly suitable for handling stubborn agglomerates formed during mixing.

Claims

1. A corn starch explosion-proof mixing system for producing paper tube adhesive, characterized in that, include: The mixing chamber is used to hold corn starch materials; A dual-mode phased-array acoustic wave module is disposed outside the hybrid cavity and configured to switch between drive mode and diagnostic mode; The dynamic control core module is electrically connected to the dual-mode phased acoustic array module; In the driving mode, the dynamic control core module controls the dual-mode phased acoustic array to generate a rotating acoustic pressure gradient field, which is used to drive the corn starch material in the mixing cavity to form a vortex mixing. In the diagnostic mode, the dual-mode phased-array acoustic wave array is used to transmit probe acoustic waves and receive echo signals; Furthermore, the dynamic control core module is configured to: reconstruct the density distribution of corn starch material in the mixing cavity based on the echo signal using an acoustic tomography algorithm, and dynamically adjust the parameters of the rotating sound pressure gradient field according to the density distribution.

2. The corn starch explosion-proof stirring system for producing paper tube adhesive according to claim 1, characterized in that, The corn starch explosion-proof mixing system also includes a basic fluidization unit, which is configured to introduce airflow into the bottom of the mixing chamber before the dual-mode phased acoustic array operates, so as to form a dense fluidized bed of corn starch material.

3. The corn starch explosion-proof stirring system for producing paper tube adhesive according to claim 1, characterized in that, The dynamic control core module dynamically adjusts the parameters of the rotating sound pressure gradient field according to the density distribution by performing the following steps: A quantitative uniformity index is calculated from the density distribution to characterize the current mixing state; The quantized uniformity index is compared with a preset uniformity target value to generate a deviation signal; Based on the deviation signal, a parameter adjustment amount that can make the uniformity index converge to the target value is determined by a preset control algorithm, and the parameters of the rotating sound pressure gradient field are updated accordingly.

4. The corn starch explosion-proof stirring system for producing paper tube adhesive according to claim 3, characterized in that, The parameters of the rotating acoustic pressure gradient field include at least one of the following: rotational angular frequency, topological charge number, or emission amplitude of each transducer unit.

5. The corn starch explosion-proof stirring system for producing paper tube adhesive according to claim 1, characterized in that, The acoustic tomography algorithm is a filtered back projection algorithm.

6. The corn starch explosion-proof stirring system for producing paper tube adhesive according to claim 1, characterized in that, The corn starch explosion-proof mixing system also includes a focused ultrasonic de-agglomeration module, which includes a high-frequency ultrasonic transducer and a movable positioning mechanism for carrying and moving the high-frequency ultrasonic transducer. The movable positioning mechanism is electrically connected to the dynamic control core module. Furthermore, the dynamic control core module is further configured as follows: Identify preset features characterizing aggregates from the density distribution and determine the spatial coordinates of the aggregates; Based on the spatial coordinates of the aggregate, the movable positioning mechanism is controlled to move the high-frequency ultrasonic transducer to the spatial coordinates of the aggregate and drive the high-frequency ultrasonic transducer to emit ultrasonic waves for targeted deagglomeration processing.

7. The corn starch explosion-proof stirring system for producing paper tube adhesive according to claim 6, characterized in that, The high-frequency ultrasonic transducer generates an acoustic cavitation effect at the spatial coordinates of the agglomerate, which is used to microscopically break up the agglomerate.

8. The corn starch explosion-proof stirring system for producing paper tube adhesive according to claim 3, characterized in that, The quantization uniformity index is the image variance or information entropy of the density distribution.

9. The corn starch explosion-proof stirring system for producing paper tube adhesive according to claim 1, characterized in that, The dual-mode phased-array acoustic wave array is composed of multiple transducer units evenly distributed in a ring along the outer wall of the hybrid cavity.

10. The corn starch explosion-proof stirring system for producing paper tube adhesive according to claim 4, characterized in that, The dynamic control core controls the spiral shape of the rotating sound pressure gradient field by setting the topological charge and the phase delay of each transducer unit.

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