Distiller's yeast fermentation room system and control method thereof

Abstract

The invention provides a distiller's yeast fermentation room system and a control method thereof. The method comprises the following steps: monitoring and acquiring control parameters of a fermentation room in real time, such as yeast core temperature, indoor temperature and humidity, CO2 and O2 concentration, and state parameters; selecting a corresponding target control curve according to the yeast type, and obtaining a corresponding target value of each parameter; dynamically regulating and controlling a heating system, a humidifying system, an air mixing system and a moisture removal and oxygen supplementation system according to the deviation between each control parameter and the corresponding target value in combination with the state parameters, and carrying out PID (Proportion Integration Differentiation) regulation by taking the curve center temperature as the main control quantity; the system comprises a plurality of fermentation rooms and each matched detection and execution device. According to the method, multi-parameter cooperative control is realized, the requirements of different yeast seeds and fermentation stages are met, and the quality stability of the distiller's yeast, the production efficiency and the energy utilization rate are remarkably improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of distiller's yeast fermentation, in particular to a distiller's yeast fermentation room system and a control method thereof. BACKGROUND

[0002] Distiller's yeast is a "saccharification and fermentation agent" for liquor brewing, and its quality directly determines the liquor's aroma type, liquor yield and flavor. The essence of distiller's yeast production is a process of natural cultivation and metabolism of microbial populations in a specific temperature and humidity environment. Therefore, accurate control of environmental parameters (such as temperature, humidity, oxygen, and carbon dioxide) in the fermentation room is the core of ensuring the quality of distiller's yeast.

[0003] Traditional distiller's yeast fermentation relies on manual experience to ventilate, dehumidify and cool through opening doors and windows, which has low control accuracy, delayed response, and is greatly affected by external climate, resulting in low production efficiency and unstable product quality, and cannot achieve large-scale and standardized production.

[0004] To improve this situation, some fermentation devices with basic environmental control equipment have appeared in the prior art. For example, a distiller's yeast fermentation device for liquor production is disclosed in Chinese Patent No. CN221028328U, which heats the fermentation room through a water tank, a heater, a serpentine pipe, etc., humidifies through an atomizing generator and a fan, and dehumidifies through an exhaust pipe. This device actively controls the temperature and humidity to some extent, improving the production environment.

[0005] However, such devices still have significant limitations:

[0006] 1. The control method is single and isolated, and can only independently control the "temperature" and "humidity" parameters through a simple on-off or closed-loop control, lacking coordinated monitoring and linkage control of multiple key parameters such as carbon dioxide concentration, oxygen concentration, and core temperature.

[0007] 2. The control logic is static and passive, and cannot automatically adjust the control strategy and target set value according to different types of distiller's yeast (such as high-temperature yeast, medium-high-temperature yeast, and medium-temperature yeast), different fermentation stages (such as pre-temperature rise and humidity maintenance, mid-temperature maintenance and high-temperature, and post-temperature reduction and dehumidification), and different seasonal climate conditions.

[0008] 3. The existing technology often has overshoot, oscillation or lagging phenomena in the control process, making it difficult to maintain a high level of stability in the fermentation environment. In addition, it relies on limited environmental sensors and cannot obtain the core temperature of the yeast, which is the most important indicator of fermentation, making the control like "scratching an itch through a shoe".

[0009] Therefore, there is an urgent need in the art for an intelligent distiller's yeast fermentation control method that can overcome the above-mentioned shortcomings. SUMMARY

[0010] The present application aims to provide a koji fermentation room system and a control method thereof, which can realize high-precision collaborative control of multiple environmental parameters, and can adaptively adjust the control strategy according to different process requirements, thereby significantly improving the quality stability, production efficiency and energy utilization rate of koji fermentation.

[0011] To achieve the above-mentioned purpose, the present application proposes the following technical solutions:

[0012] A control method of a koji fermentation room system, comprising the following steps:

[0013] Obtaining real-time monitoring data of the fermentation room, including control parameters and state parameters;

[0014] The control parameters include koji core temperature, indoor temperature, indoor humidity, CO2 concentration and O2 concentration;

[0015] The state parameters include outdoor temperature, outdoor humidity and mixed air outlet temperature;

[0016] According to the current koji type, a corresponding target control curve is selected from a plurality of pre-set control curve templates;

[0017] Based on the target control curve, a plurality of target values are obtained, including koji core temperature target value, indoor temperature target value, indoor humidity target value, CO2 concentration target value and O2 concentration target value;

[0018] Based on the deviation of each control parameter from the corresponding target value, at least one of the following control actions is dynamically selected and executed:

[0019] Radiation heat type heating of indoor air in the fermentation room is performed by a heating system;

[0020] Atomization humidification of indoor air in the fermentation room is performed by a humidification system;

[0021] CO2 concentration and O2 concentration adjustment is performed by introducing fresh air into the fermentation room through a mixed air system, or steam is introduced for heating and humidification at the same time;

[0022] CO2 concentration and O2 concentration adjustment, and / or cooling and dehumidification are performed by introducing outdoor air and / or discharging indoor air into the fermentation room through a dehumidification and oxygenation system;

[0023] Wherein, the execution parameters of the control action are adjusted by PID according to the deviation of each control parameter from the corresponding target value, combined with the state parameters, and the koji core temperature is given priority as the main control variable, and the O2 concentration is given priority as the auxiliary control variable.

[0024] As a preferred technical solution of the present application, the execution of the control action further comprises:

[0025] When the temperature of the yeast core is lower than the target temperature of the yeast core and the indoor humidity is lower than the target indoor humidity, steam is introduced into the fermentation room through a ventilation system to preferentially heat and humidify.

[0026] As a preferred technical solution of the present application, the execution of the control action further comprises:

[0027] When the temperature of the yeast core is higher than the target temperature of the yeast core, and the CO2 concentration is higher than the target CO2 concentration and / or the O2 concentration is lower than the target O2 concentration, outdoor air is introduced into the fermentation room through a moisture removal and oxygen supplementation system to preferentially adjust the CO2 concentration and the O2 concentration, and to cool.

[0028] As a preferred technical solution of the present application, the target control curve comprises a plurality of sub-curves corresponding to fermentation stages;

[0029] Based on the sub-curves, a plurality of target values are obtained, including the target temperature of the yeast core, the target indoor temperature, the target indoor humidity, the target CO2 concentration, and the target O2 concentration of each fermentation stage;

[0030] Based on the deviation of each control parameter from the corresponding target value, at least one control action is dynamically selected and executed.

[0031] As a preferred technical solution of the present application, the fermentation stages include: a preparation stage, a pre-fermentation stage, a mid-fermentation stage, and a post-fermentation stage.

[0032] As a preferred technical solution of the present application, the control curve template includes at least three types of fermentation temperature curves: high-temperature curves, medium-high-temperature curves, and medium-temperature curves.

[0033] The present application also provides a wine yeast fermentation room system for implementing the control method of the wine yeast fermentation room system, comprising a control system and a plurality of fermentation rooms;

[0034] Each of the fermentation rooms is provided with:

[0035] a heating system;

[0036] a humidification system;

[0037] a ventilation system;

[0038] a moisture removal and oxygen supplementation system;

[0039] a detection system comprising a plurality of yeast core temperature sensors, a plurality of environmental temperature and humidity detectors, and a plurality of gas concentration monitors;

[0040] The control system is configured to:

[0041] Receiving real-time monitoring data of the temperature sensor, the environment temperature and humidity detector, and the gas concentration monitor;

[0042] Selecting a target control curve according to a current type of the koji;

[0043] Outputting a control instruction to the heating system, the humidifying system, the air mixing system, and the moisture removal and oxygen supplement system.

[0044] As a preferred technical solution of the present application, the detection system further comprises a plurality of cameras, which are installed in the fermentation room through a connecting base.

[0045] As a preferred technical solution of the present application, the detection system further comprises a plurality of weighing sensors, which are arranged at the bottom of the koji block.

[0046] As a preferred technical solution of the present application, the air mixing system comprises an air mixing main pipe, a plurality of air mixing branch pipes, a plurality of guide pipes, a compressed air generator, and a steam generator.

[0047] The air mixing main pipe is arranged at the upper part of the fermentation room and extends horizontally along the length direction of the fermentation room.

[0048] The plurality of guide pipes extend vertically along the height direction of the fermentation room, and the upper end and the lower end of each guide pipe are provided with an opening.

[0049] The two ends of the air mixing branch pipe are connected to the air mixing main pipe and any air mixing chamber.

[0050] The compressed air generator is connected to the air mixing main pipe through a compressed air main pipe.

[0051] The steam generator is connected to the air mixing main pipe through a steam main pipe.

[0052] According to the above technical solution, the technical solution of the present application provides a koji fermentation room system and a control method thereof, which has the following advantages compared with the prior art:

[0053] 1. According to the data of the koji temperature, the temperature and humidity of the fermentation room, the CO2 concentration, and the O2 concentration, the fermentation room equipment is controlled to automatically realize the functions of circulating air mixing, air supplementing, gas concentration adjusting, humidifying, and heating, and the process data and the koji quality data are associated to complete the intelligent control of the fermentation room.

[0054] 2. The koji block data in the fermentation room is collected, counted, and analyzed in real time, the data collection period can be determined according to the control requirement, a stable data structure is formed, and the fermentation state of the koji block is analyzed according to the real-time data.

[0055] 3. The long-term fermentation process is divided into four stages: the main entry preparation stage, the early fermentation stage, the middle fermentation stage and the late fermentation stage. The automatic execution mode is determined according to the natural fermentation parameters of the koji block in each stage and the actual detection data. Different koji blocks adopt different control methods. During the koji block fermentation process, the temperature and humidity are highly correlated. The koji core temperature is selected as the main control variable, and the oxygen concentration is selected as the auxiliary control variable. The koji block is controlled in stages from entering the room to the completion of fermentation, which ensures the feasibility of the system and realizes the best fermentation environment.

[0056] It should be understood that all combinations of the foregoing concepts and additional concepts described in greater detail below can be seen as being part of the inventive subject matter of the present disclosure provided such concepts are not mutually inconsistent.

[0057] The foregoing and other aspects, embodiments and features of the present inventive teachings can be more fully understood from the following description taken in conjunction with the accompanying drawings. Other aspects, embodiments and features of the present inventive teachings will be apparent from the description that follows, and from the claims. BRIEF DESCRIPTION OF DRAWINGS

[0058] The accompanying drawings are not intended to be drawn to scale. In the drawings, each identical, or nearly identical, component that is illustrated in various figures is represented with a like numeral. For purposes of clarity, not every component is called out in every drawing. There now will be described, by way of example, embodiments of various aspects of the present inventive teachings with reference to the accompanying drawings in which:

[0059] Figure 1 It is a main view of the structural layout of the koji fermentation room system of the present invention;

[0060] Figure 2 It is a top view of the structural layout of the koji fermentation room system of the present invention;

[0061] Figure 3 It is a partial schematic view of the air mixing system structure of the present invention;

[0062] Figure 4 It is a partial schematic view of the heating system structure of the present invention;

[0063] Figure 5 It is a partial schematic view of the humidification system structure of the present invention;

[0064] Figure 6 It is a schematic view of the structure layout of the gas concentration monitor of the present invention;

[0065] Figure 7 It is a side view of the structural layout of the koji fermentation room system of the present invention;

[0066] Figure 8Fermentation temperature curve for high temperature koji of Example 1 of the present invention;

[0067] Figure 9 Fermentation temperature curve for high temperature koji of Example 2 of the present invention;

[0068] Figure 10 Fermentation temperature curve for medium temperature koji of Example 3 of the present invention. DETAILED DESCRIPTION

[0069] In order to make the objects, technical solutions and advantages of the embodiments of the present application clearer, the technical solutions of the embodiments of the present application will be described below in conjunction with the accompanying drawings of the embodiments of the present application. Obviously, the described embodiments are only some of the embodiments of the present application, but not all the embodiments of the present application. Based on the described embodiments of the present application, all other embodiments obtained by those of ordinary skill in the art without creative effort fall within the scope of the present application. Unless otherwise defined, the technical terms or scientific terms used herein should be understood as the common meanings thereof by those of ordinary skill in the art.

[0070] The terms "first", "second", and similar terms used in the patent application specification and claims of the present application do not denote any order, quantity, or importance, but are used to distinguish different components. Similarly, unless the context clearly indicates otherwise, the singular forms "a", "an", and "the" and the like do not denote the quantity limitation, but denote the existence of at least one. The terms "include" or "contain" and the like mean that the elements or objects appearing before "include" or "contain" cover the features, integers, steps, operations, elements and / or components listed after "include" or "contain", and do not exclude the existence or addition of one or more other features, integers, steps, operations, elements, components and / or sets thereof. "Up", "down", "left", "right" and the like are only used to represent relative positional relationships, and when the absolute positions of the described objects are changed, the relative positional relationships may also be changed accordingly.

[0071] The present application provides a kind of koji fermentation room system, including control system and multiple fermentation rooms 100, each fermentation room 100 is equipped with heating system, humidification system, air mixing system, moisture removal oxygen supplement system and detection system.Control system hardware part uses Siemens S7 series PLC, with industrial computer as core component, uses artificial operation interface, is based on PROFINET, fieldbus technology such as industrial ethernet and is constructed into DCS centralized distributed control system;Software part uses Siemens Botu, WinCC, the sensor of dispersed detection system (including environmental temperature and humidity detection, air mixing temperature detection, koji core temperature detection etc.) and field instrument, heating system, humidification system, air mixing system etc. are concentrated to a control platform, realize integrated management and control, intelligent, digital production.

[0072] Specifically, control system uses production field, central control room and remote monitoring room three-layer structure.All field equipment of bottom layer is connected with PLC in central control room, industrial computer by PROFINET fieldbus technology, and remote monitoring layer of upper layer realizes data access to central control room by industrial ethernet technology, to facilitate system expansion.Distributed hierarchical structure of distributed control and fieldbus technology is used.Fieldbus mode is used between bottom sensor and detection instrument and PLC, between PLC and industrial computer, simplify system structure, and can be replaced at any time, without affecting production.

[0073] Wherein, each fermentation room 100 is provided with several koji piles composed of fermentation frame 101, and multiple koji piles are arrayed;Each fermentation frame 101 is provided with several layers from top to bottom, as shown in Figure 1 7 layers are provided for placing koji block, and the number of layers for placing koji block can be selected according to needs.In some specific embodiments of the present application, 130 fermentation rooms are provided in a building with 5 floors, 30 koji piles are stacked in each fermentation room, each pile has 7 layers, and 26 koji blocks are placed in each layer, so that 5460 koji blocks can be placed in each fermentation room.

[0074] Wherein, as shown in Figure 4As shown, the heating system includes a floor heating circulating pump, a distribution header 200, a floor heating water supply main pipe 201, a floor heating return water main pipe 202, a floor heating pipe group 203 and a radiator group 204. During the koji fermentation process, the monitored koji temperature value, the ambient temperature value data in the fermentation room, etc. are compared with the pre-set target value of the fermentation temperature curve (target control curve), and after comparison, the air in the fermentation room 100 is automatically heated in a radiation heat transfer manner according to the need. Among them, the floor heating pipe group 203 is uniformly arranged on the ground of the fermentation room 100; the radiator group 204 is at least two groups, and is arranged on the two side walls of the fermentation room 100 along the length direction; the floor heating water supply main pipe 201 is connected with the hot water inlet of the distribution header 200, the hot water outlet of the distribution header 200 is connected with the floor heating pipe group 203 and the radiator group 204 through a plurality of shunt branch pipes, respectively, the outlet of the floor heating pipe group 203 and the radiator group 204 is connected to the return water inlet of the distribution header 200 through a plurality of return branch pipes, and the return water outlet of the distribution header 200 is connected with the floor heating return water main pipe 202. The floor heating circulating pump is arranged on the floor heating return water main pipe 202.

[0075] When the fermentation room 100 needs to be heated, the system automatically starts the floor heating pipe group 203 and the radiator group 204, both of which can be independently controlled and automatically set the temperature value according to the situation, the distribution header 200 and the floor heating circulating pump execute the action, and the distribution header 200 is automatically closed when the floor heating pipe group 203 and the radiator group 204 reach the set temperature value.

[0076] Among them, as shown in Figure 4 , 5 As shown, the humidification system includes a plurality of water pumps and a plurality of humidification water pipes 300, and a plurality of atomizing nozzles 301 are uniformly distributed on the humidification water pipes 300. The humidification water pipes 300 are arranged at the bottom end of the side wall in the fermentation room 100, close to the ground, and are connected with the water pump arranged outside the fermentation room 100 through a connecting water pipe. Clean water is pumped to the humidification water pipes in the fermentation room 100 through the outdoor water pump after being pressurized, atomized through the atomizing nozzles 301, and directly sprayed on the ground. When the indoor temperature rises, the water is vaporized to achieve humidification. Since the koji entering time of each fermentation room 100 is different, the humidification time of the fermentation room 100 should be staggered. In addition, the water spraying time is short, and considering energy saving, one water pump can be connected with the humidification water pipes 300 of 4-6 fermentation rooms 100, and constant pressure water supply is adopted for each fermentation room 100, which can humidify 4-6 fermentation rooms 100 at the same time.

[0077] When performing humidification, the system automatically runs the humidification water pump and uses a pressure sensor on the pipeline to detect the pressure value and control the humidification water at a constant pressure. When the pipeline pressure is constant (e.g., 0.3 MPa), the system opens the humidification control ball valve on the indoor humidification water pipe 300, and sprays water through the humidification water pipe 300 to humidify. The system also calculates the humidification amount in real time. When the humidification amount reaches the target value, the system closes the indoor humidification control ball valve and the water pump, and the humidification action is completed.

[0078] Among them, such as Figure 3 As shown, the air mixing system includes a main air mixing pipe 400, multiple branch air mixing pipes 401, multiple guide pipes 402, a compressed air generator, a main compressed air pipe 403, a steam generator, and a main steam pipe 404. The main air mixing pipe 400, branch air mixing pipes 401, and guide pipes 402 are installed inside the fermentation chamber 100. Specifically, the main air mixing pipe 400 is located in the upper part of the fermentation chamber 100 and extends horizontally along the length of the fermentation chamber 100; the multiple guide pipes 402 extend vertically along the height of the fermentation chamber 100, with openings at both the upper and lower ends. A mixing chamber is located below the upper opening, generating negative pressure during operation. Air from the upper part of the fermentation chamber 100 is drawn in from the upper opening and discharged from the lower opening, continuously circulating and mixing the upper and lower air within the fermentation chamber 100 to reduce the temperature difference between the upper and lower levels of the chamber. A mixing air temperature sensor is located at the lower port to detect the outlet temperature of the mixing air; the two ends of the mixing air branch pipe 401 are respectively connected to the mixing air main pipe 400 and any mixing air chamber, and are used to deliver compressed air or steam from the mixing air main pipe 400 to the mixing air chamber of the guide pipe 402, and then discharge it from the lower port of the guide pipe 402. Preferably, the multiple guide pipes 402 are arranged at equal intervals.

[0079] Both the compressed air generator and the steam generator are located outside the fermentation chamber 100. Specifically, the compressed air generator is connected to the mixing air main pipe 400 via the compressed air main pipe 403, while the steam generator is connected to the mixing air main pipe 400 via the steam main pipe 404.

[0080] When supplemental air is needed to regulate CO2 and O2 concentrations, or when the temperature difference between the upper and lower parts of the fermentation chamber is too large, compressed air is delivered to each guide pipe 402 via a compressed air generator through the mixing main pipe 400. After mixing with indoor air in the mixing chamber, the compressed air is discharged, ensuring uniform temperature and humidity between the upper and lower parts of the fermentation chamber 100 and minimizing the temperature difference between the upper and lower layers (e.g., ≤5℃). To avoid the introduced compressed air temperature being too low and affecting the indoor temperature of the fermentation chamber 100, the compressed air is preheated outdoors. In some specific embodiments, to make rational use of resources and save energy, high-temperature steam generated by a steam generator is directly used to heat the compressed air.

[0081] When the koji fermentation process needs to be humidified and heated, the high-temperature steam generated by the steam generator is delivered to the air mixing main pipe 400 through the steam main pipe, and then enters the guide pipe 402 through the air mixing branch pipe 401. After a certain temperature and speed reduction, it is mixed with the air in the fermentation room 100 chamber and discharged from the lower end of the guide pipe 402 to heat the air in the fermentation room 100 chamber in a convection heat transfer manner, and at the same time achieve the purpose of humidification. When the heating amount reaches the target value, the steam generator valve is closed, and the humidification and heating are completed.

[0082] In some embodiments, in order to reasonably utilize high-temperature steam to heat compressed air, a tubular heat exchanger can be provided. Specifically, a steam branch pipe is connected to the shell side inlet of the tubular heat exchanger at the output end of the steam generator, so that the steam passes through the shell side, and the shell side outlet is used as the steam condensate drainage port. The output end of the compressed air generator is connected to the tube side inlet of the tubular heat exchanger through the compressed air main pipe 403, and the tube side outlet is connected to the air mixing main pipe 400 through a pipeline, so that the compressed air enters the tubular heat exchanger, and then is delivered to each guide pipe 402 through the air mixing main pipe 400 after indirect heat exchange with the high-temperature steam.

[0083] Among them, as shown in Figure 1 , 7 The moisture removal and oxygen supplement system includes a plurality of moisture removal windows 500, a moisture removal fan 501, and an air guide pipe 502. The fermentation room 100 is provided with a front door and a rear door, and the front door and the rear door are respectively arranged on the opposite two side walls. A plurality of moisture removal windows 500 are uniformly arranged on the upper part of the side wall where the front door and the rear door are located, for communicating the indoor and outdoor, and each moisture removal window 500 is provided with an automatic opening and closing window on the side close to the indoor. When the automatic opening and closing window is opened, the air in and out of the fermentation room 100 can flow naturally. For the convenience of description, the moisture removal window 500 located on the side wall where the front door is located is called the front moisture removal window, and the moisture removal window 500 located on the side wall where the rear door is located is called the rear moisture removal window. The air guide pipe 502 is arranged on the side close to the outdoor of the rear moisture removal window, and the moisture removal fan 501 is arranged in the air guide pipe 502. The air in the fermentation room 100 is sucked by the negative pressure formed by the moisture removal fan 501, and the forced ventilation is realized through the convection path formed by the front moisture removal window and the rear moisture removal window. During operation, the moisture removal mode can be automatically opened according to the pre-set condition of the system, such as the natural flow mode or the forced ventilation mode.

[0084] The fermentation room 100 of the embodiment of the present application mainly adopts the mode of replacing with outdoor clean air to cool and dehumidify. Specifically, the automatic opening and closing window of the front dehumidification window, the automatic opening and closing window of the rear dehumidification window and the dehumidification fan 501 are opened; the running speed of the dehumidification fan 501 is automatically adjusted according to the micro-negative pressure detection value in the air inlet pipe 502, the opening size of the automatic opening and closing window of the rear dehumidification window is automatically adjusted according to the outdoor temperature and humidity value and the indoor temperature and humidity value and the temperature loss rate of the core temperature, and when the indoor temperature and humidity reaches the target value and the core temperature shows a slow downward trend, the automatic opening and closing window of the front dehumidification window, the automatic opening and closing window of the rear dehumidification window and the dehumidification fan are closed, and the cooling and dehumidification action is completed.

[0085] The oxygen supplement of the fermentation room 100 of the embodiment of the present application mainly adopts the mode of replacing with outdoor clean air. When oxygen needs to be supplemented, the automatic opening and closing window of the front dehumidification window, the automatic opening and closing window of the rear dehumidification window and the dehumidification fan 501 are opened to forcibly ventilate and supplement oxygen; after the oxygen supplement is completed (the oxygen concentration meets the standard), the automatic opening and closing window of the dehumidification window 500 and the dehumidification fan 501 are closed.

[0086] The detection system includes a plurality of core temperature sensors, a plurality of environmental temperature and humidity detectors, a plurality of gas concentration monitors 600, a plurality of mixed air temperature sensors, a plurality of cameras and a plurality of weighing sensors. The core temperature, the indoor temperature, the indoor humidity, the indoor CO2 concentration and O2 concentration, the mixed air outlet temperature, the appearance of the curd block and the weight loss data of the curd block in the fermentation room 100 are monitored in real time by the above sensors or detectors and are recorded. The core temperature, the indoor temperature, the indoor humidity, the indoor CO2 concentration and O2 concentration and the mixed air outlet temperature need to participate in the system control.

[0087] The "core" of the embodiment of the present application refers to the central region of the section formed by cutting the curd block from the middle part, and the "core temperature" refers to the temperature of the central region, which is the key parameter monitored and controlled by the present application. It should be understood that other expressions such as "core" that may exist in the related technical field, if the object they refer to is the same as the "core" defined by the present application, are also included in the protection scope of the present patent, and the interchange of the two does not affect the actual technical features of the technical solution.

[0088] The specific way of monitoring the core temperature of the curd block by the present application is to select 3 groups of curd piles (more or fewer curd piles can be selected according to actual conditions) in the fermentation room 100, select curd blocks at the upper, middle and lower positions of each pile, place the core temperature sensor in the central region of the curd block, monitor the core temperature of the curd block in real time, and set the core temperature monitoring data recording and transmission time as needed, such as 5 minutes, 30 minutes, 60 minutes, etc.

[0089] Preferably, the temperature sensors of the at least two groups of curd towers are wireless Pt100 type, and the temperature sensors of the remaining group of curd towers are wired Pt100 type. Among them, the temperature sensors of the curd towers are wireless Pt100 type temperature sensors, wireless transmission, and the period is adjustable. For example, the curd temperature data collection time is 2-3 minutes, and the remaining battery capacity can also be displayed. When the remaining battery capacity reaches the preset value, an alarm is given through data or audio. By collecting the temperature changes during the fermentation process of several curd cores in real time, the collected temperature changes are analyzed into Celsius temperature values, and the trend chart of the entire fermentation process is recorded.

[0090] Specifically, four indoor environment temperature and humidity detection points are selected in the fermentation room 100, and environment temperature and humidity detectors are installed at the upper, middle and lower positions of the target detection points. At least one of the environment temperature and humidity detection points is selected at the center of the fermentation room 100. In some embodiments, the environment temperature and humidity detector is a wired temperature and humidity detector and is suspended. In specific implementation, the humidity sensor and the independently configured temperature sensor can be integrated on the same probe, such as the e+e brand product, to accurately and reliably measure the temperature and humidity in the fermentation room environment. The specific parameters are as follows: humidity range 0-100%, accuracy 2.5%; temperature range -20-100℃, accuracy 0.25%. Similarly, a plurality of environment temperature and humidity detectors are arranged outside the fermentation room to detect the temperature and humidity outside.

[0091] In order to monitor the mixed air outlet temperature when the air is supplemented and the steam is heated and humidified, a mixed air temperature sensor is arranged at the lower end of the guide pipe 402.

[0092] Specifically, as shown in Figure 6 The gas concentration monitor 600 is used to monitor the CO2 concentration and O2 concentration in the fermentation room 100 in real time. When arranged, a gas concentration detection point is selected in the fermentation room 100, and gas guide pipes are arranged at the upper, middle and lower positions thereof. The indoor gas is pumped to the gas concentration monitor arranged outdoors through the gas guide pipes, and then analyzed by the gas concentration monitor 600 to detect the CO2 concentration and O2 concentration in the room. Among them, the gas concentration monitor 600 can adopt existing technologies, such as Jianda, Zhonganbo instruments, etc.

[0093] In order to facilitate the observation of the appearance change of the curd block during the fermentation process, a camera is arranged in the fermentation room 100. Specifically, two camera target points are selected in the fermentation room 100 to install the camera. Among them, the camera can adopt existing explosion-proof cameras, such as Hikvision, Dahua brand products, etc. It has a stainless steel shell, waterproof and explosion-proof, supports a rotating mode to increase the monitoring area in a vertically narrow environment, and adapts to different requirements for image quality and smoothness in different scenes.

[0094] In order to detect the weight change of the koji block during the fermentation process, a weighing sensor is arranged. Specifically, three koji block weight loss monitoring points are selected in the fermentation room 100, and a wired weighing sensor such as a Mettler Toledo high-precision sensor is installed at the bottom of the koji block to monitor the weight change of the koji block during the fermentation process in real time.

[0095] The fermentation temperature curves of a plurality of koji types determined based on experiments or manually are preset in the control system as a template selection library of target control curves, and according to the deviation of real-time indoor temperature and humidity, koji core temperature, oxygen content and other data in the fermentation room 100 from the target control curve, the fermentation stage optimization control scheme is automatically selected, and the corresponding adjustment means is adopted to realize automatic control of the entire fermentation process.

[0096] The present application also provides a control method of a koji fermentation room system, comprising the following steps:

[0097] Real-time monitoring data of the fermentation room are obtained, including control parameters and state parameters.

[0098] The control parameters are mainly used for comparison with target values and driving control, including koji core temperature, indoor temperature, indoor humidity, air mixing temperature, CO2 concentration and O2 concentration. The state parameters are used for outdoor environment monitoring and system state monitoring of the fermentation room, including outdoor temperature, outdoor humidity and air mixing outlet temperature.

[0099] According to the current koji type, a corresponding target control curve is selected from a plurality of preset control curve templates, and the control curve template at least includes fermentation temperature curves of high-temperature koji, medium-high-temperature koji and medium-temperature koji.

[0100] No matter which koji type, the fermentation generally goes through four fermentation stages of preparation stage, pre-fermentation stage, mid-fermentation stage and post-fermentation stage, so the target control curve (fermentation temperature curve) of each koji type will also be divided into sub-curves corresponding to different fermentation stages. For example, the high-temperature koji fermentation temperature curve of the whole fermentation process can be divided into the following sub-curves: high-temperature koji preparation stage-temperature sub-curve, high-temperature koji pre-fermentation stage-temperature sub-curve, high-temperature koji mid-fermentation stage-temperature sub-curve, high-temperature koji post-fermentation stage-temperature sub-curve, and other koji types are similar.

[0101] Therefore, after obtaining the control parameters and the state parameters and determining the target control curve, a plurality of target values are obtained based on the target control curve as reference parameters to regulate the control parameters. The target values include a temperature target value of the fermentation core, an indoor temperature target value, an indoor humidity target value, a CO2 concentration target value, and an O2 concentration target value. To accurately regulate the control parameters of the fermentation room, the target values of the fermentation core, the indoor temperature target value, the indoor humidity target value, the CO2 concentration target value, and the O2 concentration target value are obtained based on the target control curve of each fermentation stage of each fermentation species. The corresponding target values of the sub-curves of each fermentation stage in actual production may be the same or different.

[0102] Based on the deviations of the control parameters and the corresponding target values, including the deviation of the fermentation core temperature and the target value of the fermentation core temperature, the deviation of the indoor temperature and the target value of the indoor temperature, the deviation of the indoor humidity and the target value of the indoor humidity, the deviation of the CO2 concentration and the target value of the CO2 concentration, and the deviation of the O2 concentration and the target value of the O2 concentration, at least one of the following control actions is dynamically selected and executed:

[0103] Radiation heat type heating of the indoor air of the fermentation room by a heating system;

[0104] Atomization humidification of the indoor air of the fermentation room by a humidification system;

[0105] CO2 concentration and O2 concentration adjustment by introducing fresh air into the fermentation room through an air mixing system, or introducing steam for heating and humidification;

[0106] CO2 concentration and O2 concentration adjustment, and / or cooling and dehumidification by introducing outdoor air and / or discharging indoor air into the fermentation room through a dehumidification and oxygenation system;

[0107] The execution parameters of the control actions are adjusted by PID based on the real-time monitoring data of the control parameters and the deviations of the target values, and the state parameters, and the fermentation core temperature is given priority as the main control variable, and the O2 concentration is given priority as the auxiliary control variable.

[0108] When the fermentation core temperature is lower than the target value of the fermentation core temperature and the indoor humidity is lower than the target value of the indoor humidity, steam is introduced into the fermentation room through the air mixing system for heating and humidification. Of course, the heating system and the humidification system can also be combined for adjustment, but this execution operation is more complex than the previous operation mode.

[0109] When the temperature of the koji is higher than the target temperature of the koji, and the concentration of CO2 is higher than the target concentration of CO2 and / or the concentration of O2 is lower than the target concentration of O2, the dehumidification and oxygen supplement system is used to introduce outdoor air into the fermentation room and exhaust indoor air, while the concentrations of CO2 and O2 are adjusted, and the temperature is reduced. Of course, the new air can be supplemented by combining the air mixing system and opening the dehumidification and oxygen supplement system for adjustment, but the former operation is more rapid and simple, and the energy consumption is low.

[0110] During operation, the type of koji is selected through the control interface of the control system, and the target control curve is selected from a plurality of control curve templates, or the key parameters are customized and modified as needed. After the setting is completed and confirmed, the system will automatically execute the control logic according to the target control curve.

[0111] The preparation stage of entering the room: taking temperature + humidity + duration as the control condition, so that the environmental temperature reaches the preset temperature, and the environmental humidity reaches 95%-100% and lasts for a certain period of time.

[0112] The early fermentation stage: the key is to control the indoor temperature and humidity in the first 3 days to ensure that the indoor temperature rises slowly, and to supplement heat after 3 days to raise the temperature of the koji to the target temperature of the koji. When the temperature of the koji is greater than or equal to the target temperature of the koji, and the temperature maintenance time is greater than or equal to the preset time (24 hours), the system automatically switches to the medium-term koji curve; if the temperature of the koji is lower than the target temperature of the koji and lasts for more than or equal to the preset time (24 hours), the heating power can be adjusted to increase or the heating time can be extended.

[0113] The temperature rise speed of the koji in the fermentation temperature rise stage of this stage is too fast, which can cause the koji to grow slowly and is not conducive to "coating", therefore, the temperature rise speed of the koji and indoor humidity control are mainly used in this stage, and the heating can be appropriately supplemented if the temperature rise speed of the koji is too slow. A small amount of steam can be introduced for heating, and a proper amount of heated compressed air can be introduced for indoor upper and lower circulating air mixing to reduce the temperature difference between the upper and lower layers of the room, preferably controlled within 3-6℃, and the amount of steam or hot compressed air is controlled according to the detected indoor temperature data. The start and stop of the humidification system are controlled according to the detected indoor humidity data. At the same time, according to the detected concentrations of CO2 and O2, the concentrations are compared with the target concentrations of CO2 and O2 respectively, and when the concentrations exceed / are not up to the target values, the windows are automatically opened or a proper amount of compressed air is introduced for air supplement.

[0114] Mid-fermentation: This stage mainly keeps the indoor temperature and humidity of the fermentation room. The indoor temperature is stabilized in the ideal temperature range by humidification and heating for 10-14 days. When the indoor temperature or humidity does not meet the target value, the indoor air can be heated and humidified by passing in the appropriate amount of steam; start the heating system and humidification system to heat and humidify the indoor air, and adjust the indoor temperature difference between the upper and lower layers if necessary. When heating and humidifying by passing steam, the amount of steam needs to be controlled according to the mixed air temperature data of the air mixing system. According to the detected CO2 concentration, O2 concentration and their target values, when the target values are exceeded or not reached, the automatic window opening and closing is controlled, and the appropriate amount of fresh air is supplemented.

[0115] Late fermentation: This stage mainly keeps the indoor temperature and humidity of the fermentation room. According to the target control curve, the heating system is started to heat the indoor air when necessary, so that the indoor air temperature is controlled according to the trend of the target control curve. In addition, the opening of the air inlet and exhaust window is automatically adjusted according to the target control curve, and the exhaust fan is started to discharge the humid air to the back door side. According to the detected CO2 concentration, O2 concentration and their target values, when the target values are exceeded or not reached, the automatic window opening and closing is controlled, and the appropriate amount of fresh air is supplemented.

[0116] Example 1

[0117] High-temperature koji (Maotai-flavor type) is mainly prepared in summer (the average outdoor temperature is 25-32℃, and the average humidity is 70%-85%). Its control mainly includes four stages, and its temperature curve is as shown in Figure 8

[0118] Preparation stage:

[0119] The ideal condition for the koji block entering the room is that the indoor and outdoor temperatures are consistent, and the humidity is controlled at ≥95%. The humidity adjustment can be achieved by spraying water in the fermentation room to humidify the indoor air, so that the indoor humidity approaches the ideal condition of the koji block entering the room.

[0120] Early fermentation:

[0121] The koji pile enters the fermentation room and waits for the koji block to naturally ferment and rise in temperature, which takes about 5-7 days. The koji block rises in temperature to 45-50℃ in the first 3 days, and the temperature rise of the koji core is controlled slowly to facilitate microbial growth; the koji block rises in temperature to 65-68℃ in the 3rd-7th day, and this stage mainly controls the temperature rise speed of the koji core and the environmental humidity, while detecting and controlling the oxygen content in the room.

[0122] ​The first 3 days, to avoid the temperature rising speed of the dough core, the dough block temperature rising rate needs to be inhibited by reducing the indoor environment temperature, at this time, outdoor air is introduced into the indoor air by the moisture exhaust and oxygen supplement system to replace the indoor air, and the fermentation room is cooled, and the oxygen concentration is supplemented. However, the ventilation and cooling process will cause the indoor environment humidity to decrease, so humidification control is needed, which can be performed by the humidification system.

[0123] After 3 days, as the fermentation time advances, the respiratory heat generated during the fermentation process cannot meet the heat absorption of the fermentation shelf, ground, and wall surface temperature rise, so steam is introduced through the air mixing system for humidification, heating, and the heating system supplements heat.

[0124] In special cases, when the dough block temperature rises too slowly, an alternative solution can be used, that is, steam is introduced through the air mixing system while the fermentation room is heated and humidified.

[0125] Mid-fermentation period:

[0126] The total duration of the mid-fermentation period is about 10-14 days, and this stage mainly maintains the temperature and humidity of the fermentation room. The dough core temperature rises to 67-68°C after about 3 days and remains stable until the 20th day of fermentation. During the mid-fermentation period, the dough core temperature hardly changes, and the fermentation room environment temperature also needs to be maintained at a certain value. The respiratory heat generated during the fermentation process is not enough to supplement the overall heat loss of the fermentation room. To maintain stable environment temperature, the heating system is preferably used to heat the indoor air, and steam is introduced through the air mixing system to heat and humidify the indoor air, ensuring that the indoor environment temperature and humidity meet the requirements of the dough block fermentation.

[0127] Late fermentation period:

[0128] This stage mainly maintains the temperature and dehumidifies the fermentation room, gradually reducing the humidity of the air in the fermentation room, and the dough core temperature gradually decreases from 67-68°C to about 42°C, which needs to be controlled to decrease slowly. The outdoor air is introduced into the indoor air through the moisture exhaust and oxygen supplement system to replace the indoor air, thereby reducing the humidity of the fermentation room environment. To reduce the impact of changes in the environment temperature on the dough core temperature, the heating system is used.

[0129] The control method of the high-temperature koji described above is summarized in Table 1.

[0130] Table 1. Fermentation control method of high-temperature koji

[0131]

[0132] Example 2

[0133] Medium-high temperature koji (Luzhou-flavor type) is mainly made in spring and autumn, and its control mainly includes 4 stages, and the temperature curve is as follows Figure 9The specific control method is shown in Table 2. In the spring, the average outdoor temperature is 10-20℃, and the average humidity is 60%-75%; in the autumn, the average outdoor temperature is 15-25℃, and the average humidity is 60%-75%.

[0134] Table 2 Control method for high-temperature koji fermentation

[0135]

[0136] If the temperature and humidity difference between the upper and lower layers of the indoor environment of the fermentation room is too large in the middle of fermentation, the control means can use an alternative solution. Specifically, on the basis of the original control means, the heating system is started to heat, so that the temperature of the lower layer of the indoor environment is increased, but at this time the residual heat in the room will be increased, and the amount of outdoor air introduced needs to be increased to control the temperature.

[0137] Example 3

[0138] The koji (qingxiang type) is generally made in the spring and autumn, and its control mainly includes four stages, and the temperature curve is as shown in Figure 10 The indoor temperature of the fermentation room is low when the koji is put in, and the specific control method is shown in Table 3.

[0139] Table 3 Control method for medium-temperature koji fermentation

[0140]

[0141] Although the present application has been disclosed with reference to the preferred embodiments above, it is not intended to limit the present application. Those skilled in the art can make various modifications and improvements without departing from the spirit and scope of the present application. Therefore, the scope of protection of the present application shall be subject to the scope defined by the claims.

Claims

1. A control method of a koji fermentation room system, characterized by, The method comprises the following steps: obtaining real-time monitoring data of the fermentation room, including control parameters and state parameters; the control parameters include dough core temperature, indoor temperature, indoor humidity, CO2 concentration and O2 concentration; the state parameters include outdoor temperature, outdoor humidity and mixed air outlet temperature; selecting a corresponding target control curve from a plurality of pre-set control curve templates according to the current dough type; obtaining a plurality of target values based on the target control curve, including dough core temperature target value, indoor temperature target value, indoor humidity target value, CO2 concentration target value and O2 concentration target value; based on the deviation of each control parameter and the corresponding target value, dynamically selecting and executing at least one of the following control actions: radiation heat type heating of indoor air in the fermentation room through a heating system; atomization humidification of indoor air in the fermentation room through a humidification system; introducing fresh air into the fermentation room through a ventilation system for CO2 concentration and O2 concentration adjustment, or introducing steam for heating and humidification; introducing outdoor air and / or discharging indoor air into the fermentation room through a moisture removal and oxygen supplement system for CO2 concentration and O2 concentration adjustment, and / or cooling and dehumidification; wherein the execution parameters of the control actions are adjusted by PID according to the deviation of each control parameter and the corresponding target value, combined with the state parameters, and the dough core temperature is given priority as the main control variable, and the O2 concentration is given priority as the auxiliary control variable.

2. The koji fermentation room system control method according to claim 1, characterized by, The execution of the control actions further comprises: when the dough core temperature is lower than the dough core temperature target value, and the indoor humidity is lower than the indoor humidity target value, steam is introduced into the fermentation room through the ventilation system for heating and humidification.

3. The koji fermentation room system control method according to claim 1, characterized by, The execution of the control actions further comprises: when the dough core temperature is higher than the dough core temperature target value, and the CO2 concentration is higher than the CO2 concentration target value and / or the O2 concentration is lower than the O2 concentration target value, outdoor air is introduced into the fermentation room through the moisture removal and oxygen supplement system, and indoor air is discharged, for CO2 concentration and O2 concentration adjustment, and cooling.

4. The koji fermentation room system control method according to claim 1, characterized by, The target control curve contains a plurality of sub-curves corresponding to fermentation stages; obtaining a plurality of target values based on the sub-curves, including dough core temperature target value, indoor temperature target value, indoor humidity target value, CO2 concentration target value and O2 concentration target value; based on the deviation of each control parameter and the corresponding target value, dynamically selecting and executing at least one of the control actions.

5. The koji fermentation room system control method according to claim 4, characterized by, The fermentation stages include: preparation stage, early fermentation stage, middle fermentation stage and late fermentation stage.

6. The koji fermentation room system control method according to claim 1, characterized by, The control curve template includes at least three types of fermentation temperature curves of high-temperature dough, medium-high-temperature dough and medium-temperature dough.

7. A koji fermentation room system characterized by comprising: A control method for implementing the wine yeast fermentation room system as claimed in claim 1, comprising a control system and a plurality of fermentation rooms (100); each of the fermentation rooms (100) is provided with: a heating system; a humidification system; a ventilation system; a moisture removal and oxygen supplement system; a detection system including a plurality of dough core temperature sensors, a plurality of environmental temperature and humidity detectors, and a plurality of gas concentration monitors (600); the control system is configured to: Receive the real-time monitoring data of the temperature sensor, the environmental temperature and humidity detector, and the gas concentration monitor (600); Select a target control curve according to the current type of the dough; Output control instructions to the heating system, the humidifying system, the air mixing system, and the moisture removal and oxygen supplement system.

8. The koji fermentation room system according to claim 7, characterized by, The detection system further comprises a plurality of cameras installed in the fermentation room (100) through a connecting base.

9. The koji fermentation room system according to claim 7, characterized by, The detection system further comprises a plurality of weighing sensors arranged at the bottom of the dough block.

10. The koji fermentation room system according to claim 7, characterized by, The air mixing system comprises an air mixing main pipe (400), a plurality of air mixing branch pipes (401), a plurality of guide pipes (402), a compressed air generator, and a steam generator. The air mixing main pipe (400) is arranged at the upper part of the fermentation room (100) and extends horizontally along the length direction of the fermentation room (100). The plurality of guide pipes (402) extend vertically along the height direction of the fermentation room (100), and the upper end and the lower end of each guide pipe are provided with openings. A mixing chamber is arranged below the upper opening, and a mixing temperature sensor is arranged at the lower opening. The two ends of the air mixing branch pipe (401) are connected to the air mixing main pipe and any mixing chamber. The compressed air generator is connected to the air mixing main pipe (400) through a compressed air main pipe (403). The steam generator is connected to the air mixing main pipe (400) through a steam main pipe (404).

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