Closed chemical tabletting system with nitrogen seal positive pressure protection function

Abstract

This invention discloses a closed-loop chemical flake system with nitrogen-sealed positive pressure protection, relating to the field of chemical flake control technology. The system includes: collecting feed mass flow rate, condensate heat transfer medium reflux heat exchange, and rotor angular velocity to construct an initial state tensor; generating a predicted main compartment volume collapse based on the initial state tensor, and performing band-resistance processing according to the mechanical cutting fundamental frequency to form a lead compensation command; synchronously driving the main and auxiliary gas paths, performing pre-gas replenishment on the upper part of the main compartment and isobaric replacement on the non-discharge zone of the rotary airlock after speed limiting via a micro-pressure clamping multi-hole array; and utilizing a micro-differential pressure transmitter array, oxygen concentration meter, hardware watchdog, isolation baffle, and corrugated compensation airbag for cruise control and disaster recovery interlocking. This system can suppress transient pressure loss, reverse air intake at the discharge end, and control vibration tracking during continuous flake formation, and improve the stability of the inert atmosphere.

Description

Technical Field

[0001] This invention relates to the field of chemical flake control technology, specifically a closed chemical flake system with nitrogen sealing positive pressure protection function. Background Technology

[0002] Flake forming equipment is commonly used in the heating manufacturing process of petroleum, fine chemicals, oils, auxiliaries, and pharmaceutical intermediates. The heated liquid product is cooled by cooling components and formed into flakes or crystalline solids. The scraping, unloading, and discharge processes are carried out in a closed equipment. In industrial production, the main components are a closed shell, cooling drum, scraper, and lower discharge mechanism. Inert gas is introduced to prevent the material from contacting the air and causing oxidation, discoloration, odor emission, and dust leakage.

[0003] Chinese patent document CN212818231U discloses a crystallization slicing machine for preventing material oxidation and discoloration under nitrogen protection. This device includes a shell, a top cover, a feed inlet, an exhaust outlet, a feed hopper, a cooling drum, a nitrogen inlet pipe, a scraper, and a discharge device. The shell comprises a closed containment space consisting of cylindrical, spherical, and conical sections. The cooling drum is installed in the middle of the shell and is rotatable. The scraper is located near the outer surface of the cooling drum to remove solidified material covering the drum surface. The nitrogen inlet pipe is installed below the cooling drum, with one end connected to the inner wall of the shell and the other end flanged to external nitrogen. The pipe wall has drilled holes for venting gas into the shell. The top cover has a pressure testing port with a pneumatic regulating butterfly valve and a pressure transmitter. When the slight positive pressure in the shell reaches the set pressure, gas is released from the exhaust outlet. Liquid raw materials enter the feed hopper through the feed inlet, flow to the outer surface of the cooling drum, are cooled as the drum rotates, and form solid flakes. After being peeled off by the scraper, the flakes fall into the lower discharge device and are continuously output via a screw conveyor roller.

[0004] The aforementioned existing technologies all maintain an inert atmosphere inside the equipment by introducing nitrogen into the shell and measuring and venting pressure at the top. However, they mainly sense and control the overall pressure of the shell and the general air isolation state. In continuous production, the liquid raw material cools, solidifies, and shrinks in volume on the surface of the cooling drum, while the lower discharge device continuously discharges the sheet material. The free space and local flow field inside the equipment change with the change of the material state.

[0005] Because the existing technology only senses and regulates the upper part of the casing, and the exhaust control is mainly based on exhaust at a slightly positive pressure, it lacks the ability to effectively identify and distinguish the instantaneous volume changes caused by the rapid heat consumption during the phase change process, as well as the periodic disturbances caused by the continuous mechanical discharge from the lower part. Therefore, in applications involving special materials, continuous high-throughput operation, or applications with high airtightness requirements, local pressure changes, reverse air intake at the discharge end, material re-exposing to air, and increased burden on odor and dust control may occur inside the equipment, thereby affecting the stability of product appearance, process safety, and the smoothness of continuous operation.

[0006] Therefore, how to maintain the pressure of the sealed cavity under the conditions of phase change volume shrinkage and continuous mechanical discharge during the sealed flake formation process, and suppress reverse air intake at the discharge end, is a technical problem that urgently needs to be solved in this field. Summary of the Invention

[0007] (a) Technical problems to be solved To address the shortcomings of existing technologies, this invention provides a closed-loop chemical flake-forming system with nitrogen-sealed positive pressure protection. It generates a predicted volume collapse of the main compartment based on the initial state tensor and performs band-stop processing according to the mechanical cutting fundamental frequency to generate a lead-compensation command. It synchronously drives the main and auxiliary gas paths, pre-filling the upper part of the main compartment with gas and performing isobaric replacement on the non-discharge area of ​​the rotary airlock after speed limiting via a micro-pressure clamping multi-hole array. Cruise control and disaster recovery interlocking are achieved using a micro-differential pressure transmitter array, an oxygen concentration meter, a hardware watchdog timer, isolation baffles, and corrugated compensation airbags. This system can suppress transient pressure loss, reverse air intake at the discharge end, and control vibration tracking during continuous flake-forming, while improving the stability of the inert atmosphere; thus solving the technical problems described in the background art.

[0008] (II) Technical Solution To achieve the above objectives, the present invention provides the following technical solution: A closed-loop chemical flake formation system with nitrogen-sealed positive pressure protection function includes a closed main chamber for phase change flake formation, a rotary airlock discharge assembly connected to the lower part of the closed main chamber, a nitrogen source, a main gas path, an auxiliary gas path, a thermal and mass disturbance sensing component, and a control center. Its features are: The thermo-mass disturbance sensing component outputs the feed mass flow rate signal, the condensate heat transfer heat transfer signal, and the rotor angular velocity signal of the rotary airlock discharge assembly under the same system clock. The control center generates a predicted volume collapse of the main compartment based on the feed mass flow rate signal and the condensed heat transfer medium reflux heat exchange signal, and performs band-resistance processing on the predicted volume collapse of the main compartment according to the mechanical cutting fundamental frequency corresponding to the rotor angular velocity signal to generate an advance compensation command. The main air path is connected to the upper part of the sealed main compartment via the main pneumatic valve, and the auxiliary air path is connected to the non-dropping area of ​​the rotary airlock discharge assembly via the pre-charge bypass. A micro-pressure clamping multi-hole array is connected in series on the pre-charge bypass. Based on the advance compensation command, the control center synchronously drives the main pneumatic valve and the pre-charge bypass at the same advance moment. Before the predicted negative pressure is formed, it inputs compensation nitrogen into the sealed main compartment and inputs isobaric nitrogen after being limited by the micro-pressure clamping multi-hole array into the non-drop material area.

[0009] Furthermore, the thermal disturbance sensing components include a pump speed encoder, a thermoelectric bridge, and an edge control gateway; The edge control gateway aligns the feed mass flow rate signal, the condensate heat transfer medium reflux heat transfer signal, and the rotor angular velocity signal to the same sampling window, and encapsulates them into an initial state tensor according to a unified frame number. The initial state tensor is fixed and includes the same-clock mass flow rate, same-clock reflux heat transfer, heat mass decay index, phase change interface gradient, and uniform frame number.

[0010] Furthermore, the control center generates the predicted volume collapse of the main cabin within the same volume calculation window based on the same clock mass flow rate, same clock reflux heat transfer, heat mass decay index and phase change interface gradient. The control center calculates the mechanical cutting fundamental frequency based on the rotor angular velocity signal, and performs band-stop processing only on the periodic components in the neighborhood of the mechanical cutting fundamental frequency, while keeping the other frequency band components unchanged.

[0011] Furthermore, the control center encapsulates the result after band-stop processing into a lead compensation command; Among them, the advance compensation command includes a unified frame sequence number, the predicted amount of main cabin volume collapse, the preset peak time, and the advance time constant. The control center synchronously drives the main pneumatic valve and the pre-charge bypass only when the unified frame sequence number is consistent with the initial state tensor.

[0012] Furthermore, the rotary airlock discharge assembly has a rotor coding zero position; the control center stores the start angle and end angle corresponding to the non-discharge zone, and opens the pre-charge bypass when the current rotor phase falls between the start angle and the end angle; The precharge bypass is closed when the current rotor phase is out of the start angle and the end angle.

[0013] Furthermore, the rotary airlock discharge assembly includes a return sealing section; the micro-pressure clamping porous array is composed of sintered metal plate stacks connected in series upstream of the pre-charge bypass, and the absolute pore size is 15 micrometers to 25 micrometers. The centerline of the pre-charge bypass is located after the return sealing section and offset from the vertical by 15 to 35 degrees.

[0014] Furthermore, the system also includes a differential pressure transmitter array, an oxygen concentration meter, a hardware watchdog, an isolation baffle, and a passively forced deformation Teflon corrugated compensating airbag. When the pressure in the sealed main chamber drops below the mechanical red warning line, the hardware watchdog cuts off the power supply to the main feed motor and locks the isolation baffle. The passively forced deformation Teflon corrugated compensation airbag folds inward into the sealed main chamber. When the pressure in the sealed main chamber does not drop below the mechanical red warning line, the differential pressure transmitter array and oxygen concentration meter maintain cruise control.

[0015] Furthermore, the thermal disturbance sensing component includes an edge control gateway; The edge control gateway sends data frames to the control center according to the EtherCAT cyclic frame; The data frame always includes a timestamp field, a feed rate field, a reflux temperature difference field, an optical frame index field, a frame sequence number field, and a CRC16 check field.

[0016] Furthermore, the control center sends compensation command frames with fixed fields to the main pneumatic valve and the pre-charge bypass; The compensation instruction frame is fixed to include a frame sequence number field, a main cabin volume collapse prediction field, a preset peak time field, and a lead time constant field. The main pneumatic valve and the pre-charge bypass only respond to compensation command frames with the same frame number.

[0017] Furthermore, the hardware watchdog is directly connected to the feed main motor contactor and the isolation baffle actuator via a relay hard-wired interlocking matrix; when the pressure in the sealed main chamber drops below the mechanical red warning line, the feed main motor contactor disconnects and the isolation baffle actuator remains locked. The main feed motor contactor will not be triggered to disconnect and the isolation baffle actuator will not be locked if the pressure in the sealed main chamber does not fall below the mechanical red warning line.

[0018] (III) Beneficial Effects This invention provides a closed-loop chemical flake-forming system with nitrogen-sealing positive pressure protection, which has the following advantages: By simultaneously acquiring feed mass flow rate, condensate recirculation heat transfer, and rotor angular velocity signals through thermo-mass disturbance sensing components, the control center can determine the phase change contraction signal before the main compartment pressure drops. This ensures that the main compartment volume collapse prediction is obtained in a unified time sequence, avoiding the lag adjustment caused by relying solely on post-event pressure difference signals. By applying band-stop processing to the mechanical cutting fundamental frequency based on the main compartment volume collapse prediction, the control center separates the actual compensation demand from the phase change contraction into the mechanical disturbance caused by the rotary airlock discharge assembly. This reduces the risk of malfunctions and redundant compensation caused by the air replenishment control chain being pulled by the discharge rhythm. By connecting the main air path to the upper part of the sealed main compartment via the main pneumatic valve and the auxiliary air path to the non-discharge area of ​​the rotary airlock discharge assembly via the pre-charge bypass, the system can simultaneously complete main compartment volume compensation and discharge end isobaric replacement at the same leading moment, while integrating main compartment depressurization suppression and reverse air intake blocking into the same time-series closed loop.

[0019] A micro-pressure clamping multi-hole array is connected in series on the pre-charge bypass. The nitrogen entering the non-discharge zone is transformed into a low-kinetic-energy isobaric gas flow. This not only does not affect the local airflow disturbance of the material flow at the discharge end, but also stably squeezes out the residual air in the mechanical isolation dead cavity, enhancing the continuous stability of the nitrogen sealing boundary. At the same time, a micro differential pressure transmitter array and an oxygen concentration meter are used to control slow cruise. This is layered and interlocked with the hardware watchdog, isolation baffle, and passively forced deformation Teflon corrugated compensation airbag. This achieves forward-forward prediction, mechanical disturbance decoupling, pre-charge in the non-discharge zone, disaster recovery protection, spatial coordination and temporal synergy, positive pressure maintenance of continuous sealed agglomeration, backflow suppression, and stable operation. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the overall structure of a closed chemical flake system with nitrogen sealing positive pressure protection function according to the present invention; Figure 2 This is a schematic diagram of the arrangement of the multi-source heterogeneous phase transition disturbance sensing component of the present invention; Figure 3 This is a schematic diagram of the process for the expected collapse gap advance calculation and mechanical pseudo-disturbance stripping of the present invention. Figure 4 This is a partial cross-sectional schematic diagram of the front-mounted counter-thrust air wedge in the main cabin of the present invention; Figure 5 This is a partial cross-sectional schematic diagram of the flexible replacement structure of the discharge airlock dead cavity of the present invention; Figure 6 This is a control block diagram of the steady-state cruise correction and hard-wire interlocking fuse of the present invention; Figure 7 This is a schematic cross-sectional view of the installation of the passively forced deformation Teflon corrugated compensating airbag of the present invention. Detailed Implementation

[0021] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0022] Please see Figures 1-7 This invention provides a closed-loop chemical flake-forming system with nitrogen-sealing positive pressure protection, comprising: This step is used to extract the primary cause of the thermal-mass disturbance that first occurs in the main cabin and organize it into an initial state tensor for subsequent steps. Its overarching concept is unified under the multi-source heterogeneous phase-change disturbance sensing component, while the lower-level implementation paths correspond to the main paths of the pump speed encoder and the thermoelectric bridge, as well as the parallel alternative paths of the binocular infrared thermal imaging matrix, thereby ensuring that the overall inventive concept and implementation support maintain the same terminology system.

[0023] Step 1: Before the main cabin experiences negative pressure backflow, convert the heat extraction signs and feed propulsion signs that trigger phase change volume collapse into continuously callable initial state tensors.

[0024] Continuous closed-loop agglomeration does not begin with a pressure drop followed by the recognition of phase change contraction. In actual field operations, the initial occurrence is a change in the feed propulsion rhythm, followed by enhanced heating of the condensing heat medium, and only then does it manifest as the retreat of the high-temperature melt boundary and the expansion of the solidified liquid film within the main compartment. If only a differential pressure transmitter is relied upon, the edge control gateway only receives the result after the event has occurred, resulting in a natural lag in the subsequent compensation chain. Therefore, the execution entity is uniformly set as the edge control gateway. The feed propulsion information is output by the pump speed encoder at the feed drive end, the heating information is output by the condensing heat medium return temperature difference bridge, and in scenarios with no power or high corrosion, the phase change interface shift information is output by the binocular infrared thermal imaging matrix behind the main compartment observation window. These three components together constitute a multi-source heterogeneous phase change disturbance sensing component.

[0025] In one implementation, an encoder disc is fitted over the metering pump output shaft, and the pump speed encoder is fixed to a bracket on the outside of the explosion-proof cover. A dual-branch platinum resistance thermometer is installed before the return main enters the heat exchanger to form a thermoelectric bridge, and sensor leads pass through a metal-sealed joint to connect to the explosion-proof cavity. A quartz observation window is installed on the side wall of the main compartment, and a binocular infrared thermal imaging matrix is ​​located outside the observation window. The operator can directly observe on-site: the metering pump continuously feeds, the temperature distribution on the outer wall of the return pipe changes, and the boundary of the bright area inside the main compartment gradually recedes. The edge control gateway recognizes these three visible trajectories as different appearances of the same contraction event, rather than three isolated sets of data.

[0026] The edge control gateway first receives pump speed encoder pulse frames and temperature measurement frames from the thermoelectric bridge according to a unified system clock, and then resamples both into the same sampling window to obtain the same-clock mass flow rate. and latent heat exchange rate Subsequently, the edge control gateway compresses the two into a thermal mass decay index. This is used to represent the strength of the contraction prelude within the main cabin; if the main path is restricted, the binocular infrared thermal imaging matrix outputs the phase transition interface gradient after edge segmentation. Then, with the same mass flow rate Latent heat exchange rate and heat mass decay index Write the initial state tensor together Therefore, the output of this step is not a set of scattered sensor values, but a structured input that has been time-aligned and anomaly-filtered.

[0027] Initial state tensor Encapsulated using a fixed field order Among them, frame number This indicates the sequence identifier of the current EtherCAT loop frame, used for time synchronization in steps two and three; clock mass flow rate. This represents the mass flow rate calculated by the pump speed encoder within the current sampling window; and the same latent heat exchange rate. This represents the heat intensity calculated from the heat medium side within the current sampling window; heat mass attenuation index. This indicates the collapse trend driven by both heat removal and material propulsion within the current sampling window; phase transition interface gradient. This indicates the intensity of the solid-liquid frontal advance extracted by the optical path.

[0028] The communication layer uses EtherCAT cyclic frames. The JSON fields received by the edge control gateway are in a fixed order: timestamp (Ts), feed rate, reflux temperature difference, optical frame index, frame sequence number, and CRC16 checksum. The edge control gateway first checks if the frame sequence number is consecutive, then checks the CRC16 checksum. If the checksum fails, the current frame is discarded while retaining the previous valid frame. If the frame sequence number is broken, the gateway requests the slave station to retransmit the missing frame. The corresponding field actions are: the metering pump and condensate heat transfer circuit continue to operate, but the edge control gateway first completes the data stream before entering the calorific value decay index. The calculation avoids misinterpreting gap frames as sudden changes in operating conditions.

[0029] The edge control gateway converts the pump speed encoder pulse count into instantaneous mass flow rate based on the metering pump's displacement per revolution and the current recipe density table, and then resamples using a unified system clock to obtain the same-clock mass flow rate. The return branch uses a metering pump to maintain a constant heat transfer medium accumulation rate, and the edge control gateway uses this to convert the output of the thermoelectric bridge into the same latent heat exchange rate. .

[0030] To avoid directly splicing the two signals, the pump speed encoder path uses zero-order hold, and the thermoelectric bridge path uses cubic Hermite interpolation. The results from both paths are merged within the same sampling window before proceeding to the next step. Where: heat mass decay index : Indicates the degree to which heat extraction and feed propulsion within the current sampling window jointly lead to volume collapse. The value is a positive real number; the larger the value, the more worthwhile it is to address subsequent volume gaps in advance. (Starting time) : Represents the start time of the current sampling window, provided by the edge control gateway in cyclic frame order, used to define the integration start point; time variable : Indicates the continuous time position within the sampling window, with a value range of . to Used to accumulate the same clock mass flow rate along the sampling window. Latent heat exchange rate And confidence gate function Sampling window length : Indicates the calorific value decay index The calculation window is preferably 20ms to 300ms, more preferably 50ms to 150ms; a shorter value makes it easier to capture the prelude to sudden contraction, while a longer value makes it easier to suppress short-cycle jitter. Same mass flow rate This represents the feed advance amount calculated from the number of pulses from the pump speed encoder and after resampling. The value range is jointly limited by the metering pump displacement, material density, and linear speed setting, and is used to characterize the material occupancy trend in the main compartment. It is obtained by combining the encoder pulse count with the pump displacement per revolution and the formula density table.

[0031] Latent heat exchange rate : Represents the heat carried after conversion and resampling from the thermoelectric bridge signal. The value range is jointly limited by the heat medium temperature difference, heat medium flow rate and heat exchange path. It is obtained by combining the thermoelectric bridge output with the heat medium branch process conditions.

[0032] Confidence gate function : Represents the data continuity threshold, ranging from 0 to 1; a high value is used when the frame sequence number field is continuous and the CRC16 checksum field is normal, and a low value is used when there are missing frames, obstructions, or loose connections, used to limit the thermal mass attenuation index of amplified abnormal frames. The method of obtaining the result is the continuity of the frame sequence number and the CRC16 check result.

[0033] Regular residual This represents a stability term to prevent the denominator from becoming too small at extremely low loads. Its value range is a small positive real number, used to maintain the thermal mass decay exponent. continuous; In a representative set of embodiments, after the operator initiates continuous feeding, the edge control gateway first continuously reads the pump speed encoder pulse train, and then continuously reads the output of the thermoelectric bridge arm. When the feed viscosity increases, causing the actual advance of the metering pump to slow down while the heat carried by the condensing heat medium increases, the edge control gateway will merge this pair of changes into a heat mass decay index within the same sampling window. This arrangement, without waiting for the main cabin pressure to drop first, integrates changes in feed propulsion and thermal changes into the same causal chain. The resampling path eliminates cross-frame misscrambling, and the thermal mass attenuation index... Compressing two types of primacy factors into a single trend factor, confidence gate function Lock the impact of frame drops at the source.

[0034] Highly corrosive materials, strong explosion hazards, or metal wall coverings can cause instability in the electrical contact path, but visible traces will still remain at the solid-liquid front in the main compartment, namely, the shrinkage of the bright area of ​​the high-temperature melt and the expansion of the dark area of ​​the solidified liquid film. The binocular infrared thermal imaging matrix does not directly send the entire thermal image to the next step; instead, the edge control gateway first performs bad pixel removal, median smoothing, and Canny edge segmentation to extract the phase transition interface curve. Then, the phase transition interface gradient is calculated based on the degree of accumulation of interface temperature transitions. : Where: gradient at the phase transition interface : Represents the intensity of temperature transition along the length of the solid-liquid interface at the solid-liquid front. The value is a positive real number; a larger value indicates a steeper phase transition boundary and a more concentrated migration. Phase transition interface curve. : Represents the solid-liquid boundary trajectory obtained by edge segmentation of the binocular infrared thermal imaging matrix. The value range is limited by the field of view of the observation window and is used to provide the integration path; Temperature field : Represents the pixel temperature distribution on the plane corresponding to the observation window. The value range is limited by the melting temperature and final cooling temperature of the material, and is used to provide the source of the temperature gradient; gradient operator : Indicates the temperature field Perform spatial differentiation in the observation plane to extract temperature transitions on both sides of the solid-liquid interface; Horizontal coordinate : Represents the horizontal pixel position on the observation plane. The value range is limited by the field of view width and is used to determine the temperature field. Horizontal position; vertical coordinate : Represents the vertical pixel position on the observation plane. The value range is limited by the field of view height and is used to determine the temperature field. The longitudinal position; arc length element : Indicates the curve along the phase transition interface The length of the micro-segment is used to complete the cumulative integration of the entire interface; interface length : Represents the phase transition interface curve The total length is used to normalize the integration result; Smoothing margin : This represents a length compensation term to prevent abnormal amplification caused by extremely short interfaces. Its value range is a small positive real number, used to stabilize the gradient at the phase transition interface. ; Preferably, the thickness of the quartz observation window is set to 8mm to 15mm, the top angle of the binocular infrared thermal imaging matrix is ​​set to 15° to 35°, and Canny edge segmentation uses a dual threshold of low and high thresholds. The low threshold is used to remove fog-like heat dissipation bands, and the high threshold is used to retain the main edge of the solid-liquid interface. Subsequently, binocular parallax is used to remove reflective stripes from the observation window. The result that can be observed on-site is that even when the thermoelectric bridge is surrounded by corrosive vapor, the edge of the bright area in the main cabin is still circled frame by frame, and the edge control gateway converts the retreat of this boundary into the phase change interface gradient. It maintains the same frame format as the main path field. The binocular infrared thermal imaging matrix provides parallel paths in power-deprived scenarios, and phase transition interface gradients. Directly anchoring the solid-liquid frontal advance, binocular parallax de-reflection ensures that interface extraction is not misled by the reflection band of the observation window.

[0035] After sampling the main path and alternative paths, the edge control gateway writes the initial state tensor in a fixed order. The fields are, in order, the same mass flow rate. Latent heat exchange rate Heat mass decay index and phase transition interface gradient If the optical path is normal, the phase transition interface gradient... Synchronous writing serves as supporting evidence; if the lens is briefly blocked by steam, the edge control gateway retains the gradient of the previous effective phase transition interface. At the same time, reduce the confidence gate function The contribution to the current sampling window. Furthermore, the next step reads the initial state tensor, where field positions are fixed, source relationships are clear, and alternative paths can be seamlessly accessed. .

[0036] In one implementation, the software runtime environment of the edge control gateway is divided into three segments: the input side, the processing side, and the output side. The input side only receives cyclic frames and performs CRC16 verification; the processing side performs resampling, interpolation, interface segmentation, and field assembly; and the output side only publishes the initial state tensor. Unlike the frame sequence number field, the raw thermal image is not directly published. The corresponding on-site actions are: the metering pump continues to advance, the condensing heat medium continues to heat, the bright area boundary behind the observation window is continuously delineated, and the edge control gateway only outputs one initial state tensor at the end of each sampling window. Furthermore, fixed field mapping avoids repeated identification of data sources in subsequent steps, and segmentation of the input and processing sides ensures one-to-one coupling between algorithm actions and device actions.

[0037] Step 1: Fold the first signs of propulsion, heating, and interface migration in the main cabin into the initial state tensor. This allows the next step to directly calculate the transient gas phase collapse gap based on this, instead of deducing the cause from subsequent pressure results.

[0038] Step 2: Based on the initial state tensor The equivalent volume collapse trend of the main cabin is calculated, and then pseudo-excitation clutter that overlaps with the fundamental frequency of the bottom discharge rotor's mechanical cutting is removed from this trend. Finally, a clean advance compensation command is output. All of the following processes are executed by the control center.

[0039] The initial state tensor obtained in step one While heat extraction and feed propulsion have been prioritized as primary factors in the main compartment, under continuous discharge conditions, if the control center directly drives the main pneumatic valve based on these factors, the valve will receive not only the volume gap caused by phase change contraction but also the periodic volume tears formed when the bottom discharge rotor passes over the discharge window. These tears do not necessarily indicate a complete collapse of the main compartment, but they will drag the control chain into a cycle where pneumatic compensation repeatedly follows the mechanical beat frequency.

[0040] Therefore, this step involves the control center first extracting the actual collapse trend of the main cabin, then extracting the mechanical cutting frequency of the bottom discharge rotor, and finally using a mechanical frequency domain misaligned phase bandstop algorithm. Separate the two.

[0041] In one implementation, the control center is housed in an explosion-proof electrical control cabinet and includes an industrial computing board, a dual-port EtherCAT industrial Ethernet card, and an independent computing thread. The bottom discharge rotor is connected to the reducer via a coupling, and exhaust cutting blades are formed on the outer periphery of the rotor. An encoder disk is fixed to the tail end of the reducer. During this process, as the agglomeration belt carries away heat, the main compartment gas phase space contracts while the bottom discharge rotor moves across the discharge window at a fixed rhythm. The control center does not immediately amplify the valve action during this period but instead first separates the contraction rate from the mechanical rhythm.

[0042] The control center first receives the initial state tensor. Read the thermal mass decay index. With phase transition interface gradient By combining the free gas volume of the main compartment, the set pressure of the nitrogen sealing circuit, and the current material phase change path, the expected collapse gap that will appear in the main compartment in the next time step is deduced. Subsequently, the control center continues to read the rotational speed pulses of the bottom discharge rotor, calculates the mechanical cutting fundamental frequency, and then sends the expected collapse gap into the mechanical frequency domain misaligned phase bandstop algorithm. Mechanical frequency domain misaligned phase bandstop algorithm First, the expected collapse gap is aligned with the mechanical action time difference of the bottom discharge rotor. Then, a narrow stopband is established around the mechanical cutting fundamental frequency. As a result, the command component consistent with the overall collapse of the main compartment is preserved, while the pseudo-excitation clutter that appears synchronously with the discharge blades is stripped away. After this processing, the advance compensation command output by the control center becomes the stable input for step three.

[0043] Furthermore, the control center reads the initial state tensor at the start of each calculation window. Confirm the same mass flow rate With the same latent heat exchange rate After no frame breaks occur, extract the thermal mass attenuation index. and phase transition interface gradient .

[0044] Among them, the heat mass decay index This indicates the contraction trend caused by the combined effects of heat removal and feed propulsion; the phase change interface gradient. This indicates whether the solid-liquid front propagates into the main cabin in a concentrated manner. The control center measures the phase transition interface gradient. As the thermal mass decay index Multiplying the space correction term by the main cabin pressure allowance function yields the expected collapse gap: Where: Expected collapse gap : Represents the equivalent volume of the main cabin's free gas phase space that will be swallowed by phase change contraction in the next time sequence; the value range is positive real numbers; volume coupling coefficient. : Represents the conversion scale from primary quantity to equivalent volume. Its value range is jointly limited by the geometric volume of the main compartment, the density difference of material phase change, and the nitrogen sealing set pressure, and is used to complete the dimensional mapping. Start time : Indicates the start time of the current calculation window; the value range is limited by the EtherCAT industrial Ethernet cyclic frame sequence; volume calculation window : Indicates the time length of the cumulative first factor, preferably an integer multiple of a complete cutting cycle of a discharge rotor; Heat mass decay index : Represents the time-continuous primary factor output from step one, with values ​​ranging from positive real numbers; used to characterize the dominant contributions of heat removal and feed propulsion to the main compartment collapse; phase change interface gradient : Represents the solid-liquid front pushing intensity output from step one, with values ​​ranging from positive real numbers; used to correct for whether the contraction occurs at concentrated locations; gradient coupling coefficient. : Represents the gradient at the phase transition interface For the expected collapse gap The amplification or suppression weights, whose value range is jointly defined by material adhesion, floc bandwidth and main compartment void shape, are used to incorporate space front characteristics into volume calculation. Pressure allowable function : Indicates the allowable degree of pressure margin in the main cabin relative to the collapse gap, with a value ranging from 0 to 1; Pressure allowable function Instead of a free-fitting approach, a segmented gating rule corresponding one-to-one with the main cabin pressure boundary is adopted. When the main cabin pressure... Pressure above steady-state target This indicates that the main cabin does not currently need to amplify the expected collapse gap. When the main cabin pressure Pressure below steady-state target And higher than the mechanical red alert pressure At that time, take It increases linearly between 0 and 1; when the main cabin pressure Reaching or falling below the mechanical red alert pressure At that time, take The corresponding expression is: Among them, mechanical red alert pressure This refers to the pressure value corresponding to the mechanical red warning tape defined in step four. After this processing, The abstract function is transformed into a gating quantity that directly corresponds to the main cabin pressure boundary.

[0045] Time variable : Indicates the continuous time position within the volume calculation window, with a value range of . to ; Used to accumulate primary factor contribution; As a supplement: the control center enters the expected collapse gap Before performing the calculations, a set of volume parameters must be established. This set of volume parameters must include at least the free gas volume of the main cabin. Nitrogen sealing circuit setting pressure Material phase change path index Among them, the free gas volume of the main cabin Total geometric volume of the main cabin Deducting the volume of fixed internal components With the current material occupying volume Get; the current volume occupied by the material The same mass flow rate output from step one Calculate cumulatively window by window according to the formula density table; set the pressure of the nitrogen sealing circuit. Provided by the measured value of the pressure transmitter at the outlet of the pressure stabilizing tank; Material phase change path index The latent heat table and phase change temperature zone table are called from the current batch formula number to determine the temperature. The control center completes each volume calculation window. This means refreshing the volume parameter set once, and only after the volume parameter set has been refreshed is entry into the expected collapse gap allowed. The calculation.

[0046] In a representative embodiment, the operator feeds the molten material into the main chamber, where the flakes continuously carry away heat, and the gas phase space at the top of the main chamber gradually narrows; the control center tensors from the initial state. Read the calorific value decay index and phase transition interface gradient After that, complete the above integration first, and then calculate the expected collapse gap. The data is fed into the next processing thread instead of directly driving the main pneumatic valve. With this setting, the calorific value is converted into volumetric language, and the concentrated retreat of the solid-liquid front is separated from ordinary surface cooling.

[0047] The control center received the expected collapse gap. Next, the pulses from the bottom discharge rotor encoder disk are read synchronously, and the mechanical cutting fundamental frequency is derived based on the frequency of the blades passing through the discharge window. If this step is not completed first, the main pneumatic valve will misinterpret the short suction caused by each blade cut as the overall collapse of the main compartment. To interrupt this cycle, the control center first determines the mechanical cutting fundamental frequency: Where: mechanical cutting fundamental frequency : Indicates the periodic suction frequency formed by the bottom discharge rotor blades sweeping across the discharge window, with values ​​ranging from positive real numbers; number of blades : Indicates the total number of blades participating in the cutting of the bottom discharge rotor, with values ​​ranging from positive integers; rotor angular velocity. : Represents the mechanical rotational angular velocity of the bottom discharge rotor, with a value range limited by the reducer's output range; calculated from the encoder disc pulse, used to provide mechanical rhythm; circumferential constant. : Represents a frequency conversion constant; used to convert between angular frequency and Hertz frequency; Subsequently, the control center converts the expected collapse gap into a volume spectrum command in the frequency domain. Then it is fed into the mechanical frequency domain misaligned phase bandstop algorithm. This algorithm does not broadly attenuate all high frequencies, but instead establishes a narrow stopband near the mechanical cutting fundamental frequency, and inserts a misaligned phase term matching the time difference of the mechanical action at the front end of the stopband, causing the slow change of the overall collapse of the main cabin to cross the stopband, only stripping away the false gap that appears synchronously with the mechanical cutting: Where: Purification volume spectrum command : Indicates the mechanical frequency domain misalignment phase bandstop algorithm The processed frequency domain command takes values ​​within the range determined by the volume spectrum command. Amplitude range limitation; complex frequency domain variables : Represents the frequency variable in the Laplace domain, taking values ​​in the complex number domain; natural constant : Represents the base of the exponential delay term; used to calculate the phase misalignment duration. Mapped to frequency domain delay; phase misalignment duration : Represents the time difference between the expected collapse gap and the mechanical cutting of the bottom discharge rotor; the value range is jointly defined by the encoder disk pulse timestamp and the main compartment volume spectrum peak misalignment; stopband center angular frequency. : Indicates the fundamental frequency of mechanical cutting The corresponding angular frequency satisfies The range of values ​​is positive real numbers; The control center is in each volume calculation window Within, the expected collapse gap is discretized into a gap sequence. The rotor encoder pulses within the same window are discretized into pulse sequences. The frequency domain thread first processes the gap sequence. conduct Point discrete Fourier transform yields the volume spectrum command. Then, for the pulse sequence Perform a discrete Fourier transform of the same length to determine the frequency point corresponding to the fundamental frequency of the mechanical cutting. Phase misalignment duration From frequency point Phase difference at: in, For volume spectrum command At frequency phase, pulse sequence At frequency phase, This refers to the angular frequency corresponding to the fundamental frequency of mechanical cutting. The control center only controls the frequency point. Narrowband stopband operation is performed in the neighborhood, while the frequency points outside the neighborhood remain unchanged; after the stopband processing is completed, the processing result is inversely transformed to obtain the cleaned gap sequence called in step three.

[0048] Damping quality factor : Represents a combined measure of stopband width and edge steepness, with values ​​ranging from finite real numbers greater than 0; Volumetric Spectrum Command : Indicates the expected collapse gap The frequency domain input obtained by the transformation takes values ​​in the range of the expected collapse gap. The time-domain amplitude is determined; In a representative embodiment, the bottom discharge rotor continuously rotates past the discharge window, and the operator can see regular vibrations at the gas phase boundary below the window through the observation window; after the control center reads the encoder disk pulse, it first sets the mechanical cutting base frequency. Write to the bandstop center, then according to the phase shift duration. Adjust the stopband front position, and finally output the purified volumetric spectrum command. With this arrangement, the overall collapse of the main cabin is preserved, and the regular suction caused by blade cutting is retained within the baffle zone.

[0049] Control center commands to the purification volume spectrum Perform an inverse transformation to obtain the time-domain purification gap sequence, and then combine it with the current pressure of the nitrogen sealing circuit, the opening hysteresis of the main pneumatic valve and the available channel area of ​​the auxiliary gas path to generate an advance compensation command.

[0050] The output of step two does not use unstructured control words, but instead uses a fixed-field lead compensation instruction packet. Advanced compensation instruction package At least the current frame number Expected collapse gap Preset peak times and lead time constant Among them, the lead time constant Instead of solving online in step two, the pre-calibration values ​​of the corresponding actuator in step three are called; step two is responsible for completing the calculation within the same frame number. and Solve for and pre-calibrate Encapsulated together into the advance compensation instruction package In step three, the advance compensation instruction packet was received. Then, based only on the current frame number When performing the timing, based on the expected collapse gap Calculate the main cabin advance hedging amount based on the preset peak time. and lead time constant Arrange for the main pneumatic valve and auxiliary air circuit to operate in advance.

[0051] Preferably, the time-domain backcomputation employs a discrete process combining trapezoidal integrals and three-point backward derivatives. The former maintains the area conservation of the purge gap sequence, while the latter identifies the peak edges of the purge gap sequence. After the industrial computing board completes this discrete process, it writes the results into an EtherCAT industrial Ethernet downlink frame, which is received by the main pneumatic valve actuator and the auxiliary air path valve island, respectively. The enhanced combination scheme pre-installs a lightweight multilayer perceptron on the edge neural network card. The input terms are fixed as historical residuals, dew point humidity, and the purge gap sequence of the previous calculation window, and the output term is fixed as the volume coupling coefficient. Coupling coefficient with gradient The offset correction value; this offset correction value only corrects the solution scale, does not change the field definitions in step one, nor does it change the mechanical frequency domain misaligned phase bandstop algorithm. The central structure.

[0052] For example, the control center sets up two sequential threads on the industrial computing board. The first thread completes frequency domain back calculation and valve hysteresis compensation, and the second thread completes downlink frame encapsulation and actuator transmission. The two threads only transmit the purification gap sequence and the current frame number, and do not transmit the original pulse waveform back.

[0053] Specifically, frequency domain back-calculation can employ either bilinear discretization or backward Euler discretization; the former helps preserve the shape of the stopband edge, while the latter helps shorten the single-window solution time when the computing power of the explosion-proof controller is limited. To verify whether this step has been implemented, the main cabin pressure curve, valve stem displacement curve, and rotor pulse curve were recorded simultaneously during workshop commissioning, and only the sequential relationship of the three curves was observed to see if it changed from chasing each other at the same frequency to staggered coordination.

[0054] In a generalized implementation, when the operator switches between different linear speed gears, the mechanical rhythm of the bottom discharge rotor changes accordingly, while the control center continues to read the initial state tensor. — Solving the expected collapse gap —Read the mechanical cutting base frequency —Execute mechanical frequency domain misaligned phase bandstop algorithm —Execute the output advance compensation instructions sequentially.

[0055] The control center converts the first step's parameters into volumetric language, enabling subsequent actuators to read the same controlled object; mechanical cutting of the base frequency. Independent extraction prevents the discharge end's beat frequency from masquerading as the main compartment's overall collapse; mechanical frequency domain misalignment phase bandstop algorithm Narrow-band damping, rather than aggressive clipping, preserves the slow collapse tendency of the main cabin; the enhanced combination scheme incorporates material viscosity drift into the volume coupling coefficient. Coupling coefficient with gradient This allows us to maintain the same terminology system and the same computational chain under different environments.

[0056] Step 3: Based on the advance compensation instruction given in Step 2, before the actual negative pressure black hole is formed, complete the main compartment volume offset and discharge airlock dead cavity replacement in advance, so that the main compartment positive pressure and the discharge end anti-backflow barrier close in the same sequence.

[0057] Step two has already addressed the anticipated collapse gap. The mechanical cutting and pseudo-excitation clutter carried within the system is stripped away; however, if nitrogen is only injected into the main compartment at a single point, the injection airflow will still encounter two physical weak points near the discharge airlock. The first weak point is located in the valve stem initiation section of the main pneumatic valve. The pneumatic diaphragm valve has a viscous slip dead zone from rest to release. If the command is issued again after the pressure drops, the valve stem has not yet truly opened, and the free gas phase volume in the main compartment has already collapsed. The second weak point is located in the mechanical isolation dead chamber of the discharge airlock. The residual air in the dead chamber will be dragged into the main compartment when the rotor blade cavity switches, forming oxygen recirculation and local backflow.

[0058] Therefore, step three does not understand air replenishment as a single-path action, but rather the control center initiates two synchronous links: the main air path is responsible for the main compartment pre-emptive counter-fluidity, and the auxiliary air path is responsible for the flexible replacement of the discharge airlock dead chamber; the former crosses the valve dead zone, and the latter crosses the residual air at the discharge end. Only after the two links are combined can they form a time-space dual-track pre-emptive fluid counter-fluidity and micro-pressure flexible replacement.

[0059] In one embodiment, the main gas path enters the main compartment dome along the top of the explosion-proof cover. The main pneumatic valve is a pneumatic diaphragm valve, with a nitrogen-sealed pressure stabilizing tank installed before the valve and the nozzle after the valve facing above the free liquid surface in the main compartment. The auxiliary gas path branches off from the pressure stabilizing tank and connects to a pre-charge bypass in the non-discharge area of ​​the discharge airlock housing. The end of the bypass is connected in series with a micro-pressure clamping multi-hole array. The operator is in charge of the main pneumatic valve, which activates before the main chamber pressure drops significantly. The pre-charge bypass on the side of the discharge airlock housing then supplies air, and the rewind belt that suddenly sucks in powder mist no longer appears around the discharge window.

[0060] The control center first receives the advance compensation instruction issued in step two and analyzes the expected collapse gap within it. Lead time constant And the current frame number. Subsequently, the control center generates a main cabin pre-emptive offset on the main gas path and a dead space replacement on the auxiliary gas path, both sharing the same trigger moment. The trigger moment is not taken at the instant of the main cabin pressure drop, but rather as a lead time constant within the current calculation window, one time before the expected collapse peak. The position is such that after the valve stem of the main pneumatic valve crosses the viscous slip dead zone, the main airflow just hits the contraction boundary of the free gas phase volume in the main compartment; at the same time, the auxiliary gas path sends nitrogen into the non-drop zone of the discharge airlock, and then the micro-pressure clamping multi-hole array By stripping away high kinetic energy, the gas passes through the dead space with only a slight pressure difference, pushing the residual air away from the main compartment along the predetermined venting seam. Therefore, the output of step three is not a typical valve opening signal, but a fluid action closed loop formed by the main and auxiliary gas paths.

[0061] After receiving the lead compensation command, the control center first reads the lead time constant. This constant is jointly calibrated by the valve's idle stroke, cylinder charging / discharging lag, and valve stem sticky slip dead zone, with a preferred range of 420ms to 480ms, and more preferably 450ms as the central calibration window, because this range can cover the mechanical transition of the pneumatic diaphragm valve from the valve core seat to the valve orifice to form a stable jet. Subsequently, the control center sets the expected collapse gap. Converted to main cabin forward hedging This is then allocated to the opening period of the main pneumatic valve, causing the nozzle to form an air wedge that expands along the free surface in the dome area, rather than forming a single jet that rushes directly towards the material surface. Main compartment forward counter-impact. Determine by the following formula: Where: Main cabin forward heave : This represents the volume of gas supplied to the main cabin within the pre-opening valve zone, expressed as a positive real number; used to fill the anticipated collapse gap. Corresponding free gas phase contraction; preset peak time : The predicted time of the main cabin collapse peak in step two, located within a short window after the current control cycle; lead time constant. : The mechanical lead time required for the main pneumatic valve to generate a stable jet flow from the command received, with a value ranging from 420ms to 480ms; Flow coefficient : The flow scaling factor after the main pneumatic valve and the dome nozzle are combined, and the value range is a real number greater than 0 and less than 1; Valve port area : The main pneumatic valve at any time The effective opening area, whose value range is defined by the valve stem stroke and valve seat geometry, is used to determine the instantaneous throughput capacity; valve orifice area. The main pneumatic valve stroke-area comparison table is used to find this information. This table is written into the control center along with the valve model when the equipment leaves the factory and is not matched online during the operation phase.

[0062] Nitrogen sealing pressure : This refers to the nitrogen pressure from the pressure tank to the inlet of the main pneumatic valve; the value range is limited by the nitrogen sealing circuit setting pressure; Main compartment pressure : Current pressure in the main cabin dome region, with a value range limited by the system's safety pressure zone; used to indicate the pressure boundary of the main airflow; nitrogen density. : The density of nitrogen in the main gas path, with a value range limited by the gas supply temperature and the pressure of the pressurizer; used to complete the physical property conversion from pressure difference to volumetric flow rate; time variable. : This represents the continuous time position within the pre-opening valve interval, with a value range of . to Used to accumulate gas delivery volume; When nitrogen sealing pressure Less than or equal to the main cabin pressure At this time, the main gas path in this calculation window does not perform pre-hush, and the pre-hush amount of the main cabin is taken. When the integral yields the main cabin forward hedging amount The expected collapse gap is larger than the current window. At that time, the control center As the upper limit pair Trimming is performed. Through the above boundary treatment, the main gas path only operates when the nitrogen sealing pressure is higher than the main cabin pressure and there is indeed a collapse gap that needs to be compensated.

[0063] In a representative embodiment, the control center runs a pre-emptive counter-offsetting thread on an industrial computing board. Upon receiving a lead-over compensation command, the thread writes the valve opening start point into an EtherCAT downlink frame. The main pneumatic valve actuator then pushes the valve stem past the contact point, and nitrogen gas spreads from the dome nozzle along the main compartment's arc wall, first forming a gas wedge above the free surface, and then spreading towards the volume gap. What is observed on-site is not a violent surge of fuel, but rather the gradual dispersal of the mist band at the top of the main compartment. (Lead-over time constant) Aligning the valve stem movement with the main cabin collapse peak, and using the dome nozzles to distribute gas along the wall to advance the main cabin's counter-impact. Transformed into a planar gas wedge, the pre-action of the main pneumatic valve weakens the initial depth of the negative pressure black hole within the main cabin.

[0064] Furthermore, when the discharge airlock rotor passes the shell partition plate, a temporarily closed mechanical isolation dead space is formed in the non-discharge area of ​​the blade cavity. If air remains in the dead space, this air will be squeezed towards the main nacelle side as the rotor continues to rotate, forming an oxygen drag and rewind source. To avoid this consequence, the auxiliary air path does not directly inject high-pressure nitrogen into the blade cavity. Instead, the nitrogen is first introduced into the pre-charge bypass and then forced to pass through the micro-pressure clamping multi-hole array. Micro-pressure clamping multi-hole array The structure adopts a sintered metal plate laminate structure, preferably made of 316L sintered stainless steel or Hastelloy sintered plate, with a preferred thickness of 4 to 12 mm and an absolute pore size of 15 to 25 μm.

[0065] In this region, once the aperture enters the channel, the flow is broken down into numerous tiny channels, and the impact kinetic energy is dissipated along the plate thickness, making it easier to form laminar flow adhering to the plate wall at the outlet side. Micro-pressure clamped porous array The pressure drop relationship is characterized by the following formula, where the permeability coefficient is... With inertia coefficient This batch of micro-pressure clamped multi-hole array The pressure drop-flow rate calibration results on the nitrogen flow test bench were determined and written into the array parameter table as fixed parameters after array assembly.

[0066] Where: Micro-pressure clamping voltage drop : Nitrogen gas passes through a micro-pressure clamped porous array The pressure difference formed before and after is taken as a positive real number; it is used to dissipate the pressure potential energy of the auxiliary gas path into orifice flow resistance; nitrogen viscosity. : Dynamic viscosity of nitrogen in the auxiliary gas path; the value range is limited by the gas supply temperature; array thickness. : for micro-pressure clamping multi-hole array The flow path length ranges from 4 to 12 mm. Permeability coefficient : for micro-pressure clamping multi-hole array The pore connectivity, the range of which is limited by the sintered particle size and compaction degree; outlet flow rate : Nitrogen gas leaving the micro-pressure clamped porous array The average velocity entering the dead space afterwards, the range of which is defined by the auxiliary gas supply pressure and array geometry; nitrogen density : Density of nitrogen in the auxiliary gas path; the value range is limited by the pressure and temperature of the pressure stabilizing tank; inertia coefficient. : for micro-pressure clamping multi-hole array The inertial drag strength, the range of which is defined by the channel tortuosity and porosity; used to limit inertial penetration at higher inlet velocities; In one embodiment, the injection axis of the pre-charge bypass falls after the return seal section, and the offset angle of the bypass centerline relative to the vertical is set to 15° to 35°, allowing nitrogen to spread along the slit between the rotor outer circumference and the inner wall of the casing without directly impacting the blade cavity. The operator can observe that the rewind mist no longer appears at the transparent inspection window of the discharge airlock, and the powder mist line near the return seal section is slowly pushed away from the main compartment direction.

[0067] Furthermore, the pre-charge bypass places the dead space replacement action in the non-discharge zone, avoiding conflict with the main discharge flow; the micro-pressure clamping multi-hole array Through micro-pressure clamping pressure drop Consuming high kinetic energy, increasing the outlet flow rate It converges to a state of spreading out against the wall; the offset angle arrangement pushes the residual air out along the predetermined venting path, weakening the oxygen recirculation source.

[0068] The control center sets up a main gas path thread and an auxiliary gas path thread on the software side. The main gas path thread only receives the expected collapse gap. With lead time constant Used to generate the main cabin pre-hedge. The auxiliary gas path thread only receives rotor phase markers and pre-charge bypass opening windows, used to deliver gas in advance in non-feeding areas. The two threads share the same frame sequence number and use the same trigger point before the main compartment collapse peak as the starting time.

[0069] Furthermore, the gas wedge formed by the main gas path first supports the free gas phase volume in the main cabin dome, and the flexible isobaric displacement wall formed by the auxiliary gas path then seals the counterflow channel at the discharge end, thereby completing the spatiotemporal dual-track coordinated closure.

[0070] In a generalized implementation, the discharge end adopts the closed twin-screw continuous discharge assembly from the parallel alternative scheme. In this case, the control center still operates along the original software link, only replacing the mechanical isolation dead chamber of the discharge airlock with a compression annular cavity formed by the tapered pitch section of the twin screws, replacing the pre-charge bypass with a pre-installed air guide hole strip on the screw barrel wall, and replacing the micro-pressure clamping multi-hole array... It is positioned upstream of the gas guide zone. Nitrogen gas passes through the micro-pressure clamped porous array. Then it enters the compression ring cavity, where a dense air-sealing ring is formed around the gradually narrowing pitch section, preventing gas from flowing between the front and back of the material plug. The result that can be observed on site is that the twin screw discharge port continuously discharges material strips, and the powder mist band that rolls back along the screw groove no longer appears at the screw barrel observation hole.

[0071] In embodiments employing a closed twin-screw continuous discharge assembly, the control center still outputs the same advance compensation command package. The auxiliary air path is no longer connected to the non-discharge zone of the rotary valve, but instead connected to the air guide strip on the twin-screw housing corresponding to the tapered pitch section; a micro-pressure clamping multi-hole array is connected upstream of the air guide strip. Downstream, it leads to a compression annular cavity formed by the tapered screw section and the inner wall of the screw barrel. Nitrogen gas enters the compression annular cavity through the gas guide holes and forms a continuous gas-holding ring along the outer circumference of the material plug, used to block reverse gas flow between the main chamber side and the discharge side. Except for the different discharge actuator, the data interface and control timing of steps two through four remain unchanged.

[0072] For ease of manufacturing and verification, the main gas path is preferably adopted. Stainless steel pipes are preferred for auxiliary air circuits. Stainless steel or Hastelloy tubing is preferred, with PTFE or perfluoroelastomer rubber being the preferred seal material. The industrial control side utilizes an industrial computing board, explosion-proof valve island, and EtherCAT slave station. The software flow is fixed as receiving advance compensation commands and calculating the main cabin advance counter-impact. Calculate the pre-charge bypass opening window, issue main gas path valve position commands, issue auxiliary gas path valve position commands, and record the timing relationship of the main compartment pressure curve, oxygen concentration curve, and valve stem displacement curve. During joint commissioning, focus on observing the sequential relationship of the three curves.

[0073] Furthermore, dual-thread co-frame triggering ensures timing closure, the division of labor between the main gas path and the auxiliary gas path ensures spatial closure, and parallel alternative paths ensure that the core mechanism remains consistent across different continuous discharge assemblies.

[0074] Step 4: After the spatiotemporal dual-track compensation is completed, the differential pressure transmitter array and oxygen concentration meter take over the slow cruise correction, and in the event of software failure or gas supply instability, the hardware fuse and pure physical volume compensation are triggered in a predetermined sequence.

[0075] Step three addresses millisecond-level gaps, while step four addresses minute-level drift during continuous production. During continuous lamination in the main compartment, the dome area slowly depressurizes due to wall cooling, changes in film thickness, and deviations in the discharge rhythm, while the discharge end slowly increases oxygen levels due to residual air redistribution. If the pre-emptive reinforcement chain from step three is still used, the main pneumatic valves and auxiliary gas lines will repeatedly activate in the stable zone, re-disrupting the already smooth atmosphere. Therefore, step four divides the execution into two layers: the control center is responsible for low-frequency correction, the underlying hardware watchdog is responsible for red-line fuse failure, and the passively deformable Teflon corrugated compensating airbag is responsible for continuing to hold back the main compartment volume after the electronic chain fails.

[0076] In one implementation, three differential pressure transmitters are located in the main compartment dome, the middle of the main compartment side wall, and the transition cavity at the discharge end, respectively, while an oxygen concentration meter is located in the nitrogen sealing return main. The differential pressure transmitter array is connected to the explosion-proof isolator via a 4mA to 20mA signal and then sent to the control center. The oxygen concentration meter is connected to the same industrial computing board via an independent channel. The underlying hardware watchdog is directly connected to the feed main motor contactor and the isolation baffle actuator via a hardwired relay matrix. The main compartment pressure curve no longer oscillates along the zero-pressure boundary, and the oxygen concentration curve slowly declines along the return main. If the gas supply suddenly collapses, the feed main motor and the isolation baffle will continue to descend before the pressure, completing the interlocking action.

[0077] The control center first reads the main cabin pressure. The pressure and oxygen concentration in the discharge end transition chamber are measured, and the three quantities are written into the steady-state cruise buffer according to a fixed frame sequence number. Then, the steady-state target pressure is monitored. Reference values ​​for oxygen concentration Calculate steady-state deviation Then, a slow correction amount is generated by the cruise loop with anti-integral saturation, which is sent to the micro-opening correction port of the main pneumatic valve and the auxiliary air path to maintain the valve position. If the main cabin pressure As the system continues to approach the red alert zone, the underlying hardware watchdog directly flips the hardwired relay matrix, cutting off the power supply to the main feed motor and locking the isolation baffle. If the entire plant's DCS network fails, a strong electromagnetic storm occurs, or the control center shuts down, causing the electronic chain to fail, the passively deformable Teflon corrugated compensating airbag will rely on external atmospheric pressure to fold inward into the main compartment to reduce the geometric volume of the free gas phase space.

[0078] The control center does not directly use the main cabin pressure. Instead of a single point of error, it measures the main cabin pressure. Combined with oxygen concentration on the same normalized scale, they form a steady-state deviation. .

[0079] With this arrangement, whether the positive pressure in the main cabin is still protected and whether the nitrogen-sealing atmosphere is still maintained will be reflected in the same deviation. Steady-state target pressure It is set at the center of the steady-state cruise dead zone, which is ±30 Pa; the mechanical red warning line is fixed at +Pa and does not move towards zero pressure. Specifically: Where: steady-state deviation : Represents the control center's comprehensive assessment of the degree of gradual instability in the main cabin at the current moment, with a value range of finite real numbers; pressure weight : Indicates the main cabin pressure steady-state deviation The contribution ratio, with values ​​ranging from real numbers greater than 0; oxygen concentration weight. : Represents the steady-state deviation of oxygen concentration. The contribution ratio, taking values ​​in the range of real numbers greater than 0; steady-state target pressure This indicates the desired main cabin pressure baseline to be maintained during the fourth cruise phase, with a value range above the mechanical red alert zone. Main cabin pressure This represents the current pressure of the main cabin obtained after the differential pressure transmitter array is fused; the value range is limited by the main cabin safety pressure band; pressure normalization scale. : Represents the normalized denominator of the pressure term, with a range of positive real numbers; used to prevent small pressure fluctuations from being abnormally amplified in calculations; Current oxygen concentration This indicates the oxygen content in the main cabin atmosphere as measured by the oxygen concentration meter at the current moment. The value range is limited by both the nitrogen sealing circuit and the amount of outside air infiltration; oxygen concentration reference value. : Indicates the baseline oxygen concentration that can be maintained during the cruise phase, with a value range within the process allowable range; used to define the direction of atmosphere return; oxygen normalization scale. : Represents the normalized denominator of the oxygen concentration term, with values ​​ranging from positive real numbers; used to limit the impact of instantaneous sensor fluctuations on the overall judgment; pressure weight. Oxygen concentration weight Pressure normalization scale and oxygen normalization scale All parameters are stored as fixed parameters in the cruise parameter table. After the equipment is powered on, it is loaded once according to the main cabin specifications and the current recipe number, and remains unchanged during the operation of this batch.

[0080] In a representative embodiment, the differential pressure transmitter array is first fused by the control center, and then written into the steady-state cruise buffer along with the oxygen concentration meter signal; when the main cabin dome pressure is still at the edge of the steady-state cruise dead zone, but the oxygen concentration in the return manifold rises first, the steady-state deviation is... Having deviated from zero, the control center immediately switched to slow correction without waiting for the main cabin pressure. The pressure dropped below the mechanical red alert level. Subsequently, the differential pressure transmitter array detected the slow pressure loss, the oxygen concentration meter detected residual air recirculation, and the steady-state deviation... The two types of drift are compressed into a single control object.

[0081] Furthermore, the control center controls the steady-state deviation. A low-frequency cruise loop is employed, with the cruise cycle preferably being an integer multiple of a complete discharge rotor cutting cycle to avoid reverting to the mechanical frequency already processed in step two. Simultaneously, the underlying hardware watchdog independently compares the main compartment pressure. Similar to the mechanical red warning band, as soon as the pressure drops towards the red line, the hard-wired relay matrix flips directly without software confirmation. Slow correction amount. Generate using the following formula: Where: slow correction amount : This indicates the cruise control quantity sent from step four to the main pneumatic valve's micro-opening correction port and the auxiliary air path to maintain the valve position; its value range is limited by the actuator's stroke limit; proportional coefficient : Represents steady-state deviation The instantaneous correction gain, with values ​​ranging from positive real numbers; integral coefficient : Represents the integral state quantity For slow correction amount The cumulative effect intensity, taking values ​​in the range of positive real numbers; Differential coefficients : Represents steady-state deviation Rate of change affects slow correction amount The look-ahead inhibition strength, taking values ​​in the range of non-negative real numbers; integral state quantity : Indicates the steady-state deviation during the cruise phase The time accumulation result takes values ​​in a finite real number range; anti-integral saturation coefficient : Indicates the amount of slow correction When the actuator limit is reached, the integral state quantity The rewind strength, with values ​​ranging from positive real numbers, is used to prevent the integral state quantity from being affected. Continuous accumulation; Amplitude control quantity : Represents the control quantity after being tailored to the limits of the main pneumatic valve and auxiliary air circuit valve positions; its value range is limited by the minimum and maximum opening of the actuator; used to represent the anti-integral saturation coefficient. Provide rollback boundaries.

[0082] proportionality coefficient Integral coefficient Differential coefficients Anti-integral saturation coefficient and amplitude control amount The upper and lower limits are preset in the cruise parameter table and are loaded by the control center once after power-on.

[0083] In one implementation, the industrial computing board completes one round of slow correction. Calculation involves writing new valve position values ​​to the main pneumatic valve's micro-opening correction port and the auxiliary air path's maintaining valve position, respectively; if the main pneumatic valve has reached its set limit, the anti-integral saturation coefficient... Immediately pull back the integral state quantity This prevents the opening from accumulating in the next round of cruise circuit. In parallel, the underlying hardware watchdog continuously reads the independent differential pressure switch. Once the differential pressure switch state flips, the feed main motor contactor disconnects first, the isolation baffle actuator locks then, and the main pneumatic valve maintains its current safe position.

[0084] Furthermore, slow correction amount Maintain stable cruise and resist integral saturation coefficient To prevent long-term bias from ruining the cruise circuit, the hardwired relay matrix strictly separates software bias correction and safety fuse tripping.

[0085] The passively forced deformation Teflon corrugated compensating airbag is installed on top of the explosion-proof cover. The outer ring pressure plate is fixed to the top flange of the cover, and the inner ring pressure plate is fixed to the sliding support ring. The corrugated lines are pre-positioned facing the interior of the main cabin; the outer side is directly subjected to external atmospheric pressure, and the inner side directly faces the free gas phase space of the main cabin. When the main cabin pressure... When the convex chain does not activate during rapid descent, the external atmospheric pressure pushes the corrugated line inward toward the main cabin, effectively reducing the free gas volume of the main cabin. This purely physical compensation volume is characterized by the following formula: Where: passive compensation volume : Represents the reduction in free gas volume after the passively deformed Teflon corrugated compensation airbag caves inward into the main cabin; the value range is positive real numbers; used to hold back volume collapse when the electron chain fails; passive compensation volume. Used only for structural design verification of passively deformable Teflon corrugated compensating airbags, and not involved in the online control calculation in step four; concave stroke The mechanical clearance of the limiting support ring is limited, and its maximum value is predetermined by the mounting space on the top of the cover.

[0086] Initial effective area : Indicates the pressure projection area of ​​the corrugated airbag facing the main cabin when it is initially not folded in; the value range is limited by the size of the opening at the top of the canopy; concave travel. : Represents the displacement of the corrugated airbag towards the main cabin under external atmospheric pressure; the value range is limited by the mechanical clearance between the limiting support ring and the protective mesh cover; broken line convergence coefficient. : Indicates the wavy line follows the concave travel. The geometric coefficient that causes the effective area to shrink when the area increases, and its value range is positive real numbers; In a generalized implementation, the corrugated airbag membrane material is made of polytetrafluoroethylene laminated film, with a metal protective mesh cover on the outside and a splash-proof grid on the inside. The endpoint of the limiting support ring avoids the trajectory of splashing material. Fluoroplastic membrane materials with equivalent corrosion resistance and fatigue resistance are also included in the same path. Specifically, when the entire plant's DCS screen freezes and the control center has no downlink frame output, the corrugated area on the top of the cover first contracts inward, and the downward speed of the main cabin pressure curve slows down, giving maintenance personnel time for isolation and emergency repairs.

[0087] Furthermore, the passively deformable Teflon corrugated compensating airbag does not rely on power supply or calculation, and its initial effective area... With concave stroke Together, they provide geometric compensation volume and piecewise convergence coefficient. The compensation action is made to converge naturally when approaching its limit, preventing the membrane from impacting the internal components of the main cabin. The smooth flow field left in step three is maintained within the steady-state cruise region, and the correction layer, fusing layer, and pure physical bottom layer are fixed in sequence.

[0088] Those skilled in the art will recognize that the units and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this application.

[0089] Those skilled in the art will understand that, for the sake of convenience and brevity, the specific working processes of the systems, devices, and units described above can be referred to the corresponding processes in the foregoing method embodiments, and will not be repeated here.

[0090] In the several embodiments provided in this application, it should be understood that the disclosed systems, apparatuses, and methods can be implemented in other ways. For example, the apparatus embodiments described above are merely illustrative; for instance, the division of units is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the coupling or direct coupling or communication connection shown or discussed may be through some interfaces; the indirect coupling or communication connection between apparatuses or units may be electrical, mechanical, or other forms.

[0091] The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0092] The above description is merely a specific embodiment of this application, but the scope of protection of this application 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 this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A closed-loop chemical flake-forming system with nitrogen-sealed positive pressure protection, comprising: a closed main chamber for phase change flake-forming, a rotary airlock discharge assembly connected to the lower part of the closed main chamber, a nitrogen source, a main gas path, an auxiliary gas path, a thermo-mass disturbance sensing component, and a control center, characterized in that: The thermo-mass disturbance sensing component outputs the feed mass flow rate signal, the condensate heat transfer heat transfer signal, and the rotor angular velocity signal of the rotary airlock discharge assembly under the same system clock. The control center generates a predicted volume collapse of the main compartment based on the feed mass flow rate signal and the condensed heat transfer medium reflux heat exchange signal, and performs band-resistance processing on the predicted volume collapse of the main compartment according to the mechanical cutting fundamental frequency corresponding to the rotor angular velocity signal to generate an advance compensation command. The main air path is connected to the upper part of the sealed main compartment via the main pneumatic valve, and the auxiliary air path is connected to the non-dropping area of ​​the rotary airlock discharge assembly via the pre-charge bypass. A micro-pressure clamping multi-hole array is connected in series on the pre-charge bypass. Based on the advance compensation command, the control center synchronously drives the main pneumatic valve and the pre-charge bypass at the same advance moment. Before the predicted negative pressure is formed, it inputs compensation nitrogen into the sealed main compartment and inputs isobaric nitrogen after being limited by the micro-pressure clamping multi-hole array into the non-drop material area.

2. The closed-loop chemical flake forming system according to claim 1, characterized in that: The thermal disturbance sensing components include a pump speed encoder, a thermoelectric bridge, and an edge control gateway; The edge control gateway aligns the feed mass flow rate signal, the condensate heat transfer medium reflux heat transfer signal, and the rotor angular velocity signal to the same sampling window, and encapsulates them into an initial state tensor according to a unified frame number. The initial state tensor is fixed and includes the same-clock mass flow rate, same-clock reflux heat transfer, heat mass decay index, phase change interface gradient, and uniform frame number.

3. The closed-loop chemical flake forming system according to claim 1, characterized in that: Within the same volume calculation window, the control center generates the predicted volume collapse of the main cabin based on the same clock mass flow rate, same clock reflux heat transfer, heat mass decay index and phase change interface gradient. The control center calculates the mechanical cutting fundamental frequency based on the rotor angular velocity signal, and performs band-stop processing only on the periodic components in the neighborhood of the mechanical cutting fundamental frequency, while keeping the other frequency band components unchanged.

4. The closed-loop chemical flake forming system according to claim 3, characterized in that: The control center encapsulates the results after band-stop processing into a lead compensation command; Among them, the advance compensation command includes a unified frame sequence number, the predicted amount of main cabin volume collapse, the preset peak time, and the advance time constant. The control center synchronously drives the main pneumatic valve and the pre-charge bypass only when the unified frame sequence number is consistent with the initial state tensor.

5. The closed-loop chemical flake forming system according to claim 1, characterized in that: The rotary airlock discharge assembly has a rotor coding zero position; the control center stores the start angle and end angle corresponding to the non-discharge zone, and opens the pre-charge bypass when the current rotor phase falls between the start angle and the end angle; The precharge bypass is closed when the current rotor phase is out of the start angle and the end angle.

6. The closed-loop chemical flake forming system according to claim 1, characterized in that: The rotary airlock discharge assembly includes a return sealing section; the micro-pressure clamping porous array is composed of sintered metal plate stacks connected in series upstream of the pre-charge bypass, and the absolute pore size is 15 micrometers to 25 micrometers. The centerline of the pre-charge bypass is located after the return sealing section and offset from the vertical by 15 to 35 degrees.

7. The closed-loop chemical flake forming system according to claim 1, characterized in that: The system also includes a differential pressure transmitter array, an oxygen concentration meter, a hardware watchdog, an isolation baffle, and a passively forced deformation Teflon corrugated compensation airbag; When the pressure in the sealed main chamber drops below the mechanical red warning line, the hardware watchdog cuts off the power supply to the main feed motor and locks the isolation baffle. The passively forced deformation Teflon corrugated compensation airbag folds inward into the sealed main chamber. When the pressure in the sealed main chamber does not drop below the mechanical red warning line, the differential pressure transmitter array and oxygen concentration meter maintain cruise control.

8. The closed-loop chemical flake forming system according to claim 1, characterized in that: Thermal disturbance sensing components include an edge control gateway; The edge control gateway sends data frames to the control center according to the EtherCAT cyclic frame; The data frame always includes a timestamp field, a feed rate field, a reflux temperature difference field, an optical frame index field, a frame sequence number field, and a CRC16 check field.

9. The closed-loop chemical flake forming system according to claim 8, characterized in that: The control center sends fixed-field compensation command frames to the main pneumatic valve and the pre-charge bypass; The compensation instruction frame is fixed to include a frame sequence number field, a main cabin volume collapse prediction field, a preset peak time field, and a lead time constant field. The main pneumatic valve and the pre-charge bypass only respond to compensation command frames with the same frame number.

10. The closed-loop chemical flake forming system according to claim 7, characterized in that: The hardware watchdog is directly connected to the feed main motor contactor and the isolation baffle actuator via a relay hard-wired interlocking matrix; when the pressure in the sealed main chamber drops below the mechanical red warning strip, the feed main motor contactor disconnects while the isolation baffle actuator remains locked. The main feed motor contactor will not be triggered to disconnect and the isolation baffle actuator will not be locked if the pressure in the sealed main chamber does not fall below the mechanical red warning line.

Images