Tobacco leaf modified atmosphere insecticidal system and method in roadway type dense shelf warehouse based on flexible parameter configuration

Abstract

The invention discloses a tobacco leaf modified atmosphere insecticidal system and method in a roadway type dense shelf warehouse based on flexible parameter configuration. The system comprises a roadway sealing subsystem, a gas regulation and control subsystem, an environment monitoring subsystem and a central control subsystem. A memory is arranged in an industrial computer of the central control subsystem, and a flexible parameter database and a flexible parameter configuration module are stored in the memory. The method comprises the following steps: sealing a roadway to form an independent modified atmosphere insecticidal unit, calling a first parameter set and a second parameter set according to input insecticidal object information, performing gas replacement and maintenance control according to the second parameter set, and dynamically triggering trace nitrogen supplementation, carbon dioxide supplementation, linkage temperature adjustment and linkage humidity adjustment deviation correction control based on real-time monitoring data. According to the method, one-product-one-strategy precise insect killing for different tobacco leaf materials is achieved, the problems of fixed parameters and poor adaptability of a traditional process are solved, and the method has the advantages of being thorough in insect killing, good in quality guarantee and low in energy consumption.

Description

Technical Field

[0001] This invention belongs to the field of tobacco leaf storage and maintenance and pest control technology, specifically relating to a controlled atmosphere pest control system and method for tobacco leaves in a lane-type dense rack warehouse based on flexible parameter configuration. Background Technology

[0002] Tobacco leaves and their products are highly susceptible to pests such as tobacco beetles and tobacco mealybugs during storage. Traditional phosphine fumigation faces challenges such as increased pest resistance, pesticide residues, and environmental pollution. Modified atmosphere packaging (MAP), as a physical control method, typically employs a low-oxygen or high-carbon dioxide environment, offering advantages such as being pollution-free and residue-free, making it an ideal alternative technology.

[0003] However, existing modified atmosphere packaging (MAP) pest control technology has the following shortcomings in tobacco storage applications:

[0004] (1) Lack of specificity: Different materials such as imported tobacco leaves, domestic tobacco leaves, tobacco stems, and reconstituted tobacco leaves have different physical properties, moisture content, and pest tolerance. However, existing processes mostly use traditional fixed and uniform parameters for modified atmosphere packaging, which has unstable effects and can easily lead to incomplete pest control or affect the quality of materials.

[0005] (2) Poor adaptability: When the warehouse environment (such as seasons and regional climate) and insect infestation status change, the traditional fixed-parameter controlled atmosphere process is difficult to adapt and adjust, and lacks flexibility. Moreover, the traditional fixed-parameter controlled atmosphere can only meet the needs of a single material and cannot meet the needs of multiple materials at the same time.

[0006] (3) The process control is rough: Traditional fixed parameter controlled atmosphere processes rely heavily on human experience, and the coordinated control of temperature, humidity and gas concentration is not precise enough, making it difficult to achieve process optimization and energy saving.

[0007] (4) High cost of controlled atmosphere in the whole warehouse: Controlling the atmosphere of the whole warehouse requires a large amount of gas and high energy consumption. In dense rack warehouses, there are technical difficulties in how to effectively seal and independently control the atmosphere of individual or part of the aisles and achieve precise control.

[0008] Therefore, there is an urgent need for a technical solution that can flexibly, accurately, and automatically execute modified atmosphere insecticide processes based on different materials and environmental conditions.

[0009] To address the aforementioned problems, this invention is proposed. Summary of the Invention

[0010] The purpose of this invention is to overcome the shortcomings of existing technologies and provide a modified atmosphere packaging (MAP) system and method for tobacco leaf pest control in aisle-type high-density racking warehouses based on flexible parameter configuration. This system and method can automatically match or dynamically adjust the optimal set of MAP parameters for different pest targets, environmental conditions, and target pest control rates, achieving efficient, safe, and low-loss precision pest control.

[0011] To achieve the above objectives, the present invention adopts the following technical solution:

[0012] This invention provides a controlled atmosphere pest control system for tobacco leaves in a lane-type high-density rack warehouse based on flexible parameter configuration, comprising:

[0013] The tunnel sealing subsystem includes flexible sealing doors or flexible sealing curtains installed at both ends and the top of the target tunnel, and a sealing connection mechanism that cooperates with the tunnel boundary, for sealing the target tunnel so that the target tunnel forms an independent modified atmosphere insecticidal unit; the modified atmosphere insecticidal unit is equipped with a humidification or dehumidification device and a temperature control device.

[0014] The gas control subsystem includes a nitrogen generator, a carbon dioxide supply unit, a gas mixer, a gas delivery device, an intake assembly, an exhaust assembly, and a circulating fan. It is used to input nitrogen and / or carbon dioxide into the controlled atmosphere insecticide unit and control gas replacement and circulation. The gas control subsystem is connected to the controlled atmosphere insecticide unit via a sealed connection structure to independently perform gas replacement and gas circulation within the sealed space of the controlled atmosphere insecticide unit. The sealed connection structure may include a sealing flange and a connecting pipe. One end of the connecting pipe is connected to the gas control subsystem, and the other end is fixed and sealed through the sealing flange, passing through the side wall or top plate of the controlled atmosphere insecticide unit, thereby ensuring that the sealed integrity of the sealed space is not compromised while gas and signal transmission is achieved.

[0015] An environmental monitoring subsystem includes at least one oxygen sensor, at least one carbon dioxide sensor, and a temperature and humidity sensor. The sensors are installed in the controlled atmosphere insecticidal unit and are used to collect oxygen concentration, carbon dioxide concentration, temperature, and humidity data in the controlled atmosphere insecticidal unit at a preset sampling period of 60 to 120 seconds.

[0016] The central control subsystem includes an industrial computer and a human-machine interface, wherein the industrial computer is communicatively connected to the tunnel sealing subsystem, the gas control subsystem, and the environmental monitoring subsystem, respectively.

[0017] The industrial computer has a built-in memory that stores a flexible parameter database and a flexible parameter configuration module for implementing controlled atmosphere process control.

[0018] Preferably, the flexible sealing door is an inflatable sealing door, and the flexible sealing curtain is a high-strength PVC roller blind.

[0019] Preferably, the flexible parameter database stores a first parameter set and a second parameter set;

[0020] The first parameter set includes the following parameters: Material_Type, Material_Moisture_Range, Pest_Species, Life_Stage_Distribution, Initial_Infestation_Level, and Season_TemperatureZone.

[0021] The second parameter set, based on the parameters in the first parameter set, includes the following key configurable parameters: at least the target oxygen concentration threshold Target_O2_Level, the target carbon dioxide concentration threshold Target_CO2_Level, the gas replacement rate Gas_Replacement_Rate, the maintenance duration of the controlled atmosphere maintenance phase, and the dynamic adjustment trigger condition Dynamic_Adjustment_Trigger. The key configurable parameters also include the maximum allowable temperature Max_Temperature, the ideal humidity range Ideal_Humidity_Range, and the oxygen concentration alarm upper limit O2_Alarm_UpperLimit.

[0022] Preferably, the flexible parameter configuration module includes configuration logic:

[0023] (1) Receive insecticidal object information input through the human-computer interaction interface, and automatically match the first parameter set in the flexible parameter database based on the insecticidal object information and call the corresponding second parameter set;

[0024] (2) Based on the second set of parameters invoked, the controlled atmosphere operation is divided into at least a replacement phase and a maintenance phase and controlled accordingly:

[0025] During the replacement phase, the gas regulation subsystem is controlled to introduce nitrogen into the modified atmosphere insecticide unit and discharge the original gas according to the gas replacement rate Gas_Replacement_Rate in the second parameter set until the oxygen concentration reaches the target oxygen concentration threshold Target_O2_Level. After the target oxygen concentration threshold Target_O2_Level is reached, when the target carbon dioxide concentration threshold Target_CO2_Level in the second parameter set is greater than 0, the carbon dioxide supply device is controlled to replenish carbon dioxide to the modified atmosphere insecticide unit through the gas mixer until the carbon dioxide concentration reaches the target carbon dioxide concentration threshold Target_CO2_Level. When the target carbon dioxide concentration threshold Target_CO2_Level in the second parameter set is equal to 0, the carbon dioxide supply device is controlled to be in the off state.

[0026] During the maintenance phase, based on the real-time data of the environmental monitoring subsystem, it is determined whether the dynamic adjustment trigger condition Dynamic_Adjustment_Trigger is met. When the dynamic adjustment trigger condition Dynamic_Adjustment_Trigger is met, a dynamic adjustment command is output to execute at least one corrective control to control the oxygen concentration, carbon dioxide concentration, and temperature and humidity back to the range defined by the second parameter set. The corrective control includes: micro-nitrogen supplementation, carbon dioxide supplementation, linkage temperature regulation, and linkage humidity regulation.

[0027] (3) Record and store environmental monitoring data, execution instructions, alarm events, and data on the number and duration of gas replenishment during the replacement and maintenance phases.

[0028] Preferably, the pest control target information includes at least the material type, the material moisture content range, the pest species, the distribution of insect stages, the pest severity level, and the seasonal temperature zone. The material type includes imported tobacco leaves, domestic tobacco leaves, tobacco stems, tobacco shreds, and reconstituted tobacco leaves.

[0029] Preferably, the corrective control corresponding to the trace nitrogen supplementation specifically includes:

[0030] The environmental monitoring subsystem reads the oxygen concentration value O2_current in the controlled atmosphere insecticidal unit in real time.

[0031] When the environmental monitoring subsystem detects that the oxygen concentration O2_current in the controlled atmosphere insecticidal unit is greater than the target oxygen concentration threshold Target_O2_Level + the allowable deviation range of oxygen concentration ΔO2, the central control subsystem controls the nitrogen generator to perform micro-nitrogen supplementation. The nitrogen generator is controlled to run at a low gas replacement rate Gas_Replacement_Rate for a period of time to reduce the oxygen concentration back to Target_O2_Level and its allowable deviation range, where the allowable deviation range of oxygen concentration ΔO2 is 0.1% to 0.8%.

[0032] Preferably, the correction control corresponding to the linked temperature adjustment specifically includes:

[0033] When the environmental monitoring subsystem detects that the current temperature T_current inside the controlled atmosphere insecticide unit is greater than the maximum allowable temperature Max_Temperature set in the second parameter set, the central control subsystem outputs a linkage control command to activate the temperature regulation device inside the controlled atmosphere insecticide unit to cool it down and bring the temperature back to the temperature range defined by the second parameter set.

[0034] Preferably, the corrective control corresponding to the supplemented carbon dioxide is as follows: when the carbon dioxide concentration in the modified atmosphere insecticide unit is detected to be less than the target carbon dioxide concentration threshold Target_CO2_Level + allowable deviation range ΔCO2 set in the second parameter set, carbon dioxide is supplemented to the modified atmosphere insecticide unit until the carbon dioxide concentration returns to Target_CO2_Level and its allowable deviation range, wherein the allowable deviation range ΔCO2 is 0.1% to 0.6%.

[0035] Preferably, the correction control corresponding to the linkage humidity adjustment is as follows: when it is detected that the current humidity in the modified atmosphere insecticidal unit is not within the ideal humidity range Ideal_Humidity_Range set in the second parameter set, the central control subsystem outputs a linkage control command to activate the humidification or dehumidification device inside the modified atmosphere insecticidal unit, so that the humidity returns to the ideal humidity range Ideal_Humidity_Range.

[0036] Another aspect of the present invention provides a modified atmosphere packaging method for tobacco leaf control in an aisle-type high-density rack warehouse based on the aforementioned flexible parameter configuration, the method comprising the following steps:

[0037] S1, Lane Sealing Unit: By sending signal commands through an industrial computer, the two ends and the top of the target lane are sealed, so that the target lane forms an independent modified atmosphere pest control unit.

[0038] S2. Parameter matching and calling: Input the pest control target information through the human-computer interaction interface, automatically match the first parameter set in the flexible parameter database based on the pest control target information, and call the second parameter set corresponding to the first parameter set;

[0039] S3. Sampling and monitoring: Oxygen concentration, carbon dioxide concentration, temperature and humidity data are collected in the modified atmosphere insecticidal unit according to a preset sampling period of 60 to 120 seconds.

[0040] S4. Replacement Stage Control: The gas regulation subsystem is controlled to introduce nitrogen into the controlled atmosphere insecticide unit and discharge the original gas according to the gas replacement rate Gas_Replacement_Rate in the second parameter set, and the circulating fan is controlled to run to form gas circulation in the tunnel until the oxygen concentration reaches the target oxygen concentration threshold Target_O2_Level; after the target oxygen concentration threshold Target_O2_Level is reached, when the target carbon dioxide concentration threshold Target_CO2_Level in the second parameter set is greater than 0, the carbon dioxide supply equipment is controlled to supplement carbon dioxide to the controlled atmosphere insecticide unit through the gas mixer until the carbon dioxide concentration reaches the target carbon dioxide concentration threshold Target_CO2_Level; when the target carbon dioxide concentration threshold Target_CO2_Level in the second parameter set is equal to 0, the carbon dioxide supply equipment is controlled to be in the off state;

[0041] S5. Maintenance Phase Control: Based on the real-time data collected in step S3, determine whether the dynamic adjustment trigger condition Dynamic_Adjustment_Trigger is met;

[0042] S6. Dynamic Correction Control: When the Dynamic Adjustment Trigger condition Dynamic_Adjustment_Trigger is met, a dynamic adjustment command is output to execute at least one correction control to control the oxygen concentration, carbon dioxide concentration, and temperature and humidity back to the range defined by the second parameter set. The correction control includes: micro-nitrogen supplementation, carbon dioxide supplementation, linkage temperature regulation, and linkage humidity regulation.

[0043] S7. Data Recording and Storage: Record and store environmental monitoring data, execution instructions, alarm events, and data on the number and duration of gas replenishment during the replacement and maintenance phases.

[0044] Preferably, the corrective control corresponding to the micro-nitrogen supplementation, carbon dioxide supplementation, temperature regulation, and humidity regulation is as follows:

[0045] The specific corrective control corresponding to the micro-nitrogen supplementation is as follows: the environmental monitoring subsystem reads the oxygen concentration value O2_current in the controlled atmosphere insecticidal unit in real time. When the environmental monitoring subsystem detects that the oxygen concentration O2_current in the controlled atmosphere insecticidal unit is greater than the target oxygen concentration threshold Target_O2_Level + the allowable deviation range of oxygen concentration ΔO2, the central control subsystem controls the nitrogen generator to perform micro-nitrogen supplementation. The nitrogen generator is controlled to run at a low gas replacement rate Gas_Replacement_Rate for a period of time to reduce the oxygen concentration back to Target_O2_Level and its allowable deviation range, wherein the allowable deviation range of oxygen concentration ΔO2 is 0.1% to 0.8%.

[0046] The corrective control corresponding to the supplemented carbon dioxide is as follows: when the carbon dioxide concentration in the modified atmosphere insecticide unit is detected to be less than the target carbon dioxide concentration threshold Target_CO2_Level + allowable deviation range ΔCO2 set in the second parameter set, carbon dioxide is supplemented to the modified atmosphere insecticide unit until the carbon dioxide concentration returns to Target_CO2_Level and its allowable deviation range, wherein the allowable deviation range ΔCO2 is 0.1% to 0.6%;

[0047] The correction control corresponding to the linkage temperature regulation is as follows: when the environmental monitoring subsystem detects that the current temperature T_current in the modified atmosphere insecticidal unit is greater than the maximum allowable temperature Max_Temperature set in the second parameter set, the central control subsystem outputs a linkage control command to start the temperature regulation device inside the modified atmosphere insecticidal unit to cool down and bring the temperature back to the temperature range defined by the second parameter set.

[0048] The corrective control corresponding to the linked humidity adjustment is as follows: when the current humidity in the modified atmosphere insecticidal unit is detected to be outside the ideal humidity range Ideal_Humidity_Range set in the second parameter set, the central control subsystem outputs a linkage control command to activate the humidification or dehumidification device inside the modified atmosphere insecticidal unit, so that the humidity returns to the ideal humidity range Ideal_Humidity_Range.

[0049] The beneficial effects of this invention are:

[0050] 1. Precise Pest Control Based on "One Product, One Policy": The modified atmosphere packaging (MAP) system for tobacco leaves in aisle-style high-density shelving warehouses provided by this invention utilizes a flexible parameter database. Based on this database, the system can automatically access matching parameter sets according to specific pest information, such as material type (imported tobacco, domestic tobacco, tobacco stems, reconstituted tobacco), material moisture content range, pest species, pest life stages, and pest severity. These parameters include target oxygen concentration threshold, target carbon dioxide concentration threshold, duration, and temperature and humidity range. This completely changes the traditional fixed-parameter MAP approach, which only satisfies a single material, and can now satisfy multiple materials. This ensures effective pest control while maximizing the protection of the quality characteristics of different materials.

[0051] 2. Adaptable to Complex and Varied Application Scenarios: The modified atmosphere packaging system for tobacco leaves in aisle-type high-density shelving warehouses provided by this invention, based on flexible parameter configuration, not only targets material type but also integrates information such as season, pest severity, and pest stage distribution for parameter matching and dynamic adjustment. This allows the process to adapt to changes in the external warehouse environment and the internal pest situation, significantly improving the reliability and stability of applications in different regions and time periods.

[0052] 3. From Static Control to Dynamic Optimization: The modified atmosphere packaging (MAP) system for tobacco leaves in aisle-type high-density shelving warehouses provided by this invention features built-in dynamic adjustment trigger conditions. During the MAP maintenance phase, once the gas concentration or temperature and humidity deviate from the set range due to micro-leakage, environmental fluctuations, or other reasons, the system can automatically trigger corrective operations such as "micro-nitrogen supplementation," "carbon dioxide supplementation," "linked temperature adjustment," and "linked humidity adjustment" to quickly adjust the environmental parameters back to the target range. This process represents a leap from "open-loop" preset to "closed-loop" intelligent maintenance, ensuring the stability of the pest control environment during the long-term maintenance phase and effectively preventing incomplete pest control due to parameter changes.

[0053] 4. Synergistic effect of precision and energy saving: The modified atmosphere packaging system for tobacco leaves in aisle-type high-density shelving warehouses provided by this invention, based on flexible parameter configuration, avoids the energy waste caused by over-gasification or prolonged maintenance in traditional processes as a precaution. Through corrective operation, gas consumption and energy consumption are minimized while ensuring effectiveness, making process control more precise and economical.

[0054] 5. Compared to traditional controlled atmosphere treatment of the entire warehouse, this invention only seals and controls the atmosphere of the target aisle, reducing the treatment space by several orders of magnitude. This significantly reduces the amount of controlled atmosphere media such as nitrogen and carbon dioxide used, directly lowering the raw material costs for each pest control operation.

[0055] 6. This invention enables independent and phased controlled atmosphere spraying operations in different lanes without affecting the normal storage and retrieval of materials and warehouse management in other lanes. This improves the flexibility of warehouse operations and space utilization, and is particularly suitable for the differentiated maintenance needs of different batches and varieties of tobacco leaves. Attached Figure Description

[0056] Figure 1 The flowchart illustrates the modified atmosphere pest control method for tobacco leaves in a lane-type dense rack warehouse based on the flexible parameter configuration provided by the present invention. Detailed Implementation

[0057] The present invention will now be described in further detail with reference to the embodiments.

[0058] Those skilled in the art will understand that the following embodiments are for illustrative purposes only and should not be construed as limiting the scope of the invention. Where specific techniques or conditions are not specified in the embodiments, they are performed in accordance with the techniques or conditions described in technical literature in the field or according to product instructions. Materials or equipment whose manufacturers are not specified are all conventional products that can be obtained by purchase.

[0059] Those skilled in the art will understand that, unless specifically stated otherwise, the singular forms “a,” “an,” “the,” and “the” used herein may also include the plural forms. In the description of this invention, unless otherwise stated, “a plurality” means two or more. It should be further understood that the term “comprising” as used in this specification means the presence of the stated features, integers, steps, operations, elements, and / or components, but does not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0060] For ease of understanding, the specific data of the first and second parameter sets stored in the flexible parameter database of this invention are detailed in Tables 1 and 2.

[0061] Table 1 First Parameter Set

[0062]

[0063] Table 2 Second Parameter Set

[0064]

[0065] Example 1: Flexible low-oxygen modified insecticide for imported flue-cured tobacco (K326 variety)

[0066] Comparative Example 1 (Traditional whole-warehouse fixed-parameter controlled atmosphere)

[0067] During the summer, a whole high-density racking warehouse storing imported flue-cured tobacco (K326) was selected for controlled atmosphere storage using nitrogen. Fixed parameters were set as follows: target oxygen concentration <2.0%, no carbon dioxide added, and controlled atmosphere maintenance time fixed at 30 days. The control mode was "intermittent nitrogen filling + manual inspection": the nitrogen generator was started at regular intervals daily, or when manual inspection revealed an oxygen concentration reading >2.0%, the nitrogen filling machine was activated to fill nitrogen until the oxygen concentration was <2.0%.

[0068] Experimental Process and Results Analysis: The deoxygenation phase lasted approximately 7 days. During the maintenance phase, the oxygen concentration inside the silo rose by about 0.3% daily due to micro-leakage, requiring nitrogen supplementation for 4-8 hours daily to maintain an oxygen concentration below 2.0%. Under this mode, it must be maintained for a full 30 days to ensure 100% mortality of insect eggs. This method has a rigid cycle, high reliance on manual labor, and other operations cannot be carried out during the controlled atmosphere storage period. In terms of energy consumption, the total electricity consumption for processing one load of tobacco leaves in the entire silo throughout the entire cycle is as high as 1.26 kW·h.

[0069] Embodiment 1 of the present invention

[0070] Imported flue-cured tobacco (K326) of the same origin and year as in Comparative Example 1 was processed in an aisle-style high-density rack warehouse. Figure 1 As shown, follow these steps:

[0071] S1 tunnel sealing unit: The industrial computer sends signal commands to select the target tunnel and controls the tunnel sealing subsystem to close the inflatable sealing doors at both ends and the top, forming an independent controlled atmosphere unit.

[0072] S2 Parameter Matching and Recall: The operator inputs "Material Type: Imported Flue-cured Tobacco K326; Season: Summer" into the human-machine interface. Based on this, the industrial computer automatically matches and calls the second parameter set corresponding to the preset first parameter set "Imported Flue-cured Tobacco_K326_Summer" from the flexible parameter database. Key parameters of this second parameter set are as follows: Target_O2_Level = 1.8%, Target_CO2_Level = 0%, Maintenance_Duration = 20 days, Gas_Replacement_Rate = 150 m³ / h, Ideal_Humidity_Range = 60%±2%, ΔO2 = 0.2%.

[0073] S3 Sampling and Monitoring: The environmental monitoring subsystem deployed in the middle of the roadway is activated, collecting O2, CO2, temperature and humidity data every 60 seconds.

[0074] S4 Replacement Stage Control: The gas regulation subsystem controls the nitrogen generator to fill the roadway with nitrogen at a rate of 150 m³ / h, while simultaneously starting the circulating fan to form gas circulation. Due to the small space and strong circulation, the efficiency advantage of the continuous nitrogen filling mode is that the oxygen concentration at all points in the roadway is uniformly and stably reduced to below 1.8% within 36 hours, which is far more efficient than Comparative Example 1.

[0075] S5 Maintenance Phase Control and S6 Dynamic Correction Control: The system enters a 20-day maintenance period. On day 10, the sensor detected that the O2 concentration slowly rose to 2.15% (i.e., 1.8% + 0.35%, satisfying the condition O2_current > Target_O2_Level + ΔO2). The system then automatically triggered the "micro-nitrogen supplementation" program, running the nitrogen generator at a rate of 0.5 × 150 m³ / h for 25 minutes, precisely pulling the O2 concentration back to 1.8%. Throughout the maintenance phase, the temperature and humidity remained stable within the set range.

[0076] S7 Data Recording: All process data is automatically stored.

[0077] Effectiveness Analysis: Insect Control: After 20 days, insect sample testing showed a 100% mortality rate for all insect stages (including eggs). While ensuring the same level of insect control thoroughness, the treatment cycle was shortened by 10 days compared to control example 1. Quality Protection: Precise humidity control (60%±2%) effectively prevented deterioration of tobacco leaf quality. Economic Benefits: The gas consumption of the tunnel-type operation is only about 1 / 8 of that of the entire warehouse; and due to the shortened cycle and precise gas replenishment, the estimated energy consumption is reduced by more than 30% compared to control example 1. Automation: The entire process is unattended and operates automatically.

[0078] Example 2: Parallel independent modified atmosphere flexible operation of multiple materials

[0079] Comparative Example 2 (Traditional "one-size-fits-all" mixed controlled atmosphere mode)

[0080] A high-density warehouse containing a mix of domestically produced flue-cured tobacco (Hongda variety) and tobacco stems was selected. Since the controlled atmosphere storage could not be divided into zones, all materials were subjected to uniform, fixed parameters: oxygen <2.0%, carbon dioxide concentration target range 5%-15%, maintained for 20 days. Dry ice was manually added to supplement CO2.

[0081] Experimental process and results analysis:

[0082] Uneven gas distribution: Dry ice sublimation leads to severely uneven CO2 distribution within the warehouse, with excessively high concentrations (>20%) near the sublimation point in the lower layer and insufficient concentrations (<5%) in the upper and more distant layers. Oxygen concentrations also stratify as a result, with higher concentrations in the upper layers. This leads to significant differences in the gas environment across different locations within the warehouse, resulting in inconsistent pest control effectiveness.

[0083] The control is too extensive: temperature and humidity cannot be adjusted in different zones for different materials, which may lead to the risk of the stems absorbing moisture or the tobacco leaves drying out too much.

[0084] Effectiveness and energy consumption: The final whole-warehouse pest control needs to be maintained for a relatively long time to ensure effectiveness, with an energy consumption of approximately 1.82 kWh / dan. Furthermore, no other operations can be carried out during the whole-warehouse controlled atmosphere period.

[0085] Embodiment 2 of the present invention

[0086] The same materials as in Comparative Example 2 are handled in an aisle-type high-density racking warehouse. Figure 1 As shown, follow these steps:

[0087] In the same high-density warehouse, two adjacent aisles storing domestic flue-cured tobacco (Hongda variety) and tobacco shreds are subjected to simultaneous but independent flexible controlled atmosphere operations with different parameters.

[0088] S1 Sealed Unit: Through signal commands sent by an industrial computer, the inflatable sealed doors of two lanes are independently controlled to close, forming two parallel modified atmosphere insecticidal units: lane A for domestic flue-cured tobacco (Hongda variety) and lane B for stems.

[0089] S2 parameter matching and invocation:

[0090] Lane A: Select "Domestic Flue-cured Tobacco - Red and Large - High Insect Infestation" on the human-machine interface. Based on this, the industrial computer automatically matches and calls the second parameter set corresponding to the preset first parameter set "Domestic Flue-cured Tobacco - Red and Large - High Insect Infestation" from the flexible parameter database. The key parameters of this second parameter set are as follows: Target_O2_Level = 1.6%, Target_CO2_Level = 12%, Maintenance_Duration = 16 days, Ideal_Humidity_Range = 62%±3%.

[0091] Lane B: Select "Stretcher" on the human-machine interface. The industrial computer then automatically matches and calls the second parameter set corresponding to the preset first parameter set "Stretcher" from the flexible parameter database. Key parameters of this second parameter set are as follows: Target_O2_Level=1.8%, Target_CO2_Level=5%, Maintenance_Duration=20 days, Ideal_Humidity_Range=55%±2%.

[0092] S3 Sampling and Monitoring: The sensors in the two units work independently. The environmental monitoring subsystem deployed in the middle of each roadway is activated and collects O2, CO2, temperature and humidity data every 80 seconds.

[0093] S4 replacement phase control:

[0094] The two gas lanes began replacement simultaneously. Based on their respective gas replacement rates (Gas_Replacement_Rate), the system controlled the nitrogen generator in lane A to fill with nitrogen at a rate of 120 m³ / h until the O2 concentration reached 1.6%, and the nitrogen generator in lane B to fill with nitrogen at a rate of 110 m³ / h until the O2 concentration reached 1.8%. Simultaneously, the system controlled the carbon dioxide supply equipment in lane A to inject CO2 to a set concentration of 12%, and the carbon dioxide supply equipment in lane B to inject CO2 to a set concentration of 5%. The circulating fans operated independently within their respective lanes, ensuring rapid and uniform gas mixing and eliminating the gas stratification phenomenon observed in Comparative Example 2.

[0095] S5 Maintenance Phase Control and S6 Dynamic Correction Control:

[0096] In tunnel A: On day 5, the CO2 concentration dropped to 11.2% due to adsorption, and the system automatically activated the "replenish carbon dioxide" correction control program for fine-tuning. On day 10, the humidity rose to 65.5%, and the system automatically activated the "linked humidity adjustment" correction control program for fine-tuning. At this time, the central control subsystem output a linkage control command to activate the dehumidification device in the tunnel sealing subsystem.

[0097] Lane B: The system strictly controls humidity. When the humidity reaches 57%, the "linked humidity adjustment" correction control program is activated in advance for fine-tuning. At this time, the central control subsystem outputs a linkage control command to activate the dehumidification device inside the controlled atmosphere insecticidal unit, stabilizing the humidity below 57% to prevent problems before they occur.

[0098] S7 data logging: Two complete and independent sets of process data are recorded and stored in parallel.

[0099] Effect Analysis:

[0100] Precision pest control: After 16 days, the domestic flue-cured tobacco (Hongda variety) in Lane A was opened for storage. Insect sample testing showed a 100% mortality rate, which was 4 days shorter than the traditional method. It was particularly effective in killing pupae and eggs with strong tolerance.

[0101] Safety and mold prevention: In the entire 20-day cycle, the average humidity of tunnel B (stem wire) remained stable at 54.8%, with no signs of condensation or mold, and pests were also completely eradicated.

[0102] Quality optimization: The aroma substances of domestic flue-cured tobacco (Hongda variety) are well preserved under suitable humidity, and the low humidity environment of the stems ensures its processing characteristics.

[0103] Energy efficiency and flexibility: With two independent controlled atmosphere storage lanes, the total gas consumption is still lower than that of whole-warehouse processing, with an energy consumption of approximately 1.68 kWh / tan, resulting in reduced energy consumption. Meanwhile, other lanes in the warehouse can operate normally, achieving efficient parallel operation of controlled atmosphere pest control and storage.

[0104] This embodiment illustrates that the present invention, through "flexible parameter configuration" and "independent modified atmosphere control unit," completely solves the industry problem of traditional whole-warehouse modified atmosphere control being unable to address all aspects of mixed storage and diverse material characteristics. It not only allows for tailored solutions for different materials but also enables precise "zoning control" in space, fundamentally elevating warehouse pest control from extensive management to refined and intelligent operation.

[0105] Example 3: Adaptive Energy-Saving Controlled Atmosphere to Cope with Environmental Fluctuations

[0106] Comparative Example 3 (Rough Maintenance Mode with Fixed Frequency Air Replenishment)

[0107] Operation: During the 20-day controlled atmosphere maintenance phase of the reconstituted tobacco leaves, nitrogen supplementation is carried out in a fixed mode of timed and quantitative operation, regardless of the actual concentration readings: for example, the nitrogen generator is automatically turned on for 2 hours every 24 hours to supplement the atmosphere.

[0108] Results: When the seal is good, it leads to serious over-gas injection, resulting in more than 60% energy waste; in the event of an accidental leak, the fixed gas injection interval may not be sufficient to suppress the oxygen concentration from rising too quickly, posing a risk of pest control failure.

[0109] Embodiment 3 of the present invention

[0110] This invention leverages the advantages of real-time monitoring and dynamic triggering conditions. When processing reconstituted tobacco leaves, the first parameter set is invoked, where the dynamic_Adjustment_Trigger triggering condition is set to: O2_current > 1.8% (Target) + 0.15% (ΔO2), meaning that micro-nitrogen supplementation is triggered when O2_current reaches 1.95%.

[0111] Phase 1 (Stabilization period, days 1-12): Due to excellent sealing, the oxygen concentration fluctuated between 1.80% and 1.90%, without reaching the trigger threshold of 1.95%. No nitrogen supplementation was performed during this period, maintaining a zero-energy maintenance state.

[0112] Phase Two (Micro-Leakage Period, Days 13-17): The concentration slowly climbs to 1.98%, triggering a micro-nitrogen supplementation. The system runs the nitrogen generator at a low rate for 12 minutes, and the concentration recovers to 1.95%.

[0113] Phase 3 (fluctuation period, days 18-20): Affected by the drastic changes in the outside temperature, the concentration fluctuated more, reaching 2.05% at one point, triggering another 23-minute micro-nitrogen supplementation, and the concentration recovered to 1.95%.

[0114] This embodiment illustrates that the solution of the present invention has excellent energy efficiency. During the entire 20-day maintenance period, the system only initiated nitrogen supplementation twice, for a total duration of less than 40 minutes, as needed. Compared to the fixed-frequency solution in Comparative Example 3 (20 days × 2 hours / day = 40 hours of nitrogen supplementation), the energy-saving effect is significantly improved, and the pest control environment remains under constant control. The system can intelligently distinguish between stable periods, micro-leakage periods, and fluctuation periods, intervening only when necessary, truly achieving on-demand control and maximizing energy savings while ensuring pest control effectiveness.

[0115] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in the present invention should be included within the scope of protection of the present invention.

Claims

1. A modified atmosphere packaging system for tobacco leaves in a lane-type high-density racking warehouse based on flexible parameter configuration, characterized in that, include: The tunnel sealing subsystem includes flexible sealing doors or flexible sealing curtains installed at both ends and the top of the target tunnel, and a sealing connection mechanism that cooperates with the tunnel boundary, for sealing the target tunnel so that the target tunnel forms an independent modified atmosphere insecticidal unit; the modified atmosphere insecticidal unit is equipped with a humidification or dehumidification device and a temperature control device. The gas control subsystem includes a nitrogen generator, a carbon dioxide supply device, a gas mixer, a gas delivery device, an air intake assembly, an exhaust assembly, and a circulating fan, used to input nitrogen and / or carbon dioxide into the controlled atmosphere insecticide unit and control gas replacement and circulation. An environmental monitoring subsystem includes at least one oxygen sensor, at least one carbon dioxide sensor, and a temperature and humidity sensor. The sensors are installed inside the controlled atmosphere insecticidal unit and are used to collect data on oxygen concentration, carbon dioxide concentration, temperature, and humidity inside the controlled atmosphere insecticidal unit according to a preset sampling period. The central control subsystem includes an industrial computer and a human-machine interface, wherein the industrial computer is communicatively connected to the tunnel sealing subsystem, the gas control subsystem, and the environmental monitoring subsystem, respectively. The industrial computer has a built-in memory that stores a flexible parameter database and a flexible parameter configuration module for implementing controlled atmosphere process control.

2. The modified atmosphere packaging system for tobacco leaves in a lane-type high-density racking warehouse based on flexible parameter configuration according to claim 1, characterized in that, The flexible parameter database stores a first parameter set and a second parameter set; The first parameter set includes the following parameters: Material_Type, Material_Moisture_Range, Pest_Species, Life_Stage_Distribution, Initial_Infestation_Level, and Season_TemperatureZone. The second parameter set, based on the parameters in the first parameter set, includes the following key configurable parameters: at least the target oxygen concentration threshold Target_O2_Level, the target carbon dioxide concentration threshold Target_CO2_Level, the gas replacement rate Gas_Replacement_Rate, the maintenance duration of the controlled atmosphere maintenance phase, and the dynamic adjustment trigger condition Dynamic_Adjustment_Trigger. The key configurable parameters also include the maximum allowable temperature Max_Temperature, the ideal humidity range Ideal_Humidity_Range, and the oxygen concentration alarm upper limit O2_Alarm_UpperLimit.

3. The modified atmosphere packaging system for tobacco leaves in a lane-type high-density racking warehouse based on flexible parameter configuration according to claim 2, characterized in that, The flexible parameter configuration module includes configuration logic: (1) Receive insecticidal object information input through the human-computer interaction interface, and automatically match the first parameter set in the flexible parameter database based on the insecticidal object information and call the corresponding second parameter set; (2) Based on the second set of parameters invoked, the controlled atmosphere operation is divided into at least a replacement phase and a maintenance phase and controlled accordingly: During the replacement phase, the gas regulation subsystem is controlled to introduce nitrogen into the modified atmosphere insecticide unit and discharge the original gas according to the gas replacement rate Gas_Replacement_Rate in the second parameter set until the oxygen concentration reaches the target oxygen concentration threshold Target_O2_Level. After the target oxygen concentration threshold Target_O2_Level is reached, when the target carbon dioxide concentration threshold Target_CO2_Level in the second parameter set is greater than 0, the carbon dioxide supply device is controlled to replenish carbon dioxide to the modified atmosphere insecticide unit through the gas mixer until the carbon dioxide concentration reaches the target carbon dioxide concentration threshold Target_CO2_Level. When the target carbon dioxide concentration threshold Target_CO2_Level in the second parameter set is equal to 0, the carbon dioxide supply device is controlled to be in the off state. During the maintenance phase, based on the real-time data of the environmental monitoring subsystem, it is determined whether the dynamic adjustment trigger condition Dynamic_Adjustment_Trigger is met. When the dynamic adjustment trigger condition Dynamic_Adjustment_Trigger is met, a dynamic adjustment command is output to execute at least one corrective control to control the oxygen concentration, carbon dioxide concentration, and temperature and humidity back to the range defined by the second parameter set. The corrective control includes: micro-nitrogen supplementation, carbon dioxide supplementation, linkage temperature regulation, and linkage humidity regulation. (3) Record and store environmental monitoring data, execution instructions, alarm events, and data on the number and duration of gas replenishment during the replacement and maintenance phases.

4. The controlled atmosphere pest control system for tobacco leaves in a lane-type high-density rack warehouse based on flexible parameter configuration according to claim 3, characterized in that, The pest control target information includes at least the material type, the material moisture content range, the pest species, the distribution of insect stages, the pest severity level, and the seasonal temperature zone. The material type includes imported tobacco leaves, domestic tobacco leaves, tobacco stems, tobacco shreds, and reconstituted tobacco leaves.

5. A controlled atmosphere pest control system for tobacco leaves in an aisle-type high-density racking warehouse based on flexible parameter configuration, as described in claim 3, is characterized in that... The corrective control corresponding to the micro-nitrogen supplementation is specifically as follows: The environmental monitoring subsystem reads the oxygen concentration value O2_current in the controlled atmosphere insecticidal unit in real time. When the environmental monitoring subsystem detects that the oxygen concentration O2_current in the controlled atmosphere insecticidal unit is greater than the target oxygen concentration threshold Target_O2_Level + the allowable deviation range of oxygen concentration ΔO2, the central control subsystem controls the nitrogen generator to perform micro-nitrogen supplementation. The nitrogen generator is controlled to run at a low gas replacement rate Gas_Replacement_Rate for a period of time to reduce the oxygen concentration back to Target_O2_Level and its allowable deviation range, where the allowable deviation range of oxygen concentration ΔO2 is 0.1% to 0.8%.

6. The controlled atmosphere pest control system for tobacco leaves in a lane-type high-density racking warehouse based on flexible parameter configuration according to claim 3, characterized in that, The correction control corresponding to the linked temperature regulation is specifically as follows: When the environmental monitoring subsystem detects that the current temperature T_current inside the controlled atmosphere insecticide unit is greater than the maximum allowable temperature Max_Temperature set in the second parameter set, the central control subsystem outputs a linkage control command to activate the temperature regulation device inside the controlled atmosphere insecticide unit to cool it down and bring the temperature back to the temperature range defined by the second parameter set.

7. A modified atmosphere packaging system for tobacco leaves in a lane-type high-density racking warehouse based on flexible parameter configuration, as described in claim 3, is characterized in that... The corrective control corresponding to the supplemented carbon dioxide is as follows: when the carbon dioxide concentration in the modified atmosphere insecticide unit is detected to be less than the target carbon dioxide concentration threshold Target_CO2_Level + allowable deviation range ΔCO2 set in the second parameter set, carbon dioxide is supplemented to the modified atmosphere insecticide unit until the carbon dioxide concentration returns to Target_CO2_Level and its allowable deviation range, wherein the allowable deviation range ΔCO2 is 0.1% to 0.6%.

8. A controlled atmosphere pest control system for tobacco leaves in an aisle-type high-density racking warehouse based on flexible parameter configuration, as described in claim 3, is characterized in that... The corrective control corresponding to the linked humidity adjustment is as follows: when the current humidity in the modified atmosphere insecticidal unit is detected to be outside the ideal humidity range Ideal_Humidity_Range set in the second parameter set, the central control subsystem outputs a linkage control command to activate the humidification or dehumidification device inside the modified atmosphere insecticidal unit, so that the humidity returns to the ideal humidity range Ideal_Humidity_Range.

9. A modified atmosphere packaging method for controlling pests in tobacco leaves in a lane-type dense rack warehouse based on the flexible parameter configuration system described in claim 4, characterized in that, The method includes the following steps: S1, Lane Sealing Unit: By sending signal commands through an industrial computer, the two ends and the top of the target lane are sealed, so that the target lane forms an independent modified atmosphere pest control unit. S2. Parameter matching and calling: Input the pest control target information through the human-computer interaction interface, automatically match the first parameter set in the flexible parameter database based on the pest control target information, and call the second parameter set corresponding to the first parameter set; S3. Sampling and monitoring: Oxygen concentration, carbon dioxide concentration, temperature and humidity data are collected in the modified atmosphere insecticidal unit according to a preset sampling period of 60 to 120 seconds. S4. Replacement Stage Control: The gas regulation subsystem is controlled to introduce nitrogen into the controlled atmosphere insecticide unit and discharge the original gas according to the gas replacement rate Gas_Replacement_Rate in the second parameter set, and the circulating fan is controlled to run to form gas circulation in the tunnel until the oxygen concentration reaches the target oxygen concentration threshold Target_O2_Level; after the target oxygen concentration threshold Target_O2_Level is reached, when the target carbon dioxide concentration threshold Target_CO2_Level in the second parameter set is greater than 0, the carbon dioxide supply equipment is controlled to supplement carbon dioxide to the controlled atmosphere insecticide unit through the gas mixer until the carbon dioxide concentration reaches the target carbon dioxide concentration threshold Target_CO2_Level; when the target carbon dioxide concentration threshold Target_CO2_Level in the second parameter set is equal to 0, the carbon dioxide supply equipment is controlled to be in the off state; S5. Maintenance Phase Control: Based on the real-time data collected in step S3, determine whether the dynamic adjustment trigger condition Dynamic_Adjustment_Trigger is met; S6. Dynamic Correction Control: When the Dynamic Adjustment Trigger condition Dynamic_Adjustment_Trigger is met, a dynamic adjustment command is output to execute at least one correction control to control the oxygen concentration, carbon dioxide concentration, and temperature and humidity back to the range defined by the second parameter set. The correction control includes: micro-nitrogen supplementation, carbon dioxide supplementation, linkage temperature regulation, and linkage humidity regulation. S7. Data Recording and Storage: Record and store environmental monitoring data, execution instructions, alarm events, and data on the number and duration of gas replenishment during the replacement and maintenance phases.

10. The modified atmosphere packaging method for pest control according to claim 9, characterized in that, The specific corrective control measures corresponding to the micro-nitrogen supplementation, carbon dioxide supplementation, temperature regulation, and humidity regulation are as follows: The specific corrective control corresponding to the micro-nitrogen supplementation is as follows: the environmental monitoring subsystem reads the oxygen concentration value O2_current in the controlled atmosphere insecticidal unit in real time. When the environmental monitoring subsystem detects that the oxygen concentration O2_current in the controlled atmosphere insecticidal unit is greater than the target oxygen concentration threshold Target_O2_Level + the allowable deviation range of oxygen concentration ΔO2, the central control subsystem controls the nitrogen generator to perform micro-nitrogen supplementation. The nitrogen generator is controlled to run at a low gas replacement rate Gas_Replacement_Rate for a period of time to reduce the oxygen concentration back to Target_O2_Level and its allowable deviation range, wherein the allowable deviation range of oxygen concentration ΔO2 is 0.1% to 0.8%. The corrective control corresponding to the supplemented carbon dioxide is as follows: when the carbon dioxide concentration in the modified atmosphere insecticide unit is detected to be less than the target carbon dioxide concentration threshold Target_CO2_Level + allowable deviation range ΔCO2 set in the second parameter set, carbon dioxide is supplemented to the modified atmosphere insecticide unit until the carbon dioxide concentration returns to Target_CO2_Level and its allowable deviation range, wherein the allowable deviation range ΔCO2 is 0.1% to 0.6%; The correction control corresponding to the linkage temperature regulation is as follows: when the environmental monitoring subsystem detects that the current temperature T_current in the modified atmosphere insecticidal unit is greater than the maximum allowable temperature Max_Temperature set in the second parameter set, the central control subsystem outputs a linkage control command to start the temperature regulation device inside the modified atmosphere insecticidal unit to cool down and bring the temperature back to the temperature range defined by the second parameter set. The corrective control corresponding to the linked humidity adjustment is as follows: when the current humidity in the modified atmosphere insecticidal unit is detected to be outside the ideal humidity range Ideal_Humidity_Range set in the second parameter set, the central control subsystem outputs a linkage control command to activate the humidification or dehumidification device inside the modified atmosphere insecticidal unit, so that the humidity returns to the ideal humidity range Ideal_Humidity_Range.

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