A circulating shear vacuum emulsifier and a control system thereof

Abstract

The present application relates to the field of vacuum emulsifier, for solving the problem that the single effect of vacuum emulsifier cannot be quantified and the adaptive ability of cycle endpoint judgment is lacking, specifically a circulating shearing vacuum emulsifier and a control system thereof, the control system comprises an emulsification process monitoring module, an internal environment supervision module, a shearing effect statistics module, a cycle comprehensive evaluation module and a shearing cycle control module, the present application comprehensively analyzes the single cycle time and the material cycle number, generates single cycle effect evaluation features and total cycle effect evaluation features, realizes quantitative evaluation of single cycle effect, calculates the single cycle effect progressive value between adjacent cycles, and according to the threshold judgment result, the cycle process is divided into progressive cycle and stable cycle, whether the total cycle effect and cycle number meet the standard is also judged synchronously, realizes progressive cycle recognition and multi-condition joint judgment mechanism, and dynamically perceives whether the emulsification process enters the effect saturation stage.

Description

Technical Field

[0001] This invention relates to the field of vacuum emulsifiers, specifically a circulating shear vacuum emulsifier and its control system. Background Technology

[0002] Vacuum emulsifiers are used in the field of material emulsification. Circulating shear is a common enhanced emulsification process. A circulating pump repeatedly feeds the material into a high-shear zone within the emulsification chamber to achieve gradual particle size reduction and system homogenization. Traditional vacuum emulsifier control systems typically have basic stirring and circulation control functions. Some systems also incorporate monitoring mechanisms for environmental parameters such as temperature and pressure to ensure safe equipment operation. However, in actual operation, traditional technologies still have the following significant shortcomings when facing circulating shear conditions: On the one hand, it can only simply accumulate the time of a single shearing or the overall running time, and cannot perform stratified evaluation of the effect of a single cycle and the effect of the total cycle, making it difficult to identify the diminishing effect or progressive bottleneck in the emulsification process; On the other hand, the lack of a joint analysis mechanism for internal environmental parameters and torque dynamic characteristics makes it impossible to correct the shear effect deviation caused by internal environmental deviations. This makes the determination of the emulsification endpoint dependent on human experience or fixed time settings, which can easily lead to over-emulsification or under-emulsification.

[0003] To address the aforementioned technical problems, this invention proposes a solution. Summary of the Invention

[0004] This invention provides a cyclic shear vacuum emulsifier and its control system by comprehensively analyzing the single cycle time and the number of material cycles to generate single cycle effect evaluation features and total cycle effect evaluation features. This allows for quantitative evaluation of the single cycle effect. The single cycle effect evaluation features are then serialized to calculate the progressive value of the single cycle effect between adjacent cycles. Based on the threshold judgment results, the cycle process is divided into progressive cycles and stable cycles. The invention also simultaneously judges whether the total cycle effect and the number of cycles meet the standards, realizing a progressive cycle identification and multi-condition joint judgment mechanism. This dynamically senses whether the emulsification process has entered the effect saturation stage, avoiding over-emulsification or energy waste caused by traditional fixed-duration control methods.

[0005] The objective of this invention can be achieved through the following technical solution: a control system for a cyclic shear vacuum emulsifier, comprising an emulsification process monitoring module, an internal environment monitoring module, a shearing effect statistics module, a cyclic comprehensive evaluation module, and a shearing cycle control module; The internal environment monitoring module monitors the emulsifier environment during vacuum emulsifier operation and acquires internal environment parameters; The emulsification process monitoring module can monitor the operation of the vacuum emulsifier, obtain the stirring shaft torque, and generate a stirring shaft torque sequence. The shearing effect statistics module performs statistics on the cyclic shearing operation process, obtains the number of material cycles and the time of a single cycle, and acquires internal environmental parameters and stirring shaft torque sequence for comprehensive analysis to generate single cycle effect evaluation features and total cycle effect evaluation features. The cycle comprehensive evaluation module performs a comprehensive analysis based on the evaluation characteristics of a single cycle effect and the evaluation characteristics of the total cycle effect to obtain a prediction of the total emulsification effect of the material, and sends the prediction of the total emulsification effect of the material to the shear cycle control module. The shear cycle control module makes a judgment based on the prediction of the total emulsification effect of the material, generates a cycle completion signal or a cycle continuation signal, and controls the operation of the vacuum emulsifier through the generated signal.

[0006] In a preferred embodiment of the present invention, the internal environment parameters acquired by the internal environment monitoring module include the real-time temperature and real-time pressure inside the emulsification chamber. The internal environment monitoring module collects internal environment parameters according to a set sampling period and generates a sequence of internal environment parameter groups.

[0007] In a preferred embodiment of the present invention, the emulsification process monitoring module collects the torque of the stirring shaft in real time through a torque sensor installed on the stirring shaft, and arranges the collected torque values ​​in chronological order to generate a stirring shaft torque sequence. The emulsification process monitoring module identifies the peak torque and stable torque in the torque sequence and marks the corresponding time points.

[0008] In a preferred embodiment of the present invention, the shearing effect statistics module performs statistics on the cyclic shearing process in the following manner: The shearing effect statistics module starts timing each time the circulation pump is started and stops timing when the circulation pump stops running, and records the timing duration as the single cycle time. The shearing effect statistics module records each complete cycle of pump start-up and shutdown as a cycle count, and calculates the cycle count to obtain the material cycle count.

[0009] In a preferred embodiment of the present invention, the method for the shearing effect statistics module to generate single-cycle effect evaluation features is as follows: The shearing effect statistics module calculates the peak torque, stable torque, and single cycle duration using formulas to obtain the theoretical shearing effect. Then, it compares the internal environment parameters with preset standard environment parameters to obtain the internal environment difference. The ratio of the internal environment difference to the preset standard environment parameters is calculated to obtain the internal environment difference ratio. The theoretical shearing effect is corrected using the internal environment difference ratio to obtain the actual single cycle effect evaluation characteristics. The shearing effect statistics module sums the single-cycle effect evaluation features to obtain the total cycle effect evaluation features.

[0010] In a preferred embodiment of the present invention, the method for analyzing the evaluation characteristics of a single cycle effect by the cyclic comprehensive evaluation module is as follows: The single-cycle effect evaluation features of each loop are statistically analyzed, and a loop effect sequence is generated according to the triggering order of the loop. The difference between the single-cycle effect evaluation features of two adjacent loop effect sequences is calculated to obtain the single-cycle effect progression value. The cyclic comprehensive evaluation module makes a threshold judgment based on the progressive value of the single cycle effect, and determines the latter group of the single cycle effect evaluation features of two adjacent cycles as progressive cycle and stable cycle based on the judgment result.

[0011] In a preferred embodiment of the present invention, the method by which the cyclic comprehensive evaluation module analyzes the overall cyclic effect evaluation characteristics is as follows: The cycle comprehensive evaluation module compares the overall cycle effect evaluation characteristics with the set threshold to generate a judgment result that the overall effect meets the standard or the overall effect does not meet the standard. The cycle comprehensive evaluation module compares the total number of cycles with the set threshold number of cycles that can be achieved, and generates a judgment result that the number of cycles meets the standard or does not meet the standard. If both the overall effect and the number of cycles meet the target, the overall cycle effect is deemed satisfactory; otherwise, the overall cycle effect is deemed unsatisfactory. Among them, progressive cycle and stable cycle, cycle number meeting standard and cycle number not meeting standard, and total cycle effect qualified and total cycle effect unqualified are packaged as the prediction of the total emulsification effect of the material.

[0012] In a preferred embodiment of the present invention, the shearing cycle control module determines that emulsification is complete after simultaneously receiving signals indicating stable cycle, number of cycles reaching the target, and total cycle effect meeting the requirements; otherwise, it determines that emulsification is incomplete and controls the vacuum emulsifier to continue the cycle emulsification.

[0013] The present invention also proposes a circulating shear vacuum emulsifier, including a vessel body, a main shaft rotatably mounted on the top of the vessel body, a circulation loop connected to the outside of the vessel body, the circulation loop being connected to the bottom and side of the vessel body respectively, a circulation pump installed on the circulation loop, the circulation pump driving the material to move in the circulation loop, and a cold water pipe and a hot water pipe connected to the vessel body.

[0014] The beneficial effects of this invention are: 1. This invention obtains the single cycle time and material circulation number by timing and counting the start and stop of the circulating pump. It then combines internal environmental parameters and the torque sequence of the stirring shaft for comprehensive analysis to generate single cycle effect evaluation features and total cycle effect evaluation features. Furthermore, it calculates the theoretical shear effect using peak torque, stable torque, and single cycle time, and corrects it by the internal environmental difference ratio to achieve a quantitative evaluation of the single cycle effect and improve the accuracy of the cyclic shear effect evaluation.

[0015] 2. This invention also sorts the single-cycle effect evaluation features, calculates the single-cycle effect progression value between adjacent cycles, and classifies the cycle process into progressive cycles and stable cycles based on the threshold judgment result. It also simultaneously judges whether the total cycle effect and the number of cycles meet the standards, realizing a progressive cycle recognition and multi-condition joint judgment mechanism, dynamically sensing whether the emulsification process has entered the effect saturation stage, and avoiding over-emulsification or energy waste caused by the traditional fixed duration control method. Attached Figure Description

[0016] To facilitate understanding by those skilled in the art, the present invention will be further described below with reference to the accompanying drawings.

[0017] Figure 1 This is a system block diagram of the present invention; Figure 2 This is a system flowchart of the present invention; Figure 3 This is a structural diagram of the vacuum emulsifier.

[0018] In the diagram: 1. Vessel body; 2. Main shaft; 3. Circulation loop; 4. Circulation pump; 5. Cold water pipe; 6. Hot water pipe. Detailed Implementation

[0019] The technical solution of the present invention will be clearly and completely described below with reference to the embodiments. 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 of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0020] Example 1: Please refer to Figure 1 - Figure 3 As shown, a control system for a cyclic shear vacuum emulsifier includes an emulsification process monitoring module, an internal environment monitoring module, a shearing effect statistics module, a cyclic comprehensive evaluation module, and a shearing cycle control module. The internal environment monitoring module monitors the emulsifier environment during operation and acquires internal environment parameters. Specifically, the internal environment parameters acquired by the internal environment monitoring module include the real-time temperature and real-time pressure inside the emulsification chamber. These parameters are acquired through temperature sensors and pressure sensors installed on the walls of the emulsification chamber, respectively. The internal environment monitoring module collects the above-mentioned internal environment parameters according to the set fixed sampling period, and combines the temperature and pressure values ​​collected each time into an internal environment parameter group. As time goes by, multiple internal environment parameter groups are arranged in the order of collection time to generate an internal environment parameter group sequence.

[0021] The emulsification process monitoring module is used to monitor the stress state of the stirring shaft during the operation of the vacuum emulsifier. A torque sensor installed on the stirring shaft collects the stirring shaft torque in real time and arranges the collected torque values ​​in chronological order to generate a stirring shaft torque sequence. Furthermore, the emulsification process monitoring module can automatically identify the peak torque and stable torque in the torque sequence. The peak torque is the maximum torque value reached by the stirring shaft after the start of a single cycle, reflecting the initial resistance of the material to shear in the early stage of the cycle. The stable torque is defined as the average torque value when the torque value fluctuation range in the later stage of a single cycle does not exceed the threshold, reflecting the stable flow state of the material in the cycle. The emulsification process monitoring module also marks the time points corresponding to the peak torque and stable torque.

[0022] The shearing effect statistics module performs statistics on the cyclic shearing process, specifically as follows: The shearing effect statistics module starts timing every time the circulation pump is started and stops timing when the circulation pump stops running, and records the timing duration as the single cycle time. The shearing effect statistics module records each complete process of the pump from start to stop as a cycle count, and accumulates the cycle counts to obtain the material cycle count; The specific method for generating single-cycle effect evaluation features in the shearing effect statistics module is as follows: For the i-th cycle, i=1, 2, 3…n, the shearing effect statistics module obtains the peak torque, stable torque, and single cycle time corresponding to that cycle, and calculates the theoretical shearing effect E using the formula: Where Tp is the peak torque of the i-th cycle, Ts is the stable torque of the i-th cycle, t is the single cycle time of the i-th cycle, and q is a constant used to characterize the nonlinear contribution of the single cycle time to the shearing effect. When the cycle time is short, the shearing effect has not been fully utilized; when the cycle time exceeds a certain value, the effect gain gradually saturates. The shearing effect statistics module compares the measured internal environmental parameters within this cycle with the preset standard environmental parameters. The preset standard environmental parameters include standard temperature and standard pressure. The standard values ​​are usually the optimal process parameters of the material formulation under ideal emulsification conditions. The specific method for calculating the internal environment difference ratio is as follows: the internal environment deviation ratio is obtained by weighted averaging of the temperature deviation ratio and the pressure deviation ratio. The temperature difference deviation ratio is calculated by dividing the absolute value of the difference between the actual temperature value and the standard temperature by the standard temperature. The pressure deviation ratio is calculated by dividing the absolute value of the difference between the actual pressure and the standard pressure by the standard pressure. The theoretical shearing effect is corrected by the internal environment difference ratio to obtain the actual single-cycle effect evaluation characteristics, Es=E×(1-V), where V is the internal environment deviation ratio and Es is the single-cycle effect evaluation characteristics. The shearing effect statistics module sums the single-cycle effect evaluation features of each iteration to obtain the total cycle effect evaluation features.

[0023] The comprehensive evaluation module receives single-cycle effect evaluation features and total cycle effect evaluation features from the shear effect statistics module, performs comprehensive analysis, generates a prediction of the total emulsification effect of the material, and sends it to the shear cycle control module. The specific analysis method is as follows: The single-cycle effect evaluation features of each loop are statistically analyzed, and a loop effect sequence is generated according to the loop triggering order. The difference between the single-cycle effect evaluation features of two adjacent loops in the sequence is calculated to obtain the single-cycle effect progression value, which reflects the improvement of the shearing effect between two adjacent loops.

[0024] The loop comprehensive evaluation module makes a threshold judgment based on the incremental value of the single loop effect: a positive threshold is set. If the incremental value of the single loop effect is greater than or equal to the positive threshold, it means that the (i+1)th loop still has an improvement compared to the i-th loop, so the (i+1)th loop is judged as an incremental loop; if the incremental value of the single loop effect is less than the positive threshold, it means that the improvement of the i+1th loop compared to the i-th loop has approached saturation, so the (i+1)th loop is judged as a stable loop.

[0025] The cycle comprehensive evaluation module compares the total cycle effect evaluation characteristics with the pre-set total effect threshold. If the total cycle effect evaluation characteristics are greater than or equal to the total effect threshold, a total effect compliance judgment result is generated; otherwise, a total effect non-compliance judgment result is generated. The comprehensive evaluation module compares the current total number of iterations with a pre-set threshold for the number of iterations. If the total number of iterations is greater than or equal to the threshold, a result indicating that the number of iterations meets the threshold is generated; otherwise, a result indicating that the number of iterations does not meet the threshold is generated. The above analysis results, including the judgment results of progressive and stable cycles, the judgment results of whether the number of cycles meets or does not meet the standard, and the judgment results of whether the overall cycle effect is qualified or unqualified, are packaged together into a material overall emulsification effect prediction data package and sent to the shear cycle control module. If the shearing cycle control module receives three signals simultaneously—stable cycle, cycle count met, and total cycle effect qualified—it determines that emulsification is complete, generates a cycle completion signal, controls the vacuum emulsifier to stop the cycle emulsification, and ends the current production process. If any of the above three conditions are not met, it is determined that emulsification is not complete, a cycle continuation signal is generated, and the vacuum emulsifier is controlled to continue the next cycle of emulsification. The system will repeat the cycle shearing operation until the three conditions are met simultaneously, or the maximum number of cycles or the maximum cycle shearing time is reached.

[0026] Example 2: Please refer to Figure 1 - Figure 3 As shown, a circulating shear vacuum emulsifier includes a vessel body 1, a main shaft 2 rotatably mounted on top of the vessel body 1, and a circulation loop 3 connected to the outside of the vessel body 1. The circulation loop is connected to the bottom and side of the vessel body 1 respectively. A circulation pump 4 is installed on the circulation loop 3. The circulation pump 4 drives the material to move in the circulation loop 3. Each time, the circulation pump 4 draws material from the bottom of the vessel body 1 and puts it back into the upper part of the vessel body 1 through the circulation loop 3, ensuring that the material at the bottom of the vessel body 1 can be fully emulsified. The vessel body 1 is also connected to a cold water pipe 5 and a hot water pipe 6.

[0027] Thresholds, preset values, or preset ranges are set for result comparison and analysis to determine whether they are good or bad. The magnitude of these values ​​is determined by a combination of large-scale model analysis of the sample data and human experience. They can also be adjusted appropriately based on seasonal or common-sense influence conditions. Similarly, the weighting ratio coefficients and influence factors are set based on the magnitude of each parameter's influence on the results. These values ​​are assigned to reflect the overall impact on the results. They are also determined by a combination of large-scale model analysis of the sample data and human experience. They can also be adjusted appropriately based on seasonal or common-sense influence conditions.

[0028] The preferred embodiments of the present invention disclosed above are merely illustrative of the invention. These preferred embodiments do not exhaustively describe all details, nor do they limit the invention to any specific implementation. Clearly, many modifications and variations can be made based on the content of this specification. This specification selects and specifically describes these embodiments to better explain the principles and practical applications of the invention, thereby enabling those skilled in the art to better understand and utilize the invention. The invention is limited only by the claims and their full scope and equivalents.

Claims

1. A control system for a circulating shear vacuum emulsifier, characterized in that, It includes an emulsification process monitoring module, an internal environment monitoring module, a shear effect statistics module, a cycle comprehensive evaluation module, and a shear cycle control module; The internal environment monitoring module monitors the emulsifier environment during vacuum emulsifier operation and acquires internal environment parameters; The emulsification process monitoring module can monitor the operation of the vacuum emulsifier, obtain the stirring shaft torque, and generate a stirring shaft torque sequence. The shearing effect statistics module performs statistics on the cyclic shearing operation process, obtains the number of material cycles and the time of a single cycle, and acquires internal environmental parameters and stirring shaft torque sequence for comprehensive analysis to generate single cycle effect evaluation features and total cycle effect evaluation features. The cycle comprehensive evaluation module performs a comprehensive analysis based on the evaluation characteristics of a single cycle effect and the evaluation characteristics of the total cycle effect to obtain a prediction of the total emulsification effect of the material, and sends the prediction of the total emulsification effect of the material to the shear cycle control module. The shear cycle control module makes a judgment based on the prediction of the total emulsification effect of the material, generates a cycle completion signal or a cycle continuation signal, and controls the operation of the vacuum emulsifier through the generated signal.

2. The control system of the circulating shear vacuum emulsifier according to claim 1, characterized in that, The internal environment parameters acquired by the internal environment monitoring module include the real-time temperature and real-time pressure inside the emulsification chamber. The internal environment monitoring module collects internal environment parameters according to a set sampling period and generates a sequence of internal environment parameter groups.

3. The control system of the circulating shear vacuum emulsifier according to claim 1, characterized in that, The emulsification process monitoring module collects the torque of the stirring shaft in real time through a torque sensor installed on the stirring shaft, and arranges the collected torque values ​​in chronological order to generate a stirring shaft torque sequence. The emulsification process monitoring module identifies the peak torque and stable torque in the torque sequence and marks the corresponding time points.

4. The control system of the circulating shear vacuum emulsifier according to claim 1, characterized in that, The specific method by which the shearing effect statistics module performs statistics on the cyclic shearing process is as follows: The shearing effect statistics module starts timing each time the circulation pump is started and stops timing when the circulation pump stops running, and records the timing duration as the single cycle time. The shearing effect statistics module records each complete cycle of pump start-up and shutdown as a cycle count, and calculates the cycle count to obtain the material cycle count.

5. The control system of the circulating shear vacuum emulsifier according to claim 1, characterized in that, The method by which the shearing effect statistics module generates single-cycle effect evaluation features is as follows: The shearing effect statistics module calculates the peak torque, stable torque, and single cycle duration using formulas to obtain the theoretical shearing effect. Then, it compares the internal environment parameters with preset standard environment parameters to obtain the internal environment difference. The ratio of the internal environment difference to the preset standard environment parameters is calculated to obtain the internal environment difference ratio. The theoretical shearing effect is corrected using the internal environment difference ratio to obtain the actual single cycle effect evaluation characteristics. The shearing effect statistics module sums the single-cycle effect evaluation features to obtain the total cycle effect evaluation features.

6. The control system of the circulating shear vacuum emulsifier according to claim 1, characterized in that, The method for analyzing the characteristics of a single cycle effect evaluation in the cyclic comprehensive evaluation module is as follows: The single-cycle effect evaluation features of each loop are statistically analyzed, and a loop effect sequence is generated according to the triggering order of the loop. The difference between the single-cycle effect evaluation features of two adjacent loop effect sequences is calculated to obtain the single-cycle effect progression value. The cyclic comprehensive evaluation module makes a threshold judgment based on the progressive value of the single cycle effect, and determines the latter group of the single cycle effect evaluation features of two adjacent cycles as progressive cycle and stable cycle based on the judgment result.

7. The control system of the circulating shear vacuum emulsifier according to claim 1, characterized in that, The method used by the comprehensive evaluation module to analyze the characteristics of the overall cycle effect is as follows: The cycle comprehensive evaluation module compares the overall cycle effect evaluation characteristics with the set threshold to generate a judgment result that the overall effect meets the standard or the overall effect does not meet the standard. The cycle comprehensive evaluation module compares the total number of cycles with the set threshold number of cycles that can be achieved, and generates a judgment result that the number of cycles meets the standard or does not meet the standard. If both the overall effect and the number of cycles meet the target, the overall cycle effect is deemed satisfactory; otherwise, the overall cycle effect is deemed unsatisfactory. Among them, progressive cycle and stable cycle, cycle number meeting standard and cycle number not meeting standard, and total cycle effect qualified and total cycle effect unqualified are packaged as the prediction of the total emulsification effect of the material.

8. The control system of the circulating shear vacuum emulsifier according to claim 1, characterized in that, The shearing cycle control module determines that emulsification is complete after simultaneously receiving signals indicating stable cycle, sufficient number of cycles, and satisfactory overall cycle effect. Otherwise, it determines that emulsification is incomplete and controls the vacuum emulsifier to continue the cycle emulsification.

9. A circulating shear vacuum emulsifier, applied to the control system as described in any one of claims 1-8, characterized in that, The vessel includes a vessel body (1), a main shaft (2) is rotatably mounted on the top of the vessel body (1), and a circulation loop (3) is connected to the outside of the vessel body (1). The circulation loop is connected to the bottom and side of the vessel body (1) respectively. A circulation pump (4) is installed on the circulation loop (3). The material is driven to move in the circulation loop (3) by the circulation pump (4). A cold water pipe (5) and a hot water pipe (6) are also connected to the vessel body (1).

Images