Atomization process self-adaptive control method and system based on pressure feedback characteristics

Abstract

The invention discloses an atomization process self-adaptive control method and system based on pressure feedback characteristics, and relates to the technical field of atomization process control. Comprising the following steps: S1, collecting gas pressure data in real time, synchronously obtaining a valve opening and closing control state, and carrying out data preprocessing; s2, continuous pressure change characteristics and valve opening and closing control states are analyzed, the actual influence degree of valve actions on pressure is evaluated, and whether an effective pressurizing stage is entered or not is judged; s3, after the effective pressurizing stage is judged, the accumulation degree of the inertia effect in the current pressurizing process is quantified, and pressurizing inertia characteristics are obtained; and S4, integrating the pressure of the current gas and the pressurizing inertia characteristics, predicting the natural evolution of the pressure after the action of the valve is stopped, judging whether the valve is cut off in advance or not, and inhibiting the pressure deviation through compensation adjustment. The problems that in the gas atomization powder preparation process, atomization pressure adjustment response lag and overshoot are difficult to consider at the same time, and consequently atomization stability is reduced and powder quality fluctuates are solved.

Description

Technical Field

[0001] This invention relates to the field of atomization process control technology, specifically to an adaptive control method and system for atomization processes based on pressure feedback characteristics. Background Technology

[0002] Gas atomization powder production is an industrial technology widely used in the preparation of metal and alloy powders. It involves using high-pressure gas to impact and break up molten metal at high speed, causing it to fragment and cool into fine powder. The resulting powder has a significant impact on downstream additive manufacturing, powder metallurgy, and spraying processes in terms of particle size distribution, sphericity, and flowability. During atomization, the pressure state of the high-pressure gas directly affects the metal fragmentation behavior and atomization stability, and is typically regulated and maintained by the gas path system and electric valves. As powder production processes develop towards higher stability, higher consistency, and finer powders, the dynamic control of atomization pressure and its matching with equipment operating conditions have become important engineering problems in the operation and control of gas atomization powder production equipment.

[0003] For example, invention patent CN120984890A discloses a method for preparing flexible circuit board metal material powder by gas atomization. The method involves melting the metal raw materials for flexible circuit boards to obtain molten metal, then using a pressure device to pass the molten metal into an atomizing device for atomization. During atomization, high-pressure gas is used to break up the molten metal into droplets. The droplets are then cooled and collected to obtain metal powder. This method, through stable control of the molten metal, can effectively prepare flexible circuit board-specific metal powder with high sphericity, narrow particle size distribution, and low oxygen content. It significantly improves the powder's flowability and spreading uniformity, making it suitable for precision printing or additive manufacturing processes. It avoids the problems of large particle size deviation and high defect rate caused by traditional atomization methods. The resulting metal powder exhibits excellent conductivity and flexibility after sintering, making it suitable for manufacturing flexible electronic devices in high-frequency, high-flexibility scenarios.

[0004] For example, the invention patent with announcement number CN120901294B discloses a rotating electrode atomization powder making control system and control method. It establishes a multivariate machine learning prediction model between electrode rotation speed, plasma arc power, and protective gas flow rate and powder particle size and sphericity. Based on the target powder particle size and sphericity, the optimal electrode rotation speed, plasma arc power, and protective gas flow rate are calculated using the multivariate machine learning prediction model. The optimal process parameters are applied to the powder making process, and the powder making system is run. During atomization, the electrode rotation speed, arc power, and gas pressure are monitored in real time, and the process parameters are dynamically adjusted to compensate for fluctuations. Images of powder particles in flight are acquired using an image acquisition unit, and the particle size distribution and sphericity are analyzed in real time using an AI vision model. Based on the analysis results, the electrode rotation speed, plasma arc power, and protective gas flow rate are adjusted accordingly.

[0005] However, when existing air atomization powder making equipment uses electric valves for pressure regulation, the valve opening has a dead zone, the valve action and pipeline pressurization inertia are relatively fast, and the pressure transmitter detection is lagging. As a result, it is difficult to balance "rapid pressure arrival" and "avoiding overshoot" during the process of reaching the set atomization pressure. This often leads to problems such as long pressure arrival time, pressure fluctuations or exceeding the set value, which affect the atomization stability and powder quality.

[0006] Therefore, in order to address the above problems, there is an urgent need for an adaptive control method and system for the atomization process based on pressure feedback characteristics. Summary of the Invention

[0007] Technical problems to be solved

[0008] To address the shortcomings of existing technologies, this invention provides an adaptive control method and system for the atomization process based on pressure feedback characteristics. This solves the problem of lag in atomization pressure regulation response and difficulty in balancing overshoot during gas atomization powder production, which leads to decreased atomization stability and fluctuations in powder quality.

[0009] Technical solution

[0010] To achieve the above objectives, the present invention provides the following technical solution: an adaptive control method for the atomization process based on pressure feedback characteristics, comprising the following steps: S1, real-time acquisition of gas pressure data in the pipeline, and simultaneous acquisition of valve opening and closing control status; preprocessing of the acquired pressure data to obtain continuous pressure change characteristics; S2, construction of a sliding time window, analysis of continuous pressure change characteristics and valve opening and closing control status, assessment of the actual impact of valve action on pipeline pressure, and determination of whether the valve has overcome the dead zone and entered the effective pressurization stage; S3, after determining that it is in the effective pressurization stage, analysis of the persistence and intensity characteristics of the pressure rise process, quantification of the accumulation of inertial effect in the current pressurization process, and obtaining pressurization inertial characteristics as input basis for judging the natural evolution of pressure; S4, combining the current gas pressure and pressurization inertial characteristics, predicting the natural evolution of pressure after stopping valve action, and determining whether to prematurely shut down the valve based on the predicted natural evolution of pressure; after the valve shuts down, pressure deviation is suppressed by directional compensation adjustment to achieve rapid arrival and stable maintenance of atomization pressure.

[0011] Furthermore, the pressure data of the gas in the pipeline is collected in real time, and the valve opening and closing control status is acquired simultaneously. The specific process for preprocessing the collected pressure data to obtain continuous pressure change characteristics is as follows: A pressure transmitter located in the high-pressure gas pipeline downstream of the electric ball valve collects the gas pressure value in the pipeline in real time and records the corresponding sampling timestamp. Simultaneously, the valve control signal output from the PLC to the electric ball valve is collected. The gas pressure values ​​in the pipeline are sorted and time-aligned according to the sampling timestamp, and abnormal sampling points caused by instantaneous jumps and communication jitter are detected. When a single point in the pipeline... When the change in gas pressure exceeds the maximum change threshold, the nearest valid value is used to replace the sampling point; smoothing is performed on the gas pressure value in the pipeline within a time window to reduce the impact of sensor noise and pipeline transient disturbances on the judgment of pressure change trend, and minimum-maximum normalization is performed on the gas pressure value in the pipeline; the pressure change rate is calculated based on the gas pressure value in the pipeline at adjacent sampling times using the time difference method; an atomization process control database is established, and the original and pre-processed gas pressure values ​​in the pipeline, pressure change rate, and valve control signals are written into the atomization process control database.

[0012] Furthermore, the specific process of constructing a sliding time window and analyzing the continuous pressure change characteristics and valve opening and closing control state is as follows: After the electric ball valve receives the valve opening control signal and enters the atomization start pressure regulation process, a sliding time window is continuously constructed, and the pressure change rate and valve control signal at the corresponding moment within the sliding time window are acquired in real time. Based on the valve control signal, the valve opening state value is constructed. When the valve control signal is in an effective valve opening state, the valve opening state value is assigned a value of 1, and otherwise it is assigned a value of 0.

[0013] Furthermore, the specific process for evaluating the actual impact of valve action on pipeline pressure is as follows: multiply the pressure change rate at each sampling moment within the sliding time window by the corresponding valve opening state value to obtain the instantaneous response value; integrate the instantaneous response values ​​at all sampling moments within the window to obtain the cumulative pressure change response value; simultaneously, integrate the absolute value of the valve opening state value within the window to obtain the effective valve opening action duration; divide the cumulative pressure change response value by the effective valve opening action duration to obtain the valve action pressure response judgment value.

[0014] Furthermore, the specific process for determining whether the valve has overcome the dead zone and entered the effective pressurization stage is as follows: The valve action pressure response judgment value is calculated in real time. When the valve control signal is in an effective open state, and the corresponding valve action pressure response judgment value shows a cumulative change with time within the sliding time window, it is determined that the electric ball valve's opening action has overcome the dead zone and generated a continuous response to the pipeline pressure, entering the effective pressurization stage. Conversely, when the valve control signal is in an effective open state, but the corresponding valve action pressure response judgment value does not show a cumulative change with time within the sliding time window, it is determined that the electric ball valve's opening action has not yet had an effective impact on the pipeline pressure, and is in the valve's dead zone stage. The valve action pressure response judgment value and the corresponding stage state are written into the atomization process control database to indicate whether the preconditions for entering the pressurization inertia assessment and pressure prediction assessment are met.

[0015] Furthermore, after determining that the effective pressurization stage has been reached, the persistence and intensity characteristics of the pressure rise process are analyzed, and the cumulative degree of inertial effect during the current pressurization process is quantified to obtain the pressurization inertia characteristics. The specific process for using these characteristics as input for judging the natural evolution of pressure is as follows: When the current stage is identified as an effective pressurization stage, the pressurization inertia assessment process is executed: the pressure change rate within the sliding time window is read, the pressure change rate at each sampling moment within the window is squared, and the sign of the pressure change rate at the corresponding moment is determined. When the pressure change rate is positive, the corresponding square of the pressure change rate is retained; when the pressure change rate is non-positive, the square of the pressure change rate is set to zero. The square of the pressure change rate at all sampling moments within the window is integrated to obtain the cumulative intensity value of the pressurization inertia. The cumulative intensity value of the pressurization inertia is continuously monitored during the effective pressurization stage and written into the atomization process control database as input for the pressure prediction assessment process.

[0016] Furthermore, considering the current gas pressure and pressurization inertia characteristics, the specific process for predicting the natural pressure evolution after the valve operation is stopped is as follows: When the current stage is the effective pressurization stage, pressure prediction and evaluation are allowed: Receive the gas pressure value in the pipeline at the current moment, the pressure change rate, and the cumulative intensity value of pressurization inertia; Based on the sliding time window, perform an integral operation on the pressure change rate and add it to the smallest positive number to obtain the cumulative pressure change; divide the current cumulative intensity value of pressurization inertia by the cumulative pressure change to obtain the equivalent duration of pressurization inertia; add the equivalent duration of pressurization inertia to the current gas pressure value in the pipeline to obtain the natural pressure prediction value.

[0017] Furthermore, the specific process for determining whether to prematurely shut off the valve based on the pressure natural evolution prediction results is as follows: continuously monitor the predicted value of natural pressure and compare it with the atomization pressure threshold: when the predicted value of natural pressure is greater than or equal to the atomization pressure threshold, it is determined that after stopping the valve opening action at the current moment, the pipeline pressure can naturally reach the target pressure level under the action of inertia, and an early shut-off command is generated; when the predicted value of natural pressure is less than the atomization pressure threshold, it is determined that stopping the valve opening action at the current moment will result in the target pressure not being reached, and the existing valve opening control state is maintained; the early shut-off command is sent to the PLC, the valve opening control signal is immediately stopped, and the current valve position state of the electric ball valve is locked.

[0018] Furthermore, the specific process of suppressing pressure deviation through directional compensation adjustment to achieve rapid arrival and stable maintenance of atomization pressure is as follows: After the electric ball valve is closed, the change in gas pressure value in the pipeline is continuously monitored. When the gas pressure value in the pipeline deviates from the maximum pressure range centered on the atomization pressure threshold, and the duration of the deviation exceeds the allowable time threshold, compensation control is triggered: according to the direction of deviation, the electric ball valve is operated intermittently for a limited duration to correct the pressure deviation; at the end of the atomization stage, a valve closing command is generated and sent to the PLC to control the electric ball valve to continue to close until the opening is 0% and then stop closing the valve; the predicted value of natural pressure arrival, the early closing command, the valve control status, and the change data of gas pressure value in the pipeline during the pressure stabilization process are written into the atomization process control database as a record of the complete atomization pressure regulation process.

[0019] The second aspect of this invention provides an adaptive control system for the atomization process based on pressure feedback characteristics, comprising: a pressure data acquisition and processing module for real-time acquisition of gas pressure data in the pipeline and simultaneous acquisition of valve opening and closing control status; preprocessing the acquired pressure data to obtain continuous pressure change characteristics; an atomization stage coupling identification module for constructing a sliding time window, analyzing the continuous pressure change characteristics and valve opening and closing control status, evaluating the actual impact of valve action on pipeline pressure, and determining whether the valve has overcome the dead zone and entered the effective pressurization stage; a pressurization inertia accumulation quantification module for analyzing the persistence and intensity characteristics of the pressure rise process after determining that it is in the effective pressurization stage, quantifying the accumulation degree of inertia effect in the current pressurization process, obtaining pressurization inertia characteristics, and using them as input for judging the natural evolution of pressure; and a pressure prediction and cutoff control module for comprehensively considering the current gas pressure and pressurization inertia characteristics to predict the natural evolution of pressure after the valve action is stopped, and determining whether to cut off the valve in advance based on the pressure natural evolution prediction results; and after the valve is cut off, suppressing pressure deviation through directional correlation compensation adjustment to achieve rapid arrival and stable maintenance of atomization pressure.

[0020] Beneficial effects

[0021] The present invention has the following beneficial effects:

[0022] (1) This invention, through the coupled analysis of pressure change characteristics and valve control status, can accurately identify whether the electric ball valve has overcome the dead zone of effectiveness and has a real effect on pipeline pressure during the atomization start-up pressure regulation process, avoid blind adjustment when the valve has not yet taken effect, and improve the reliability of the atomization pressure regulation process.

[0023] (2) In this invention, by comprehensively evaluating the duration and intensity of the pressure rise process during the effective pressurization stage, a characteristic quantity characterizing the pressurization inertia effect is formed, enabling the system to reflect the inertial accumulation state of gas pressure in the pipeline, and providing a reliable basis for subsequent pressure natural evolution prediction.

[0024] (3) The present invention, by combining the current pressure state and the characteristics of pressurization inertia, predicts the natural evolution of pressure after the valve stops operating, and can determine the best cut-off time without relying on empirical parameters, effectively shortening the time for atomization pressure to reach, while reducing the risk of pressure overshoot and fluctuation.

[0025] (4) In this invention, when the pressure deviates from the target range, the valve is adjusted in a limited manner according to the direction of deviation to avoid frequent or large valve actions, thereby achieving stable maintenance of atomization pressure and improving the stability of the atomization process and the consistency of powder quality.

[0026] Of course, any product implementing this invention does not necessarily need to achieve all of the advantages described above at the same time. Attached Figure Description

[0027] Figure 1 The flowchart shows the adaptive control method for the atomization process based on pressure feedback characteristics.

[0028] Figure 2 This is a structural diagram of an adaptive control system for the atomization process based on pressure feedback characteristics.

[0029] Figure 3 This is a trend chart for predicting the natural pressure to full pressure based on the characteristics of pressurization inertia.

[0030] Figure 4 This is a schematic diagram of a high-pressure gas transmission pipeline structure.

[0031] Figure 5 This is a schematic diagram of an adaptive control circuit for the atomization process based on pressure feedback characteristics. Detailed Implementation

[0032] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. As those skilled in the art will understand, 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.

[0033] Please see Figures 1-5 This invention provides a technical solution: an adaptive control method for the atomization process based on pressure feedback characteristics, such as... Figure 1 As shown, the process includes the following steps: S1, real-time acquisition of gas pressure data in the pipeline and simultaneous acquisition of valve opening and closing control status; preprocessing of the acquired pressure data to obtain continuous pressure change characteristics; S2, construction of a sliding time window, analysis of continuous pressure change characteristics and valve opening and closing control status, assessment of the actual impact of valve action on pipeline pressure, and determination of whether the valve has overcome the dead zone and entered the effective pressurization stage; S3, after determining that it is in the effective pressurization stage, analysis of the persistence and intensity characteristics of the pressure rise process, quantification of the accumulation of inertial effect during the current pressurization process, and obtaining pressurization inertial characteristics as input basis for judging the natural evolution of pressure; S4, combining the current gas pressure and pressurization inertial characteristics, predicting the natural evolution of pressure after stopping valve action, and determining whether to shut down the valve in advance based on the prediction results of the natural evolution of pressure; after the valve is shut down, pressure deviation is suppressed by directional compensation adjustment to achieve rapid arrival and stable maintenance of atomized pressure.

[0034] Specifically, the system collects real-time pressure data of the gas in the pipeline and simultaneously acquires the valve opening and closing control status. The preprocessing of the collected pressure data to obtain continuous pressure change characteristics involves: a pressure transmitter located in the high-pressure gas pipeline downstream of the electric ball valve collects the gas pressure value in real-time and records the corresponding sampling timestamp; simultaneously, the valve control signal output from the PLC to the electric ball valve is acquired. The pressure transmitter is directly connected to the gas in the pipeline, and its range covers the entire pressure range required for the atomization process. The analog signal output by the pressure transmitter is converted into a digital signal by the PLC analog signal acquisition module before participating in subsequent data processing. The valve control signal is the open or closed valve control status output by the PLC, used to characterize whether the electric ball valve is in operation at the current moment. The sampling frequency is set by the programmable logic controller (PLC) according to control accuracy requirements, ranging from 100Hz to 500Hz. This ensures complete coverage of the rapid pressure changes in the pipeline during the electric ball valve's activation and effective pressurization stages, while also considering the data processing capabilities and real-time requirements of the control system, guaranteeing the temporal continuity and traceability of the pressure change process.The gas pressure values ​​in the pipeline are sorted and time-aligned according to the sampling timestamp to ensure that the pressure data and valve control signals are analyzed together on the same time reference, avoiding distortion of the correspondence between pressure changes and valve actions due to sampling delays or communication asynchrony. Abnormal sampling points caused by instantaneous jumps and communication jitter are detected. When the change in gas pressure value at a single point in the pipeline exceeds the maximum change threshold, the sampling point is replaced with the nearest valid value. The maximum change threshold can be determined based on three times the absolute deviation of the median of the pressure change sequence, used to distinguish between true pressure changes and non-physical jumps caused by electromagnetic interference, communication jitter, or transient noise. The nearest valid value is selected as the valid pressure data closest in time to the abnormal sampling point to maintain the continuity of the pressure sequence. The gas pressure values ​​in the pipeline are smoothed within a time window, preferably using a moving average filter, to reduce the impact of sensor noise and pipeline transient disturbances on the judgment of pressure change trends. The time window length is preferably 3 to 10 sampling points, used to smooth the pressure without weakening the true pressure rise. Under the premise of trend analysis, the interference of high-frequency noise on subsequent pressure change rate calculation and trend judgment is reduced. Minimum-maximum normalization is performed on the gas pressure values ​​in the pipeline, mapping the pressure data to a unified normalized numerical range to construct a dimensionless feature space for pressure changes. This ensures comparability of pressure change characteristics under different operating conditions and pressure ranges, facilitating subsequent feature evaluation based on trends and relative changes, without relying on specific absolute pressure dimensions. The pressure change rate is calculated using the time difference method based on the gas pressure values ​​in the pipeline at adjacent sampling times, characterizing the pressure change trend per unit time. The pressure difference and corresponding time interval based on adjacent sampling times are calculated to reflect the dynamic response characteristics of the gas pressure in the pipeline. A nebulization process control database is established, writing the original and pre-processed gas pressure values ​​in the pipeline, pressure change rate, and valve control signals into the database. This provides unified data support for nebulization stage identification, pressurization inertia assessment, natural pressure prediction, and subsequent control decisions, and also serves for historical record recording and operational status tracing of the nebulization process.

[0035] like Figure 4The diagram shows a schematic of a high-pressure gas delivery pipeline. In the diagram, 1 represents a pressure transmitter, 2 represents an electric ball valve, and 3 represents a manual shut-off valve, all arranged sequentially on the high-pressure gas delivery pipeline. The electric ball valve, as a key pressure regulating component in the atomization process, directly affects the pressure rise of the gas in the pipeline due to its opening change. The pressure transmitter is used to monitor the gas pressure changes downstream of the electric ball valve in real time. The manual shut-off valve is used for equipment maintenance or emergency isolation and does not participate in automatic pressure regulation control. During the atomization start-up pressure regulation process, due to the effective opening dead zone of the electric ball valve, although the valve is continuously open in the initial stage, the gas in the pipeline has not yet formed effective flow, and the pressure transmitter feedback value is close to zero. When the valve opening exceeds the effective range, gas begins to enter the pipeline, and the pressure feedback signal gradually increases. Combining the above structural characteristics, after pressure feedback occurs, the valve opening is precisely controlled through intermittent valve actuation and pressure trend assessment. When the predicted pressure condition is reached, the valve opening action is stopped in time, allowing the pipeline pressure to naturally evolve to the target atomization pressure under inertia, thus balancing rapid pressure rise and pressure stability.

[0036] like Figure 5 The diagram shows the schematic of an adaptive control circuit for the atomization process based on pressure feedback characteristics. It is used to achieve the opening and closing control of the electric ball valve and real-time acquisition and feedback of pipeline pressure. A DC power supply is used, where DV is the positive terminal of 24V DC and DM is the negative terminal of 24V DC, providing operating power to the electric ball valve and pressure transmitter. The electric ball valve is controlled through three terminals: a remote opening terminal, a remote closing terminal, and a common terminal. The common terminal is supplied with a 24V positive DC voltage internally by the valve, eliminating the need for an external power supply to the PLC. The PLC drives intermediate relays K1 and K2 through two digital outputs: when the PLC outputs an open valve command, the corresponding digital output activates relay K1, connecting its normally open contact to the common terminal and the remote opening terminal, thereby driving the electric ball valve to perform the opening action; when the PLC outputs a close valve command, the corresponding digital output activates relay K2, connecting its normally open contact to the common terminal and the remote closing terminal, thereby driving the electric ball valve to perform the closing action. The pressure transmitter is installed in the high-pressure gas pipeline downstream of the electric ball valve. Its output analog signal is input to the PLC via the PLC's analog input terminals AI+ and AI− to characterize the gas pressure state in the pipeline in real time, providing basic data for subsequent atomization stage identification, pressurization inertia assessment, and pressure prediction control. The circuit structure shown in the figure achieves a decoupled connection between valve actuation and pressure feedback, ensuring reliable control action and continuous pressure acquisition, providing a feasible hardware foundation for adaptive control strategies based on pressure feedback characteristics.

[0037] In this implementation scheme, by synchronously acquiring and uniformly preprocessing the gas pressure in the pipeline and the valve control status, a pressure change feature sequence that is time-continuous, noise-suppressed, and comparable is constructed. This effectively reduces the impact of sensor noise, communication jitter, and transient disturbances on pressure judgment while ensuring the data's authenticity and usability. Through time alignment, outlier correction, smoothing, and normalization, the pressure change features can accurately reflect the true relationship between valve action and pipeline response, providing a stable and reliable data foundation for subsequent atomization stage identification, pressurization inertia assessment, and pressure prediction, thereby improving the response accuracy and control stability of the atomization pressure regulation process.

[0038] Specifically, the process of constructing a sliding time window to analyze the continuous pressure change characteristics and valve opening / closing control state is as follows: After the electric ball valve receives the valve opening control signal and enters the atomization start-up pressure regulation process, the programmable logic controller (PLC) triggers the atomization start-up state flag bit, and the sliding time window mechanism is activated in the current state. The sliding time window is continuously constructed, and the pressure change rate and valve control signal at the corresponding moment within the sliding time window are acquired in real time. The sliding time window ends at the current sampling moment, and the window length is set according to the valve response characteristics and dynamic pressure change characteristics, preferably 1 to 3 seconds, to cover the effective time range of the valve action affecting the pressure. This ensures that the window covers the pressure change process in the initial stage of valve operation while avoiding the introduction of irrelevant historical data that could interfere with the judgment results. The window is updated by scrolling forward with the sampling moment to ensure the real-time and continuous nature of the analysis process. An opening state value is constructed based on the valve control signal. The opening state value is a binary ratio; when the valve control signal is in a valid opening state, the opening state value is assigned a value of 1, and otherwise, a value of 0. Among them, the valve control signal comes from the valve drive command output by the PLC. It is used to clearly characterize whether the electric ball valve is in the control state of performing valve opening action at each sampling time. The valve opening state value is synchronized with the pressure change rate as a discrete state quantity in time. It is used to evaluate the coupling relationship between valve action and pressure change in the future, thereby avoiding the control ambiguity introduced by judging solely based on the pressure signal.

[0039] In this implementation plan, by synchronously collecting and uniformly preprocessing the gas pressure and valve control status in the pipeline, a stable and continuous pressure change characteristic is constructed. While suppressing the influence of noise and abnormal disturbances, the temporal consistency and analyzability between pressure data and valve actions are improved. By combining the sliding time window to perform correlation analysis between pressure change trends and valve status, the valve's effective behavior can be accurately identified and quantified, providing a reliable basis for subsequent pressurization stage judgment and control decisions. This enhances the stability, repeatability, and engineering feasibility of pressure regulation control in the atomization process.

[0040] Specifically, the process for evaluating the actual impact of valve action on pipeline pressure is as follows: The pressure change rate at each sampling moment within the sliding time window is multiplied by the corresponding valve-opening state value to obtain the instantaneous response value. This instantaneous response value characterizes the immediate response of pipeline pressure to valve action per unit time when the valve is in the open state. When the valve is in the closed state, the pressure change rate is suppressed by setting the valve-opening state value to 0, thus avoiding interference from pressure fluctuations caused by non-valve factors on the valve response evaluation. The instantaneous response values ​​at all sampling moments within the window are integrated to obtain the cumulative pressure change response value. This integration accumulates the instantaneous response values ​​within the sliding time window, reflecting the overall impact of valve action on pipeline pressure within the time window. The integration can be implemented using a discrete summation method, facilitating real-time calculation in the PLC computing unit. Simultaneously, the absolute value of the valve opening state within the window is integrated to obtain the effective valve opening action duration. This effective valve opening action duration characterizes the cumulative duration the valve is actually in the open state within the sliding time window. By integrating the valve opening state value, statistical deviations in duration caused by intermittent valve action or control jitter can be avoided. The valve action pressure response judgment value is obtained by dividing the cumulative pressure change response value by the effective valve opening action duration. This value quantifies the average pressure change level caused by the valve within a unit effective valve opening time, thereby eliminating the influence of different valve opening durations on the pressure response evaluation results. This ensures the judgment value stably reflects whether the valve action has had a substantial and continuous effect on the pipeline pressure, making it suitable as an objective basis for subsequent valve effectiveness determination.

[0041] The specific formula for determining the valve's action pressure response value is as follows:

[0042] ;

[0043] In the formula, This indicates the valve action pressure response judgment value, which is used to quantitatively determine whether the opening action of the electric ball valve has produced a real and effective response to the pipeline pressure. It uses the pressure change rate to reflect whether the pressurization has actually occurred, and eliminates the influence of the valve's ineffective stage and irrelevant pressure disturbances, thereby determining whether the electric ball valve has overcome the effective dead zone and entered the effective pressurization stage. This indicates the end point of the sliding time window, i.e., the current time. Indicates the start time of the sliding time window; This represents any moment within the sliding time window and is the integration time variable; This indicates the valve open status value, used to indicate whether the valve is in a valid open state; This indicates the gas pressure value inside the pipeline, used to reflect the real-time pressure level of the atomizing gas path; It represents the rate of pressure change, used to characterize whether the pressure is rising and the dynamic intensity of the rise, and is an important characteristic quantity for determining whether pressurization has begun.

[0044] In this implementation scheme, by jointly analyzing pressure change characteristics and valve control status within a sliding time window, the actual effect of valve action on pipeline pressure can be objectively quantified, effectively distinguishing the valve's dead zone from the actual pressurization stage and avoiding misjudgments caused by relying solely on valve position or instantaneous pressure. Simultaneously, by performing time normalization on the pressure response, the evaluation results are unaffected by valve opening time and control jitter, improving the stability and robustness of valve effectiveness identification and pressurization process judgment. This provides a reliable and feasible data foundation for subsequent pressurization inertia assessment and pressure prediction, facilitating the rapid establishment and stable control of atomized pressure.

[0045] Specifically, the process for determining whether a valve has overcome its dead zone and entered the effective pressurization stage is as follows: The valve action pressure response judgment value is calculated in real time, reflecting the effective response intensity of pipeline pressure changes over time under the valve's opening command. When the valve control signal is in an effective open state, and the corresponding valve action pressure response judgment value shows a cumulative change increasing over time within the sliding time window, it indicates that within multiple consecutive sampling moments, the valve opening action has had a stable and continuous positive impact on the gas flow in the pipeline, and the pressure change is no longer solely caused by noise or transient disturbances. This indicates that the electric ball valve's opening action has overcome its dead zone and produced a continuous response to the pipeline pressure, entering the effective pressurization stage. Conversely, when the valve control signal is in an effective open state, but the corresponding valve action pressure response judgment value does not show a cumulative change increasing over time within the sliding time window, it indicates that although the valve is in an open state... Under control commands, but if the valve core has not yet reached the effective opening degree that allows stable gas passage, or if the pressure change is still at a random fluctuation level, it is determined that the opening action of the electric ball valve has not yet had an effective impact on the pipeline pressure and is in the valve's dead zone stage. Entering the subsequent evaluation would be meaningless. Among them, "exhibiting a cumulative change with time within the sliding time window" is used to characterize the continuous increasing trend of the valve action pressure response judgment value. Its determination can be achieved through the following formal conditions: Based on the continuously calculated valve action pressure response judgment value, when the increment of the judgment value at adjacent moments within the sliding time window is higher than the minimum effective increment threshold, it is determined that the valve action pressure response judgment value exhibits a cumulative change with time. The minimum effective increment threshold can be adaptively determined based on the baseline noise level, preferably 1.5 to 3 times the absolute deviation of the median of the valve action pressure response judgment value within the sliding time window. The valve action pressure response judgment value and the corresponding stage status are written into the atomization process control database to indicate whether the preconditions for entering the pressurization inertia assessment and pressure prediction assessment are met. This is used to clearly identify the current coupling state of the valve and pipeline in the control logic and serve as the precondition for whether to start the pressurization inertia assessment and natural pressure prediction process. This avoids the accidental triggering of subsequent control strategies before the valve has taken effect, thereby improving the reliability and feasibility of the overall control process.

[0046] In this implementation scheme, by introducing a coupling judgment mechanism between valve action and pressure change, the dead zone stage of valve activation can be accurately identified and eliminated before the valve actually takes effect, avoiding misjudging noise or transient disturbances as effective pressurization behavior. This ensures that subsequent inertial assessment and pressure prediction are performed only under real pressurization conditions, effectively improving the judgment accuracy, control stability and overall response reliability of the atomization pressure regulation process.

[0047] Specifically, after determining that the pressure is in an effective pressurization phase, the duration and intensity of the pressure rise process are analyzed, and the cumulative degree of inertial effect during the current pressurization process is quantified to obtain the pressurization inertial characteristics. The specific process for using these characteristics as input for judging the natural evolution of pressure is as follows: When the current stage is identified as an effective pressurization phase, the pressurization inertial assessment process is executed: the pressure change rate within the sliding time window is read, reflecting the dynamic change trend of pipeline pressure per unit time. The pressure change rate at each sampling moment within the window is squared. This square operation enhances the contribution of the pressure change rate amplitude to the inertial assessment result, giving higher weight to continuous and large-amplitude pressure rise processes in the assessment result. The sign of the pressure change rate at the corresponding moment is determined; when the pressure change rate is positive, it is considered positive. The corresponding square of the pressure change rate is retained to characterize the pressurization behavior that actually contributes to the continuous rise in pressure. When the pressure change rate is non-positive, the square of the pressure change rate is set to zero to avoid the pressure drop or stagnation interfering with the pressurization inertia assessment results. The square of the pressure change rate at all sampling moments within the window is integrated. By accumulating the intensity of positive pressure change over time, the persistence and intensity characteristics of the pressure rise during the current pressurization process are comprehensively reflected, and the cumulative intensity value of pressurization inertia is obtained. The cumulative intensity value of pressurization inertia is continuously monitored during the effective pressurization phase and updated in real time according to the update rhythm of the sliding time window, so that the inertial characteristics can dynamically reflect the evolution trend of the current pressurization state and be written into the atomization process control database as input to the pressure prediction and assessment process.

[0048] The specific formula for the cumulative strength value of pressurized inertia is as follows:

[0049] ;

[0050] In the formula, It represents the cumulative intensity of pressurization inertia, used to quantify the degree of inertial accumulation during the pipeline pressure rise process in the effective pressurization stage. By squaring and accumulating the positive pressure change rate within the sliding time window, it highlights the continuous and strong pressure rise behavior. At the same time, it eliminates the influence of pressure drop or no rise stage through the indicator function, thus forming a characteristic quantity that characterizes the strength of the pressurization inertia effect. This indicates the end point of the sliding time window, i.e., the current time. Indicates the start time of the sliding time window; This represents any moment within the sliding time window and is the integration time variable; This indicates the gas pressure value inside the pipeline, used to reflect the real-time pressure level of the atomizing gas path; It represents the rate of pressure change, used to depict the trend and intensity of pipeline pressure changes over time, and is a key dynamic characteristic for determining whether the pressure continues to rise. This indicates an indicator function. It takes the value 1 when the rate of pressure change is positive, which is used to retain the pressure rise phase; and takes the value 0 when the rate of pressure change is non-positive, which is used to eliminate the influence of pressure drop or fluctuation phases on inertia accumulation.

[0051] In this implementation scheme, by jointly quantifying the intensity and duration of pressure changes during the effective pressurization phase, the inertial accumulation effect formed during the rise of gas pressure in the pipeline can be accurately characterized, avoiding the interference of instantaneous fluctuations on inertial judgment, and providing stable and reliable feature inputs for subsequent natural pressure evolution prediction, thereby improving the accuracy of overshoot suppression and pressure arrival timing judgment and the overall control stability during atomization pressure regulation.

[0052] Specifically, considering the current gas pressure and pressurization inertia characteristics, the specific process for predicting the natural pressure evolution after the valve operation stops is as follows: When the current stage is an effective pressurization stage, pressure prediction and evaluation are allowed: Based on the judgment results of the preceding atomization stage coupling identification module and the pressurization inertia accumulation quantification module, it is confirmed that the current pipeline pressure change has entered a continuous and stable effective pressurization state, thereby avoiding premature prediction before the valve has taken effect or the pressure response is unstable, ensuring that the preconditions for pressure prediction are clear and physically meaningful; The current pipeline gas pressure value, pressure change rate, and pressurization inertia accumulation intensity value are received; Among them, the current pipeline gas pressure value is used to characterize the actual pressure level at the prediction start time, the pressure change rate is used to reflect the current pressurization speed characteristics, and the pressurization inertia accumulation intensity value is used to characterize the inertia accumulation intensity formed during the pressure rise in the previous time period; Based on the sliding time window, the pressure change rate is integrated and added to the smallest positive number. The cumulative pressure change is obtained, reflecting the overall magnitude of pressure change within the time window. This is used to normalize the scale of inertial characteristics, avoiding inconsistencies in prediction results caused by different pressurization rates or window lengths. The equivalent duration of pressurization inertia is obtained by dividing the current cumulative pressurization inertia value by the cumulative pressure change. Essentially, this normalizes the "accumulated inertia intensity" according to the "current pressure growth scale," thus obtaining the "sustainable pressure increment" that inertia can still equivalently drive the pressure to continue increasing after the valve opening stops. This is used to characterize the equivalent pressure contribution that the gas pressure in the pipeline may continue to increase under the action of inertia after the valve operation stops. The equivalent duration of pressurization inertia is added to the current gas pressure value in the pipeline to obtain the natural pressure prediction value. The natural pressure prediction value is used to simulate the natural evolution of pipeline pressure under the condition that no external regulation is applied when the valve opening operation is stopped immediately at the current moment. This provides a direct and quantifiable decision basis for whether to shut down the valve in advance.

[0053] The specific formula for predicting natural pressure is as follows:

[0054] ;

[0055] In the formula, This represents the natural pressure prediction value, which is used to predict the pressure level that the pipeline pressure may naturally evolve to after the valve operation stops during the effective pressurization phase. It estimates the subsequent pressure increment under inertial action by combining the current pressure state with the inertial accumulation characteristics formed during the pressurization process, thereby obtaining the natural pressure prediction value. This indicates the end point of the sliding time window, i.e., the current time. Indicates the start time of the sliding time window; This represents any moment within the sliding time window and is the integration time variable; It represents the cumulative inertial strength during pressurization, used to characterize the cumulative inertial strength formed during the pressure rise within the sliding time window, reflecting the potential for the pressure to continue rising; This indicates the gas pressure value inside the pipeline, serving as the starting point for pressure prediction; It represents the rate of pressure change, used to characterize the dynamic characteristics of pipeline pressure changes over time, and is an important basic quantity for assessing pressure persistence trends. This represents extremely small positive numbers, preventing the denominator from being zero or close to zero, ensuring computational feasibility, while suppressing the inertial amplification effect in the low dynamic range and enhancing physical rationality. The preferred value range is... arrive .

[0056] In this embodiment, Table 1 is a data table of predicted values ​​for natural pressure rise. The table details the normalized gas pressure in the pipeline, the cumulative intensity of pressurization inertia, the cumulative pressure change, and the predicted value for natural pressure rise at five different times. Specifically, the normalized gas pressure in the pipeline at time 1 is 0.55, the cumulative intensity of pressurization inertia is 0.00210, the cumulative pressure change is 0.150, and the predicted value for natural pressure rise is 0.564; the normalized gas pressure in the pipeline at time 2 is 0.58, the cumulative intensity of pressurization inertia is 0.00245, the cumulative pressure change is 0.142, and the predicted value for natural pressure rise is 0.597; the normalized gas pressure at time 3 is... The normalized gas pressure in the pipeline at time 4 is 0.61, the cumulative pressure inertia is 0.00280, the cumulative pressure change is 0.134, and the predicted natural pressure drop is 0.631. The normalized gas pressure in the pipeline at time 4 is 0.63, the cumulative pressure inertia is 0.00305, the cumulative pressure change is 0.128, and the predicted natural pressure drop is 0.654. ​​The normalized gas pressure in the pipeline at time 5 is 0.65, the cumulative pressure inertia is 0.00320, the cumulative pressure change is 0.122, and the predicted natural pressure drop is 0.676.

[0057] Table 1. Predicted values ​​of natural pressure.

[0058]

[0059] like Figure 3 The figure shows the natural pressure to pressure prediction trend based on the pressurization inertia characteristics. The horizontal axis represents the time number during the atomization start-up and pressure regulation process, and the vertical axis represents the normalized pressure-related values. Solid dots represent the current gas pressure value in the pipeline, solid square dots represent the natural pressure to pressure prediction value obtained based on the pressurization inertia characteristics, and dashed lines represent the target atomization pressure threshold. It illustrates the relationship between the actual pressure and the natural pressure to pressure prediction results over time during the effective pressurization phase. (See Table 1 and...) Figure 3 It can be seen that the predicted natural pressure rise value is consistently higher than the current pipeline pressure value, indicating that even when the valve is still open, the existence of continuously releasing pressurizing inertia within the pipeline has been identified, providing a basis for the subsequent natural pressure rise. Furthermore, the predicted natural pressure rise value crosses the atomization pressure threshold before the actual pressure, indicating that even if the valve is stopped prematurely at the current moment, the pipeline pressure can still naturally reach the target atomization pressure under inertial action, providing a reliable criterion for early control cutoff. Simultaneously, the prediction results are consistent with the pressure rise trend and change smoothly, indicating that the prediction method based on pressurizing inertia characteristics can stably reflect the pressure evolution trend and avoid overshoot risks caused by sensor lag. Moreover, it can be seen that the predicted natural pressure rise value at time 4 is already higher than the threshold, indicating that the valve can be shut off at this point, and the pressure can still meet the conditions.

[0060] In this implementation plan, under the premise that the pipeline has entered a stable and effective pressurization state, the real-time pressure information and pressurization inertia characteristics are modeled in a unified manner. By performing scale normalization processing on the inertial effect, the natural evolution trend of pressure after valve shutdown can be quantitatively predicted. This transforms the valve shut-off timing from experience-based judgment to prediction decision based on physical characteristics, effectively reducing the risks of pressure overshoot and pressure hysteresis, and improving the accuracy, stability and controllability of the atomization pressure establishment process.

[0061] Specifically, the process for determining whether to prematurely shut down the valve based on the pressure natural evolution prediction results is as follows: The predicted natural pressure rise value is continuously monitored. This value reflects the predicted pressure level that the pipeline pressure might reach under inertia if the valve operation is stopped immediately at the current moment. This predicted pressure level is compared with the atomization pressure threshold, which is determined based on the target atomization pressure set by the process and serves as the criterion for pressure regulation control. The predicted natural pressure rise value and the atomization pressure threshold are in the same normalized space. When the predicted natural pressure rise value is greater than or equal to the atomization pressure threshold, it is determined that after stopping the valve opening operation at the current moment, the pipeline pressure can naturally reach the target pressure level under inertia. An early shutdown command is generated to instruct the control system not to further increase the valve opening. To avoid pressure overshoot or drastic fluctuations caused by continuous valve opening; when the predicted natural pressure is less than the atomization pressure threshold, it is determined that stopping the valve opening action will prevent the target pressure from being reached. The existing valve opening control state is maintained to ensure that the pipeline pressure is still in a state of continuous rise, meeting the requirements for pressure build-up speed during the atomization start-up phase; an early stop command is sent to the PLC to immediately stop outputting the valve opening control signal and lock the current valve position of the electric ball valve. Valve position locking is used to keep the valve control signal unchanged during the inertial pressurization phase, so that the valve opening remains unchanged, avoiding frequent valve start-stop due to control jitter or repeated commands, thereby ensuring the continuity and stability of the natural pressure evolution process and preventing repeated start-stop actions during the inertial pressurization process.

[0062] In this implementation plan, by directly incorporating the pressure natural evolution prediction results into the valve shut-off determination, the valve control is transformed from a passive response to a forward-looking decision based on inertial behavior. This allows the valve opening action to be stopped in advance while ensuring that the target atomization pressure can be reached, effectively suppressing pressure overshoot and pressure regulation oscillation. At the same time, it reduces the mechanical shock caused by frequent valve start-stop, and improves the stability, controllability and overall operational reliability of the atomization pressure build-up process.

[0063] Specifically, the process of suppressing pressure deviation through direction-dependent compensation adjustment to achieve rapid arrival and stable maintenance of atomization pressure is as follows: After the electric ball valve is closed, the change in gas pressure value in the pipeline is continuously monitored. Pressure monitoring is performed based on the real-time feedback signal of the pressure transmitter and maintains the same dimension and time reference as the atomization pressure threshold to ensure the consistency and reliability of compensation judgment. When the gas pressure value in the pipeline deviates from the maximum pressure range centered on the atomization pressure threshold, and the duration of the deviation exceeds the allowable time threshold, compensation control is triggered. The maximum pressure range is used to limit the allowable pressure fluctuation range in the atomization process, and the upper and lower limits of the maximum pressure range are preferably set to ±2% to ±5% of the atomization pressure threshold. The allowable time threshold is used to distinguish between transient fluctuations and continuous deviations, preferably 0.5 seconds to 3 seconds, to avoid frequent triggering of compensation actions due to short-term noise or transient disturbances. According to the direction of deviation, the electric ball valve is operated intermittently for a limited duration to correct the pressure deviation. The intermittent opening or closing operation refers to the programmable logic controller (PLC) performing a fixed compensation control according to the specified time. The system employs a pulse-based control mechanism. Within a continuous control cycle, a short-duration, effective valve opening or closing control signal is output only at discrete compensation moments. Between adjacent compensation moments, the valve control signal remains inactive, causing the electric ball valve opening to change in discrete, stepwise increments rather than continuously. When the pressure is below the lower limit of the maximum pressure range, gas pressure is replenished through restricted intermittent valve opening operations. When the pressure is above the upper limit of the maximum pressure range, pressure is suppressed from further increases through restricted intermittent valve closing operations. The limited duration constrains the impact of a single compensation action, preventing over-compensation from causing new pressure fluctuations. The limited duration is the duration of a single valve opening or closing action, preferably 0.1 to 0.5 seconds. The time interval between two adjacent compensation actions is preferably not less than 1 second, limiting the impact of a single compensation on pipeline pressure and avoiding new pressure fluctuations caused by continuous or excessive adjustments. The compensation control is pulse-based, with each compensation action corresponding to an independent, time-limited control pulse. The amplitude is determined by the inherent actuation characteristics of the valve, and the effect is progressively corrected through a pressure feedback closed loop. At the end of the atomization stage, a valve closing command is generated and sent to the PLC to control the electric ball valve to continue closing until the opening reaches 0%, thus ensuring that the pipeline is in a safe and stable closed state after atomization, avoiding residual pressure or malfunctions from affecting subsequent processes. The predicted value of natural pressure rise, the early shutdown command, the valve control status, and the changes in gas pressure in the pipeline during the pressure stabilization process are written into the atomization process control database to form a complete record of the atomization pressure regulation process. This allows for traceable analysis of pressure regulation behavior, compensation effect, and operating status, providing data support for subsequent process optimization and system maintenance, and serving as a record of the complete atomization pressure regulation process.

[0064] In this implementation scheme, a limited compensation adjustment mechanism based on the direction and duration of pressure deviation is introduced after the valve is shut off, enabling the atomization pressure to quickly return to and stabilize within the allowable fluctuation range. This avoids misadjustment caused by transient noise and prevents new pressure oscillations caused by overcompensation. Combined with clear constraints on the compensation timing, amplitude, and triggering conditions, the atomization pressure adjustment process is made controllable, stable, and traceable, thereby effectively improving the stability, safety, and process consistency of pressure control during the atomization stage.

[0065] Reference Figure 2 As shown, the second aspect of the present invention provides an adaptive control system for the atomization process based on pressure feedback characteristics, applied to the aforementioned adaptive control method for the atomization process based on pressure feedback characteristics. The system includes: a pressure data acquisition and processing module for real-time acquisition of gas pressure data within the pipeline and simultaneous acquisition of valve opening and closing control status; preprocessing the acquired pressure data to obtain continuous pressure change characteristics; and an atomization stage coupling identification module for constructing a sliding time window, analyzing the continuous pressure change characteristics and valve opening and closing control status, evaluating the actual impact of valve action on pipeline pressure, and determining whether the valve has overcome the dead zone and entered the effective phase. The system comprises several modules: an effective pressurization phase; a pressurization inertia accumulation quantification module, which analyzes the duration and intensity of the pressure rise after determining that the phase is effective, quantifies the accumulation of inertial effects during the current pressurization process, and obtains pressurization inertia characteristics as input for judging the natural evolution of pressure; and a pressure prediction and cutoff control module, which combines the current gas pressure and pressurization inertia characteristics to predict the natural evolution of pressure after the valve stops operating, and determines whether to cut off the valve in advance based on the predicted natural evolution results. After the valve is cut off, pressure deviation is suppressed through directional compensation adjustment to achieve rapid arrival and stable maintenance of atomized pressure.

[0066] In this implementation scheme, by organically coordinating pressure data acquisition, atomization stage identification, pressurization inertia quantification, and pressure prediction control, the valve pressure regulation process is transformed from a passive response to an active control based on pressure evolution characteristics. This enables accurate identification of valve activation timing, rational utilization of pressurization inertia, and advance decision-making for valve shut-off. Simultaneously, directional compensation adjustment is introduced during the pressure stabilization stage to effectively reduce pressure overshoot and fluctuation risks, thereby improving the speed, stability, and overall process consistency of the atomization pressure build-up process.

[0067] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0068] The preferred embodiments of the present invention disclosed above are merely illustrative of the invention. These preferred embodiments do not exhaustively describe all details, nor do they limit the invention to the specific implementations described. As those skilled in the art will understand, many modifications and variations can be made based on the content of this specification. This specification selects and specifically describes these embodiments to better explain the principles and practical applications of the invention, thereby enabling those skilled in the art to better understand and utilize the invention. The invention is limited only by the claims and their full scope and equivalents.

Claims

1. An adaptive control method for atomization process based on pressure feedback characteristics, characterized in that, Includes the following steps: S1: Real-time acquisition of gas pressure data in the pipeline and simultaneous acquisition of valve opening and closing control status; preprocessing of the acquired pressure data to obtain continuous pressure change characteristics; S2, construct a sliding time window, analyze the characteristics of continuous pressure changes and valve opening and closing control status, evaluate the actual impact of valve action on pipeline pressure, and determine whether the valve has overcome the dead zone and entered the effective pressurization stage. S3. After determining that it is an effective pressurization stage, analyze the duration and intensity characteristics of the pressure rise process, quantify the degree of accumulation of inertial effect in the current pressurization process, and obtain the pressurization inertial characteristics as the input basis for judging the natural evolution of pressure. S4, taking into account the current gas pressure and pressurization inertia characteristics, predicts the natural evolution of pressure after the valve stops operating, and determines whether to shut off the valve in advance based on the prediction results of the natural evolution of pressure; after the valve is shut off, pressure deviation is suppressed by directional compensation adjustment, so as to achieve rapid arrival and stable maintenance of atomization pressure.

2. The adaptive control method for atomization process based on pressure feedback characteristics according to claim 1, characterized in that, The process of acquiring real-time gas pressure data in the pipeline and simultaneously obtaining valve opening and closing control status, and preprocessing the acquired pressure data to obtain continuous pressure change characteristics, is as follows: The pressure transmitter, located in the high-pressure gas pipeline downstream of the electric ball valve, collects the gas pressure value in the pipeline in real time and records the corresponding sampling timestamp. It also collects the valve control signal output from the PLC to the electric ball valve simultaneously. The gas pressure values ​​in the pipeline are sorted and time-aligned according to the sampling timestamp, and abnormal sampling points caused by instantaneous jumps and communication jitter are detected. When the change amplitude of the gas pressure value in a single pipeline exceeds the maximum change threshold, the sampling point is replaced with the nearest valid value. The gas pressure values ​​in the pipeline are smoothed within a time window to reduce the impact of sensor noise and pipeline transient disturbances on the judgment of pressure change trends, and the gas pressure values ​​in the pipeline are normalized by minimum and maximum. The pressure change rate is calculated based on the gas pressure values ​​in the pipeline at adjacent sampling times using the time difference method. An atomization process control database is established, and the original and pre-processed gas pressure values ​​in the pipeline, the pressure change rate, and valve control signals are written into the atomization process control database.

3. The adaptive control method for atomization process based on pressure feedback characteristics according to claim 1, characterized in that, The specific process of constructing a sliding time window and analyzing the characteristics of continuous pressure changes and the valve opening and closing control state is as follows: After the electric ball valve receives the valve opening control signal and enters the atomization start-up pressure regulation process, it continuously constructs a sliding time window and acquires the pressure change rate and valve control signal at the corresponding moment within the sliding time window in real time. Based on the valve control signal, it constructs the valve opening state value. When the valve control signal is in an effective valve opening state, the valve opening state value is assigned a value of 1, otherwise it is assigned a value of 0.

4. The adaptive control method for atomization process based on pressure feedback characteristics according to claim 1, characterized in that, The specific process for assessing the actual impact of valve action on pipeline pressure is as follows: The instantaneous response value is obtained by multiplying the rate of pressure change at each sampling moment within the sliding time window with the corresponding valve opening state value. The cumulative response value of pressure change is obtained by integrating the instantaneous response values ​​at all sampling moments within the window. Simultaneously, the absolute value of the valve opening state value within the window is integrated to obtain the effective valve opening action duration; the cumulative pressure change response value is divided by the effective valve opening action duration to obtain the valve action pressure response judgment value.

5. The adaptive control method for atomization process based on pressure feedback characteristics according to claim 1, characterized in that, The specific process for determining whether the valve has overcome the dead zone and entered the effective pressurization stage is as follows: The valve action pressure response judgment value is calculated in real time. When the valve control signal is in an effective open state and the corresponding valve action pressure response judgment value shows an increasing cumulative change with time within the sliding time window, it is determined that the opening action of the electric ball valve has overcome the dead zone and generated a continuous response to the pipeline pressure, and has entered the effective pressurization stage. Conversely, when the valve control signal is in an effective open state, and the corresponding valve action pressure response judgment value does not show an increasing cumulative change over time within the sliding time window, it is determined that the opening action of the electric ball valve has not yet had an effective impact on the pipeline pressure and is in the valve's dead zone stage. The valve action pressure response judgment value and the corresponding stage status are written into the atomization process control database to indicate whether the prerequisites for entering the pressurization inertia assessment and pressure prediction assessment are met.

6. The adaptive control method for atomization process based on pressure feedback characteristics according to claim 1, characterized in that, After determining that the pressurization stage is effective, the process of analyzing the persistence and intensity characteristics of the pressure rise process, quantifying the accumulation degree of inertial effect during the current pressurization process, and obtaining pressurization inertial characteristics as input basis for judging the natural evolution of pressure is as follows: When the current stage is identified as an effective pressurization stage, the pressurization inertia evaluation process is executed: read the pressure change rate within the sliding time window, perform a square operation on the pressure change rate at each sampling moment within the window, and determine the sign of the pressure change rate at the corresponding moment. When the pressure change rate is positive, retain the corresponding square of the pressure change rate; when the pressure change rate is non-positive, set the square of the pressure change rate to zero. The cumulative pressure inertia strength value is obtained by integrating the squares of the pressure change rates at all sampling times within the window. During the effective pressurization phase, the cumulative intensity value of pressurization inertia is continuously monitored and written into the atomization process control database as an input to the pressure prediction and evaluation process.

7. The adaptive control method for atomization process based on pressure feedback characteristics according to claim 1, characterized in that, The specific process for predicting the natural evolution of pressure after the valve operation is stopped, based on the combined characteristics of the current gas pressure and pressurization inertia, is as follows: When the current stage is the effective pressurization stage, pressure prediction and evaluation are allowed: receive the gas pressure value in the pipeline at the current moment, the pressure change rate, and the cumulative intensity of pressurization inertia. Based on the sliding time window, the pressure change rate is integrated and added to the smallest positive number to obtain the cumulative pressure change. The current cumulative intensity of pressurization inertia is divided by the cumulative pressure change to obtain the equivalent duration of pressurization inertia. The equivalent duration of pressurization inertia is added to the current gas pressure value in the pipeline to obtain the predicted value of natural pressure.

8. The adaptive control method for atomization process based on pressure feedback characteristics according to claim 1, characterized in that, The specific process for determining whether to prematurely shut off the valve based on the pressure natural evolution prediction results is as follows: Continuously monitor the predicted natural pressure and compare it with the atomization pressure threshold: When the predicted pressure value is greater than or equal to the atomization pressure threshold, it is determined that after stopping the valve opening action at the current moment, the pipeline pressure can naturally reach the target pressure level under the action of inertia, and an early shutdown command is generated. When the predicted natural pressure is less than the atomization pressure threshold, it is determined that stopping the valve opening action will result in the target pressure not being reached, and the existing valve opening control state is maintained. The early shutdown command is sent to the PLC, which immediately stops outputting the valve opening control signal and locks the current valve position status of the electric ball valve.

9. The adaptive control method for atomization process based on pressure feedback characteristics according to claim 1, characterized in that, The specific process of suppressing pressure deviation through direction-related compensation adjustment to achieve rapid arrival and stable maintenance of atomization pressure is as follows: After the electric ball valve is shut off, the gas pressure in the pipeline is continuously monitored. When the gas pressure in the pipeline deviates from the maximum pressure range centered on the atomization pressure threshold and the duration of the deviation exceeds the allowable time threshold, compensation control is triggered: the electric ball valve is opened or closed intermittently for a limited duration according to the direction of deviation to correct the pressure deviation. At the end of the atomization stage, a valve closing command is generated and sent to the PLC to control the electric ball valve to continue closing until the opening degree is 0% and then stop closing the valve. The predicted value of natural pressure rise, the early cut-off command, the valve control status, and the change data of gas pressure in the pipeline during the pressure stabilization process are written into the atomization process control database as a record of the complete atomization pressure regulation process.

10. An adaptive control system for atomization process based on pressure feedback characteristics, characterized in that, include: The pressure data acquisition and processing module is used to acquire the pressure data of the gas in the pipeline in real time and simultaneously obtain the valve opening and closing control status. The collected pressure data is preprocessed to obtain continuous pressure change characteristics; The atomization stage coupling identification module is used to construct a sliding time window, analyze the characteristics of continuous pressure changes and valve opening and closing control status, evaluate the actual impact of valve action on pipeline pressure, and determine whether the valve has overcome the dead zone and entered the effective pressurization stage. The pressurization inertia accumulation quantification module is used to analyze the persistence and intensity characteristics of the pressure rise process after determining that the effective pressurization stage has been reached, quantify the degree of accumulation of inertial effect in the current pressurization process, and obtain the pressurization inertia characteristics, which serve as the input basis for judging the natural evolution of pressure. The pressure prediction and cutoff control module is used to predict the natural evolution of pressure after the valve stops operating by comprehensively considering the current gas pressure and the inertia characteristics of the pressurization. Based on the prediction results of the natural pressure evolution, it determines whether to cut off the valve in advance. After the valve is cut off, the pressure deviation is suppressed by directional compensation adjustment, so as to achieve rapid arrival and stable maintenance of atomization pressure.

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