Intelligent temperature and humidity control system for lazi strip production environment

Abstract

The application relates to the technical field of environment temperature and humidity regulation, in particular to a spicy strip production environment temperature and humidity intelligent regulation system, which comprises a temperature and humidity sensor, an executing mechanism and a core controller; the core controller is configured with a state discrimination module which is used for acquiring a target temperature interval and a target humidity interval, an actual temperature and an actual humidity; when the lower limit of the target temperature interval is greater than the actual temperature and the actual humidity is in a preset falling risk area, a normal control loop is suspended, and transition state control is triggered; a pre-accumulation module is started under the transition state control, the heater is prohibited from starting and the humidifier is started; a pulse and veto module controls the intermittent starting of the heater after the prohibition is removed; a steady state handover module is used for controlling the exit from the transition state control and the recovery of the normal control loop. The application can resolve the asymmetric hysteresis of equipment response through time sequence logic nesting, block the cliff-like drop of relative humidity and prevent the flash skinning of spicy strips.

Description

Technical Field

[0001] This application relates to the technical field of environmental temperature and humidity control, and in particular to an intelligent temperature and humidity control system for spicy snack production environments. Background Technology

[0002] In the modern processing and manufacturing of snack foods such as spicy strips, flexible co-production of multiple varieties on the same line has become a mainstream trend for improving production line efficiency. In key processes such as extrusion puffing, cooling, and subsequent seasoning and mixing of spicy strips, the temperature and relative humidity of the workshop environment have a decisive impact on the physical form of the semi-finished product. Spicy strips fresh from the extrusion puffing machine have a rich microporous structure; the openness and water retention of these micropores directly determine the penetration and absorption rate of subsequent chili oil and seasonings. To adapt to the process requirements of different formulations (such as switching from low-moisture gluten to high-moisture konjac snacks), the production line needs to dynamically adjust the set temperature and humidity of the workshop environment over a large range when switching work orders. This ensures that different varieties of spicy strips maintain optimal surface micropore tension and internal moisture gradient under specific temperature and humidity conditions, thereby guaranteeing the consistency of the final product's taste and flavor.

[0003] A search revealed Chinese invention patent publication number CN118149431A, which discloses a method, system, and storage medium for IoT control of temperature and humidity. This prior art acquires the current indoor dry-bulb temperature and relative humidity, and sets corresponding upper and lower temperature and humidity thresholds based on the current seasonal characteristics. The system calculates the deviation between the actual temperature and humidity and the set values, and then controls the status of devices such as air conditioners, dehumidifiers, and humidifiers accordingly. This solution fully considers the inverse physical coupling relationship between dry-bulb temperature and relative humidity in the air. Through the linkage feedback control based on seasonal and set temperature and humidity ranges, it can effectively maintain indoor temperature and humidity within the set target range under steady-state conditions, effectively balancing environmental comfort and the energy consumption of home appliances.

[0004] However, the aforementioned linkage control technology based on steady-state deviation feedback suffers from severe dynamic adaptability defects when applied to the flexible co-production of multiple varieties of spicy strips. In special scenarios involving recipe changes, when a new work order requires a significant increase in both the target temperature and humidity of the workshop, existing technology outputs heating and humidification commands simultaneously based on the deviation. This exposes a core technical problem: industrial heating equipment responds extremely quickly, often raising air temperature within seconds, while the water mist dispersion and vaporization process of industrial humidification equipment is extremely slow, with a physical delay of minutes. This asymmetric hysteresis characteristic of "fast heating and slow humidification" at the physical execution level leads to an exponential increase in saturated vapor pressure when air temperature rises sharply. However, during the transition period when the absolute moisture content cannot be replenished in time, the relative humidity in the workshop drops precipitously, creating an extremely dry window period lasting more than ten minutes. Under this extreme transient environment, the surface moisture of the freshly produced, high-temperature spicy strips undergoes a violent flash evaporation effect, causing the surface micropores to rapidly shrink and close due to excessive water loss, forming a hardened crust. This surface crust forms a dense physical barrier, preventing the chili oil from penetrating the internal pores during subsequent mixing processes. This results in a serious batch quality issue where the product has an oily surface and a dry, tasteless interior. Current technologies, lacking intervention on the asymmetric physical response time of the equipment and relying solely on numerical deviations for concurrent control, cannot prevent this thermodynamic transient humidity collapse. Consequently, they completely fail to meet the stringent process requirements for smooth temperature and humidity transitions in the flexible production of spicy strips. Summary of the Invention

[0005] In order to resolve the asymmetric hysteresis of equipment response through nested timing logic and prevent the relative humidity from plummeting to avoid the flash evaporation and skin formation of spicy strips, this application provides an intelligent temperature and humidity control system for the spicy strip production environment.

[0006] The intelligent temperature and humidity control system for spicy snack production environment provided in this application adopts the following technical solution: The intelligent temperature and humidity control system for spicy snack production environment includes a temperature and humidity sensor located in the workshop environment, an actuator with a heater and a humidifier, and a core controller; the core controller is configured with:

[0007] The state discrimination module is used to obtain the target temperature range and target humidity range of the workshop environment, and to obtain the actual temperature and actual humidity of the workshop environment through the temperature and humidity sensor; when the lower limit of the target temperature range is greater than the actual temperature and the actual humidity is in the preset drop risk zone, the normal control loop is suspended and the transitional control is triggered.

[0008] Under the transient control, the pre-installed energy storage module prevents the heater from starting and the humidifier from turning on; when the actual humidity reaches the preset energy storage target value and is maintained at the preset first time threshold, the prohibition is lifted.

[0009] The pulse and veto module controls the heater to start intermittently after the prohibition is lifted. If the actual humidity drops to a preset warning line, the heater is cut off and the humidifier is turned on until the actual humidity recovers to the preset energy storage target value.

[0010] The steady-state handover module exits the transitional control and resumes the normal control loop when the actual temperature and actual humidity stabilize within the corresponding target range and continue to a preset second time threshold.

[0011] Optionally, the preset fall risk zone is defined based on the following conditions:

[0012] Obtain the preset thermodynamic drop tolerance;

[0013] Calculate the sum of the lower limit of the target humidity range and the thermodynamic drop tolerance to obtain the humidity risk threshold;

[0014] The range in which the actual humidity is less than or equal to the humidity risk threshold constitutes the preset fall risk zone.

[0015] Optionally, the logic for defining the preset energy storage target value is as follows:

[0016] Obtain the preset absolute humidity drop resistance reserve compensation amount;

[0017] The upper limit threshold for system safety against condensation is obtained based on the actual temperature.

[0018] Calculate the sum of the lower limit of the target humidity range and the absolute humidity drop resistance reserve compensation amount;

[0019] The smaller of the summed values ​​and the system's safety anti-condensation upper limit threshold are compared and set as the preset energy storage target value.

[0020] Optionally, the configuration logic for the system's safety anti-condensation upper limit threshold and the absolute humidity drop resistance reserve compensation amount is as follows:

[0021] The absolute humidity drop resistance reserve compensation is configured to characterize the water vapor consumption equivalent caused by the heating phase after the heater is unblocked.

[0022] Obtain the preset temperature-dew point mapping table;

[0023] Based on the actual temperature, dynamically query the temperature dew point mapping table to obtain the corresponding system safety anti-condensation upper limit threshold.

[0024] The system's safety anti-condensation upper limit threshold is configured as a boundary input parameter to limit the sum value when the humidifier is continuously turned on.

[0025] Optionally, the front-end energy storage module is configured with an anomaly fallback fault tolerance mechanism:

[0026] The duration of time the humidifier is turned on is accumulated in real time;

[0027] Obtain the preset maximum timeout threshold;

[0028] When the duration reaches the maximum timeout threshold and the actual humidity does not reach the preset energy storage target value, an abnormal interception signal is generated.

[0029] Based on the abnormal interception signal, the command to remove the prohibition is intercepted, the state of prohibiting the heater from starting is forcibly maintained, and a forced shutdown command is triggered.

[0030] Optionally, the logic configuration in the pulse and veto module for controlling the intermittent start of the heater is as follows:

[0031] Obtain the preset connection time threshold and disconnection time threshold;

[0032] The heater is controlled to cyclically and alternately execute an on command that lasts for a specified on time threshold and a stop command that lasts for a specified off time threshold;

[0033] Within the disconnection time threshold for executing the stop command, the humidifier is kept on, and the disconnection time threshold is configured to pause the water vapor dispersion compensation period of the heater.

[0034] Optionally, in the pulse and veto module, the definition and triggering logic of the preset warning line are configured as follows:

[0035] Obtain the sensor delay warning buffer band that characterizes the physical response delay of the temperature and humidity sensor;

[0036] Add the lower limit of the target humidity range to the sensor delay warning buffer band to obtain the preset warning line;

[0037] During the alternating execution of the start command and the stop command, the actual humidity is compared with the preset warning line in real time;

[0038] When the actual humidity drops to the preset warning line, a veto command with the highest priority is triggered, forcibly shutting down the heater regardless of the current execution status.

[0039] Optionally, the action of forcibly cutting off the heater is configured as follows:

[0040] Configure a highest priority interrupt task that is independent of the loop logic that alternates between executing the start and stop instructions;

[0041] When the highest priority veto instruction is triggered, an interrupt signal is generated in response to the highest priority interrupt task;

[0042] Based on the interrupt signal, the heating control circuit of the heater is directly cut off, bypassing the current alternating execution state.

[0043] Optionally, the logic configuration for restoring the conventional control loop in the steady-state handover module is as follows:

[0044] When the actual temperature and the actual humidity are respectively within the corresponding target range and the interrupt signal is not triggered, the handover timer is started;

[0045] If the interrupt signal is not triggered during the period when the handover time reaches a preset second time threshold, a steady-state anchoring command is generated.

[0046] Based on the steady-state anchoring command, the system exits the transient control and transfers control to the conventional control loop.

[0047] Optionally, the deployment of the temperature and humidity sensor and its logical configuration with the preset warning line are as follows:

[0048] The temperature and humidity sensors are physically deployed at the points in the production line where materials leave the processing equipment.

[0049] Obtain the inherent measurement delay time of the temperature and humidity sensor;

[0050] The sensor delay warning buffer band is set based on the inherent measurement delay time;

[0051] The actual humidity collected in real time by the temperature and humidity sensor at the location node is configured as a forced data input to compare with the preset warning line and trigger the highest priority veto command.

[0052] In summary, this application includes the following beneficial technical effects:

[0053] 1. By using a nested timing logic approach, the asymmetric response lag between the rapid heating of the heating equipment and the slow humidification of the humidification equipment is effectively resolved. This fundamentally prevents the precipitous drop in relative humidity in the workshop during the production formula switching process, thereby completely eliminating batch quality accidents caused by the rapid shrinkage and hardening of the spicy strip surface due to flash evaporation of moisture.

[0054] 2. Before the heating demand is triggered, the heater is prevented from starting by the pre-storage module and the humidifier is turned on separately to raise the humidity in the workshop to the safe energy storage target value in advance. At the same time, combined with the anti-condensation boundary limit, the humidity reserve is ensured to be sufficient and not exceed the safe limit of condensation, so as to achieve a dual balance between humidity increase and production safety protection.

[0055] 3. Introducing an early warning line based on sensor response delay and a highest priority interruption veto mechanism during the pulse heating stage can instantly cut off the heater and start humidification compensation before the humidity drops to the process red line, building a bottom-level anti-breakdown safety net to ensure that the temperature and humidity control process is always under control. Attached Figure Description

[0056] Figure 1 This is a diagram of the physical hardware and control topology of the system in this application;

[0057] Figure 2 This is the architecture diagram of the core controller functional modules of this application. Detailed Implementation

[0058] The following is in conjunction with the appendix Figure 1-2 This application will be described in further detail.

[0059] In flexible, multi-variety production lines for spicy snacks, existing temperature and humidity control technologies based on steady-state deviation feedback suffer from a core flaw: they cannot adapt to the asymmetric hysteresis of equipment response. When production work orders require simultaneous increases in both target temperature and humidity, existing technologies output heating and humidification commands concurrently. However, the millisecond-level heating response of industrial heaters and the minute-level water mist vaporization rate of industrial humidifiers create significant asymmetric hysteresis. This hysteresis leads to an exponential increase in saturated vapor pressure when air temperature rises sharply, preventing timely replenishment of absolute moisture content and causing a precipitous drop in relative humidity, resulting in an extremely dry window of several minutes. The hot spicy snacks, fresh from the extrusion machine, experience surface moisture flash evaporation in this environment, causing rapid contraction and closure of surface micropores to form a hardened crust. Ultimately, this prevents the red oil from penetrating during subsequent mixing processes, resulting in batch quality issues where the product has an oily surface and a dry, tasteless interior.

[0060] This application discloses an intelligent temperature and humidity control system for spicy snack production environments, including a temperature and humidity sensor deployed in the spicy snack production workshop, an actuator integrating a heater and humidifier, and a core controller. The temperature and humidity sensor uses a high-precision capacitive temperature and humidity transmitter with a measurement response time (T63) of no more than 8 seconds and a measurement accuracy of no less than ±2%RH and ±0.2℃. It is physically deployed at the point in the production line where the material leaves the processing equipment, specifically at the beginning of the cooling section at the outlet of the extrusion machine. This location is a critical quality control point where the semi-finished spicy snack product has just left the high-temperature processing stage. The collected temperature and humidity data directly serves as the forced input data source for the core controller. The heater of the actuator uses an industrial electric heating tube driven by a solid-state relay, or a steam heating system driven by an electric proportional regulating valve, with a response time of no more than 2 seconds. The humidifier uses a high-pressure micro-mist humidifier or an ultrasonic industrial humidifier, equipped with a workshop circulating axial flow fan. The conventional airflow of the circulating axial flow fan is 5000 m³ / h. 3 / h-10000m 3 The system can achieve a stable airflow speed of 0.3m / s-0.5m / s within the workshop, ensuring uniform dispersion of water mist throughout the space. The core controller adopts an industrial general-purpose programmable logic controller, specifically a Siemens S7-1200 series or Mitsubishi FX5U series, which features digital input / output and analog signal acquisition functions. All control logic is implemented through the program module of the core controller.

[0061] like Figure 1 As shown in the diagram, this figure visually illustrates the overall physical architecture of the system, the deployment of key equipment, and the control relationships of the signals. On the left side of the production line are, in order, the "extrusion puffing machine" and the "cooling section," with material flowing between them. The core feature of this system is the physical deployment of "temperature and humidity sensors" at specific "material exit points from processing equipment" to collect environmental data in real time that best matches the material's characteristics. This data is transmitted to the central "core controller," which, according to preset logic, instructs the "actuators" on the right (specifically including "heaters" and "humidifiers") via signal lines to regulate the environment.

[0062] like Figure 2 As shown in the figure, this figure will Figure 1 The core controller is represented by four interconnected software logic modules. These four modules are connected sequentially to form a complete control chain:

[0063] Status discrimination module: responsible for receiving sensor data and determining the environmental status;

[0064] Pre-installed energy storage module: responsible for calculating humidity-resistant drop compensation during the initial transition phase;

[0065] Pulse and veto module: responsible for performing complex, prioritized timing control between heating and humidification;

[0066] Steady-state handover module: responsible for smoothly restoring to normal control at the end of the transition state.

[0067] The core controller, based on the pre-deployed temperature and humidity sensors and actuators, performs the entire process of status identification. The core controller obtains the spicy snack product formula and process parameters corresponding to the current production work order through the industrial standard communication interface of the workshop manufacturing execution system. The industrial standard communication interface adopts the Profinet or Modbus TCP industrial Ethernet protocol, adapting to the common industrial control system architecture of food processing workshops, ensuring the real-time performance and stability of data transmission. From the formula and process parameters, the core controller extracts the target temperature range and target humidity range of the workshop environment. The lower limit of the target temperature range is the minimum production environment temperature required by the new work order, and the upper limit is the maximum permissible production environment temperature. The lower limit of the target humidity range is the minimum production environment relative humidity required by the new work order, and the upper limit is the maximum permissible production environment relative humidity.

[0068] The core controller collects real-time data on the actual temperature and humidity of the workshop environment through temperature and humidity sensors deployed at the location nodes where materials leave the processing equipment on the production line, with a cycle of 100ms. This 100ms acquisition cycle matches the measurement response time of the temperature and humidity sensors used in this implementation, which is no more than 8s, ensuring complete capture of the continuous changes in temperature and humidity in the workshop. This avoids data loss due to fluctuations in critical operating conditions and is compatible with the typical computational load of industrial programmable logic controllers, ensuring stable operation of the control logic. The temperature and humidity data collected by this location node is the sole mandatory input data source for the core controller's execution status identification, directly reflecting the real environmental conditions of the spicy snack semi-finished product. This avoids control failures caused by deviations between the average data across the entire workshop and the data from key quality control nodes, overcoming the accuracy deficiencies of existing technologies that use average data across the entire area for control.

[0069] The core controller synchronously defines the preset drop risk zone. The core controller first obtains the preset thermodynamic drop tolerance. The thermodynamic drop tolerance ranges from 3% to 5%. This value is set based on the inherent thermodynamic characteristics of air. During the initial 30 seconds of temperature rise, the saturated vapor pressure of the air will momentarily increase with the temperature rise, causing a momentary small drop in relative humidity of 3%-5%. This tolerance is used to cover the momentary fluctuations caused by this thermodynamic characteristic, avoiding frequent false triggering of transient control under boundary conditions, and ensuring that the system can identify the potential risk of humidity drops in advance, changing the existing technology's hysteretic control mode that only performs adjustments after a significant deviation in humidity.

[0070] The core controller calculates the sum of the lower limit of the target humidity range and the thermodynamic drop tolerance to obtain the humidity risk threshold. The core controller defines the range where the actual humidity is less than or equal to the humidity risk threshold as the preset drop risk zone.

[0071] The core controller performs a dual-condition synchronous judgment. It compares the lower limit of the target temperature range with the actual temperature. If the lower limit is greater than the actual temperature, it determines that there is a clear need for temperature increase in the current operating condition. Simultaneously, the core controller compares the actual humidity with a preset drop risk zone. If the actual humidity falls within the preset drop risk zone, it determines that there is a potential risk of a precipitous drop in relative humidity in the current operating condition.

[0072] When both of the above conditions are met simultaneously, the core controller immediately suspends the conventional control loop and triggers transient control. The conventional control loop is a common temperature and humidity independent PID feedback control loop in existing technology. This loop only outputs heating and humidification commands based on the deviation between the actual temperature and humidity values ​​and the set values, which cannot adapt to the asymmetric response hysteresis of heating and humidification equipment and is prone to causing a precipitous drop in relative humidity. When the core controller suspends the conventional control loop, it simultaneously cuts off the conventional control loop's output control authority over the heater and humidifier, ensuring that subsequent control actions are executed only by the transient control logic.

[0073] If the above two conditions are not met simultaneously, the core controller maintains the normal operation of the conventional control loop and continuously performs steady-state closed-loop regulation of temperature and humidity.

[0074] The core controller receives the transient control command triggered earlier and immediately executes the pre-heating cutoff and humidification start-up operations. The core controller sends a first-priority control command to the actuator, forcibly prohibiting the heater from starting, locking the heater's heating enable signal, and cutting off the output permissions of all heating control loops. This prevents the heating action from occurring at the execution level, avoiding the risk of a sudden drop in humidity caused by the simultaneous start-up of heating and humidification equipment in existing technologies. Simultaneously, the core controller sends a humidifier start-up command to the actuator and starts the workshop's supporting circulating axial flow fan. This allows the water mist output by the humidifier to quickly diffuse within the workshop space with the circulating airflow, improving the vaporization efficiency of the water mist and ensuring a uniform and stable increase in workshop humidity.

[0075] The core controller synchronously completes the definition of the preset energy storage target value, and the definition process is strictly executed in sequence. The core controller first retrieves the preset absolute humidity drop compensation reserve, which ranges from 8% to 12%. This value is set based on the thermodynamic characteristics of air. During the heating phase after the heater is released, as the workshop air temperature rises from the actual temperature to the lower limit of the target temperature range, the saturated water vapor pressure will increase exponentially with the temperature rise, and the relative humidity will decrease synchronously. This compensation is used to accurately cover the equivalent of water vapor consumption caused by the entire heating process, reserving sufficient drop safety margin for relative humidity during the subsequent heating process, and avoiding an unbuffered drop in relative humidity due to temperature rise.

[0076] The core controller uses real-time temperature and humidity sensors at the points where materials leave the processing equipment in the production line to determine the system's safe anti-condensation upper limit threshold. The core controller has a pre-stored temperature-dew point mapping table, compiled according to the air enthalpy-humidity diagram specification in GB / T 50155-2015 "Standard for Terminology of Heating, Ventilation and Air Conditioning," and corrected for the lowest surface temperature of the enclosure structure in the spicy snack production workshop. This lowest surface temperature is typically 2-3°C lower than the ambient temperature. Each temperature node in the mapping table corresponds to the highest relative humidity value at which condensation will not occur. The core controller dynamically queries this mapping table every 100ms based on the real-time actual temperature to obtain the corresponding system's safe anti-condensation upper limit threshold, which is limited to a maximum value of 85%. This value is set according to the hygiene and production safety regulations for food production workshops, preventing excessively high relative humidity from causing condensation on walls and equipment surfaces, preventing condensate dripping and contaminating the spicy snack semi-finished products, production equipment, and raw materials, and eliminating secondary production quality risks caused by condensation.

[0077] The core controller calculates the sum of the lower limit of the target humidity range and the absolute humidity drop resistance reserve compensation. This sum is then compared to the system's safety anti-condensation upper limit threshold, and the smaller of the two values ​​is set as the preset energy storage target value. This defining logic ensures that the workshop humidity has sufficient drop resistance reserve while strictly controlling the humidity to not exceed the condensation safety boundary, achieving a dual balance between humidity energy storage needs and production safety. Compared to the boundless humidification control of existing technologies, this effectively avoids the risk of condensation contamination during the production process.

[0078] While continuously prohibiting the heater from starting, the core controller controls the humidifier to operate at full power. Simultaneously, it collects and monitors the actual humidity of the workshop environment in real time via temperature and humidity sensors deployed at the material detachment points from the processing equipment on the production line, every 100ms. When the actual humidity reaches the preset energy storage target value, and this state continues to reach the preset first time threshold, the core controller releases the prohibition command on heater startup. The first time threshold ranges from 30s to 60s, a value set based on the spatial airflow characteristics of the spicy snack production workshop. The circulating axial flow fans in a typical spicy snack production workshop can achieve an airflow velocity of 0.3m / s to 0.5m / s. This duration ensures that the water mist output by the humidifier is fully dispersed and vaporized throughout the workshop, achieving a uniform and stable humidity distribution across all areas, eliminating situations where local humidity levels are below standard, and ensuring that the humidity energy storage effect comprehensively covers the entire production workshop.

[0079] The core controller is configured and implements an anomaly fallback fault-tolerance mechanism during the pre-energy storage phase, providing safety assurance for the equipment and operating conditions during the energy storage process. Starting from the moment the humidifier is turned on, the core controller continuously accumulates its running time in real time, while simultaneously retrieving a preset maximum timeout threshold, which is set to 45 minutes. This value is based on the basic operating parameters of a typical spicy snack production workshop, with a space volume of 500m³. 3 -1000m 3 The rated humidification capacity of the matching industrial humidifier is 50kg / h-100kg / h. Under normal operating conditions and good workshop airtightness, the maximum time required to raise the relative humidity of the workshop from the normal production value to the preset energy storage target value shall not exceed 45 minutes. If the time exceeds this, it can be determined that the humidifier has equipment failure such as water shortage or pipeline blockage, or that the workshop doors and windows or exhaust fans are not closed, resulting in the inability to continuously raise the humidity of the workshop.

[0080] When the humidifier's continuous operation time reaches the maximum timeout threshold, and the core controller detects that the actual humidity has not yet reached the preset energy storage target value, the core controller immediately generates an abnormal interception signal. Based on this abnormal interception signal, the core controller directly intercepts the relevant instructions to lift the heater's prohibition, forcibly maintaining the state of prohibiting the heater from starting. At the same time, it issues a forced shutdown command to the production line control system, stopping the puffing process on the production line. Simultaneously, it triggers the on-site audible and visual alarm devices, using audible and visual prompts to inform on-site maintenance personnel to promptly investigate humidifier equipment malfunctions and abnormal operating conditions in the workshop. This prevents ineffective humidification and subsequent erroneous heating operations under abnormal equipment conditions from the source, ensuring the quality and safety of spicy snack production.

[0081] The core controller receives the previously released heater start-up prohibition command, executes pulse heating control logic, and simultaneously runs the highest priority humidity rejection protection logic in parallel. The core controller first obtains preset on-time and off-time thresholds. The on-time threshold ranges from 10s to 15s, and the off-time threshold ranges from 20s to 30s. These values ​​are set based on the asymmetric response characteristics of heating and humidification equipment. Industrial heaters can complete temperature rise responses within seconds, while industrial humidifiers have a physical delay of minutes in the water mist dispersion and vaporization process. Through time-slicing duty cycle control, the heating rate of the workshop can be forcibly slowed down to match the physical speed of water mist dispersion and vaporization in the humidifier, avoiding a sudden temperature rise caused by continuous full-power operation of the heater, and allowing sufficient time for the humidifier to continuously replenish the absolute moisture content of the workshop.

[0082] The core controller controls the heater to alternately execute an on command with a continuous on time threshold and a stop command with a continuous off time threshold. During the off time threshold when the heater executes the stop command, the core controller keeps the humidifier continuously on, configuring the off time threshold as a period to pause the heater's water vapor dispersion compensation. This continuously replenishes the absolute moisture content in the workshop, offsetting the relative humidity decrease caused by the increase in saturated vapor pressure during heating, thus changing the existing technology's delayed control mode that only replenishes water vapor after a significant humidity deviation.

[0083] The core controller synchronously completes the definition of the preset warning line, and the definition process is strictly executed in sequence. The core controller first obtains the sensor delay warning buffer band, which characterizes the physical response delay of the temperature and humidity sensor. The value of the sensor delay warning buffer band is 2%. This value is set based on the inherent parameters of the temperature and humidity sensor deployed in the previous steps. The high-precision capacitive temperature and humidity sensor used in this embodiment has an inherent measurement response time T63 of 5s-8s. Within this response time, the actual humidity in the workshop will continue to fall as the temperature rises. This 2% sensor delay warning buffer band, based on the inherent measurement delay time of 5s-8s of the temperature and humidity sensor, is used to cover the sensor's measurement delay, trigger protection actions in advance, and avoid the risk of lag when the actual humidity has fallen below the lower limit of the target humidity range, but the sensor measurement data has not been fed back in time.

[0084] The core controller calculates the sum of the lower limit of the target humidity range and the sensor delay warning buffer zone to obtain the preset warning line. Throughout the entire cycle of the heater alternately executing start and stop commands, the core controller compares the actual humidity collected by the temperature and humidity sensors at the point where the material leaves the processing equipment with the preset warning line in real time, at 100ms intervals. The actual humidity collected at this point is the sole mandatory data input triggering the rejection command, directly reflecting the real environmental conditions of the spicy snack semi-finished product. This ensures that the protection logic directly responds to the core quality control area where the product is located, avoiding control failures caused by deviations between the average data across the entire workshop and the data at key nodes.

[0085] When the actual humidity drops to the preset warning threshold, the core controller triggers a highest-priority rejection instruction, disregarding the current heater's execution status and forcibly shutting it off. This forced heater shutdown is achieved through a highest-priority interrupt task independent of the heater's intermittent start-up loop logic. The core controller configures the humidity monitoring and shutdown logic as a periodic interrupt task or a hardware interrupt task within the programmable logic controller program. This interrupt task has a higher execution priority than all loop control tasks within the core controller, with an execution cycle of no more than 50ms, ensuring response latency is controlled within milliseconds. This overcomes the response lag limitations caused by the sequential execution of control logic in existing technologies.

[0086] When the highest priority rejection instruction is triggered, the core controller responds to the highest priority interrupt task by generating an interrupt signal. Based on this interrupt signal, it bypasses the current alternating execution state of the heater and directly cuts off the heater's heating control loop. Simultaneously, it controls the humidifier to operate at full power until the actual humidity returns to the preset energy storage target value defined in the previous steps. Once the actual humidity returns to the preset energy storage target value, the core controller cancels the rejection instruction and resumes the intermittent start-up cycle control of the heater. When the cycle control is resumed, it restarts the cycle execution from the start instruction at the on-time threshold, continuing the heating process of the workshop environment while ensuring the humidity safety boundary.

[0087] The core controller inherits the pulse heating and rejection protection cycle control process of the previous steps. It continuously collects the actual temperature and humidity of the workshop environment in real time through temperature and humidity sensors deployed at the location nodes where materials leave the processing equipment in the production line at a cycle of 100ms, and performs the entire process of steady-state determination and control handover.

[0088] The core controller performs synchronous verification of the steady-state entry conditions. The verification period is consistent with the temperature and humidity acquisition period, which is 100ms, to ensure the real-time nature of the steady-state determination. The core controller compares the real-time acquired actual temperature with the target temperature range to confirm that the actual temperature is stably within the target temperature range. The core controller synchronously compares the real-time acquired actual humidity with the target humidity range to confirm that the actual humidity is stably within the target humidity range. The core controller synchronously checks the entire control process record to confirm that no highest priority interrupt signal or rejection instruction set in the preceding steps was triggered throughout the verification period, eliminating the potential risk of abnormal temperature and humidity fluctuations.

[0089] When all the above steady-state entry conditions are simultaneously met, the core controller starts the handover timing. The target value of the handover timing is a preset second time threshold, which ranges from 120s to 180s. This value is set based on the actual operating conditions of spicy strip production. The discharge frequency of the puffing process in the spicy strip production line is usually one batch every 60s. This duration can fully cover the production cycle of 2-3 batches, ensuring that the stable temperature and humidity state is not affected by the instantaneous airflow of a single batch discharge. At the same time, it fully covers the entire cycle of airflow circulation in the workshop, eliminating the misjudgment caused by instantaneous sensor sampling errors and local airflow fluctuations. It confirms that the high-risk transition period of strong thermal and humidity coupling drop has been completely eliminated, avoiding temperature and humidity rebound after the switch of control, and ensuring the continuous stability of production conditions.

[0090] During the handover timing cycle, the core controller continuously monitors the actual temperature and humidity of the workshop environment and the interrupt signal triggering status. If no interrupt signal or rejection command is triggered throughout the period when the handover timing reaches the second time threshold, and the actual temperature and humidity remain stable within the corresponding target range, the core controller generates a steady-state anchoring command.

[0091] Based on steady-state anchoring commands, the core controller officially exits the transitional control mode. Before handing over control, the core controller first synchronizes and matches the temperature and humidity settings of the conventional control loop with the current stable actual temperature and humidity in the workshop. Then, it smoothly and completely transfers control of the actuators of the heater and humidifier to the conventional control loop, completing the entire process of temperature and humidity transitional regulation after the change of spicy strip production formula. This avoids fluctuations in operating conditions caused by command jumps during the control switch, achieving a seamless connection between transitional and steady-state control.

[0092] If the actual temperature or humidity deviates from the corresponding target range during the handover timing operation, or if an interrupt signal or rejection command is triggered, the core controller will immediately terminate the current handover timing and return to the cyclic control stage of pulse heating and rejection protection until all steady-state entry conditions are met again, and then restart the handover timing.

[0093] This specific implementation constructs a complete closed-loop control system: the state identification module enables early prediction of high-risk operating conditions, breaking through the limitation of existing technologies that can only provide feedback and adjustment after the fact, and providing a precise triggering premise for subsequent timing control; the pre-energy storage module eliminates the conflict basis of asymmetric hysteresis between heating and humidification from the root by pre-cutting the heating command and unidirectional humidity boosting, and achieves a balance between energy storage effect and production safety by limiting the anti-condensation boundary; the pulse and veto module further matches the response speed of heating and humidification through duty cycle control, and builds a bottom-level anti-breakdown safety net through an independent high-priority interruption veto mechanism, completely eliminating the possibility of relative humidity falling below the process red line; the steady-state handover module realizes the smooth connection between transition state and conventional steady-state control, avoiding operating condition fluctuations caused by control switching. The entire solution does not require complex algorithms or high-performance hardware. It resolves the physical contradictions that existing technologies cannot solve by simply nesting time-series logic. It eliminates the flash evaporation and skin formation defects in the flexible production line changeover process of spicy strips from the root, ensuring the consistency of the taste and flavor of spicy strip products. At the same time, it has extremely low deployment costs and extremely high operational reliability, and can be widely adapted to the production environment control scenarios of spicy strips and similar snack foods.

[0094] The implementation principle of the intelligent temperature and humidity control system for spicy strip production environment in this application embodiment is as follows: This application, by constructing a transitional state control strategy with nested time-series logic, accurately resolves the problem of a precipitous drop in relative humidity caused by the asymmetric hysteresis between the fast response of the heater and the slow response of the humidifier in the flexible production of spicy strips. This completely eliminates batch quality accidents caused by flash evaporation and crusting on the surface of the spicy strips, resulting in the inability of red oil to penetrate and the product becoming dry, hard, and tasteless. The system first uses a state identification module to predict the heating demand and humidity drop risk. After triggering the transitional state control, the pre-installed energy storage module forcibly prohibits the heater from starting and turns on the humidifier separately, raising the humidity in the workshop to a preset energy storage target value that balances drop resistance reserves and anti-condensation safety, thus eliminating the problem at its source. In addition to addressing the conflict between heating and humidification responses, the pulse and rejection module intermittently starts the heater to match the humidifier's diffusion rate and interrupts the task with the highest priority to monitor the actual humidity in real time. Once the preset warning line is reached, the heater is immediately forcibly cut off and humidification is restarted, forming a bottom-layer anti-breakdown safety net to ensure that the relative humidity is always not lower than the process red line. Finally, the steady-state handover module smoothly restores the normal control loop when the temperature and humidity are stable within the target range and there is no interruption trigger, achieving seamless connection. The entire solution, with its low-cost and highly reliable nested timing logic, eliminates the damage to the microporous structure of spicy strips caused by transient temperature and humidity collapses from the root, ensuring the consistency of product taste and flavor in a multi-variety co-production environment.

[0095] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A smart temperature and humidity control system for the production environment of spicy strips, characterized in that, It includes a temperature and humidity sensor located in the workshop environment, an actuator with a heater and humidifier, and a core controller; the core controller is configured with: The state discrimination module is used to obtain the target temperature range and target humidity range of the workshop environment, and to obtain the actual temperature and actual humidity of the workshop environment through the temperature and humidity sensor; when the lower limit of the target temperature range is greater than the actual temperature and the actual humidity is in the preset drop risk zone, the normal control loop is suspended and the transitional control is triggered. Under the transient control, the pre-installed energy storage module prevents the heater from starting and the humidifier from turning on; when the actual humidity reaches the preset energy storage target value and is maintained at the preset first time threshold, the prohibition is lifted. The pulse and veto module controls the heater to start intermittently after the prohibition is lifted. If the actual humidity drops to a preset warning line, the heater is cut off and the humidifier is turned on until the actual humidity recovers to the preset energy storage target value. The steady-state handover module exits the transitional control and resumes the normal control loop when the actual temperature and actual humidity stabilize within the corresponding target range and continue to a preset second time threshold.

2. The system according to claim 1, characterized in that, The preset fall risk zone is defined based on the following conditions: Obtain the preset thermodynamic drop tolerance; Calculate the sum of the lower limit of the target humidity range and the thermodynamic drop tolerance to obtain the humidity risk threshold; The range in which the actual humidity is less than or equal to the humidity risk threshold constitutes the preset fall risk zone.

3. The system according to claim 1, characterized in that, The logic for defining the preset energy storage target value is as follows: Obtain the preset absolute humidity drop resistance reserve compensation amount; The upper limit threshold for system safety against condensation is obtained based on the actual temperature. Calculate the sum of the lower limit of the target humidity range and the absolute humidity drop resistance reserve compensation amount; The smaller of the summed values ​​and the system's safety anti-condensation upper limit threshold are compared and set as the preset energy storage target value.

4. The system according to claim 3, characterized in that, The configuration logic for the system's safety anti-condensation upper limit threshold and the absolute humidity drop resistance reserve compensation amount is as follows: The absolute humidity drop resistance reserve compensation is configured to characterize the water vapor consumption equivalent caused by the heating phase after the heater is unblocked. Obtain the preset temperature-dew point mapping table; Based on the actual temperature, dynamically query the temperature dew point mapping table to obtain the corresponding system safety anti-condensation upper limit threshold. The system's safety anti-condensation upper limit threshold is configured as a boundary input parameter to limit the sum value when the humidifier is continuously turned on.

5. The system according to claim 4, characterized in that, The front-end energy storage module is equipped with an anomaly fallback fault tolerance mechanism: The duration of time the humidifier is turned on is accumulated in real time; Obtain the preset maximum timeout threshold; When the duration reaches the maximum timeout threshold and the actual humidity does not reach the preset energy storage target value, an abnormal interception signal is generated. Based on the abnormal interception signal, the command to remove the prohibition is intercepted, the state of prohibiting the heater from starting is forcibly maintained, and a forced shutdown command is triggered.

6. The system according to claim 1, characterized in that, The logic configuration for controlling the intermittent start of the heater in the pulse and veto module is as follows: Obtain the preset connection time threshold and disconnection time threshold; The heater is controlled to cyclically and alternately execute an on command that lasts for a specified on time threshold and a stop command that lasts for a specified off time threshold; Within the disconnection time threshold for executing the stop command, the humidifier is kept on, and the disconnection time threshold is configured to pause the water vapor dispersion compensation period of the heater.

7. The system according to claim 6, characterized in that, In the pulse and rejection module, the definition and triggering logic of the preset warning line are configured as follows: Obtain the sensor delay warning buffer band that characterizes the physical response delay of the temperature and humidity sensor; Add the lower limit of the target humidity range to the sensor delay warning buffer band to obtain the preset warning line; During the alternating execution of the start command and the stop command, the actual humidity is compared with the preset warning line in real time; When the actual humidity drops to the preset warning line, a veto command with the highest priority is triggered, forcibly shutting down the heater regardless of the current execution status.

8. The system according to claim 7, characterized in that, The action of forcibly cutting off the heater is configured as follows: Configure a highest priority interrupt task that is independent of the loop logic that alternates between executing the start and stop instructions; When the highest priority veto instruction is triggered, an interrupt signal is generated in response to the highest priority interrupt task; Based on the interrupt signal, the heating control circuit of the heater is directly cut off, bypassing the current alternating execution state.

9. The system according to claim 8, characterized in that, The logic configuration for restoring the conventional control loop in the steady-state handover module is as follows: When the actual temperature and the actual humidity are respectively within the corresponding target range and the interrupt signal is not triggered, the handover timer is started; If the interrupt signal is not triggered during the period when the handover time reaches a preset second time threshold, a steady-state anchoring command is generated. Based on the steady-state anchoring command, the system exits the transient control and transfers control to the conventional control loop.

10. The system according to claim 7, characterized in that, The deployment of the temperature and humidity sensor and its logical configuration with the preset warning line are as follows: The temperature and humidity sensors are physically deployed at the points in the production line where materials leave the processing equipment. Obtain the inherent measurement delay time of the temperature and humidity sensor; The sensor delay warning buffer band is set based on the inherent measurement delay time; The actual humidity collected in real time by the temperature and humidity sensor at the location node is configured as a forced data input to compare with the preset warning line and trigger the highest priority veto command.

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