Method for optimizing production process of oxygen-permeable and environmentally friendly lightweight foamed plant material

Abstract

The present application relates to the technical field of production and manufacturing and scheduling, and discloses a production process optimization method for oxygen-permeable and breathable environment-friendly light foamed plant materials, which comprises the following steps: first, establishing a batch-oriented data entity and binding basic data, then controlling a moisture saturation and ventilation drying device to perform twice saturation and drainage operations on the same batch of samples to generate two standard wet and dry states; on this basis, corresponding flux data is obtained by using a low-pressure air flux measuring device. By calculating the effective air permeability state coefficient of the same batch before and after wetting and drying, the wet and dry air permeability retention rate is obtained, which is converted into a sequence time compensation coefficient and a batch earliest sequence time. Finally, a constrained scheduling allocation is performed according to the resource available time, and a non-automatic covering dispatching record is generated and locked to trigger subsequent operations. The present application converts the actual air permeability state of the foamed plant material into a scheduling constraint, thereby improving the air permeability consistency of the final product.

Description

Technical Field

[0001] This invention relates to the field of manufacturing and scheduling technology, and more specifically, to a method for optimizing the production process of oxygen-permeable, environmentally friendly, lightweight foamed planting materials. Background Technology

[0002] In continuous or quasi-continuous production processes of environmentally friendly lightweight foamed planting materials (such as biodegradable polylactic acid foamed granules, polylactic acid-cellulose acetate foamed matrix, biochar composite matrix, and porous planting materials such as foamed glass), products typically require quality inspection after foaming and cooling to schedule subsequent transfer, coating, or packaging operations. Current production scheduling and management primarily rely on basic quality inspection indicators such as material formulation type, dry density, moisture content, or static porosity as the basis for scheduling and release.

[0003] However, extensive soilless substrate cultivation practices have shown that foamed materials face continuous alternation between irrigation and drainage in practical applications. During the process from saturation to drainage, moisture easily redistributes between the micropores and connecting pore necks within the material. Some pore sizes are occupied by residual water films, leading to the contraction of connected gas phase pathways and increased pore tortuosity. This evolution of the internal microstate induced by the wet-drying process results in significant differences in the actual effective oxygen diffusion capacity of the same batch of materials with the same static air-filled porosity.

[0004] Existing production scheduling systems, when executing resource allocation, only use static quality inspection indicators as criteria for process flow judgment, failing to incorporate the sensitivity of pore connectivity to wet-dry alternation into data processing. This leads to some batches that appear to meet porosity standards under static testing, but whose internal gas phase channels are not yet stable and whose wet-dry connectivity has significantly decreased, being prematurely scheduled into the coating or packaging stages. This scheduling method ultimately results in problems such as uneven water absorption and degassing, delayed root zone oxygen supply, and batch performance inconsistencies when the substrate is actually used for cultivation. Current production management processes lack methods to translate the actual usable oxygen permeability into hard constraints for process assignment. Summary of the Invention

[0005] This invention provides an optimized production process for oxygen-permeable, environmentally friendly, lightweight foamed planting materials, which solves the technical problems mentioned in the background art.

[0006] This invention provides a method for optimizing the production process of oxygen-permeable, environmentally friendly, lightweight foamed planting materials, applied to a production management system. The production management system includes continuous discharge or mold cavity forming equipment, moisture saturation and ventilation drying equipment, a low-pressure airflow measuring device with a sealed ventilation fixture, and a production execution terminal. The method includes:

[0007] Establish batch-oriented production management data entities and bind them to batch basic data that includes downstream resource sets; Obtain a sample of foamed planting material, and control the moisture saturation and ventilation drying equipment to perform two saturation drainage operations on the sample to generate two standard wet-dry states of the same batch; Under the two standard wet and dry conditions, the corresponding low-pressure air flux data were measured using the low-pressure air flux measuring device. Based on the batch basic data and the low-pressure air flux data, the effective air permeability state coefficient of the same batch before and after wet drying is calculated to extract the wet-dry air permeability retention rate. Calculate the transition time compensation coefficient based on the wet-dry air permeability retention rate, and convert it into the earliest transition time of the batch. Based on the earliest batch transfer time, the wet-dry breathability retention rate, and the availability time of the target downstream resources in the downstream resource set, batch sorting and resource allocation are performed to obtain the transfer start time and packaging release time of the target downstream resources. The sequence start time and the packaging release time are converted into a dispatch time field that can be executed by the equipment, a dispatch record containing the sequence start time and the packaging release time is generated and locked, and then sent to the production execution terminal.

[0008] Beneficial effects include: By establishing and calculating the wet-dry air permeability retention rate in the management system, this invention upgrades the release mechanism, which originally relied on a single static porosity or density, to a scheduling mechanism that dynamically adjusts the waiting time for each batch to proceed based on the oxygen permeability status. This effectively intercepts batches that meet the static indicators but have potential for attenuation in the actual oxygen diffusion path, delaying their entry into the coating and packaging operations. This reduces product performance fluctuations in downstream processes and end-cultivation scenarios, and improves the stability and batch consistency of oxygen supply to the root zone of lightweight foamed planting materials. Attached Figure Description

[0009] Figure 1 This is a two-dimensional block diagram of the production management system architecture and equipment connection of the present invention; Figure 2 This is the main flowchart of the production management optimization method of the present invention; Figure 3 This is a two-dimensional structural diagram of the sample under ventilation conditions of the present invention. Detailed Implementation

[0010] The subject matter described herein will now be discussed with reference to exemplary embodiments. It should be understood that these embodiments are discussed only to enable those skilled in the art to better understand and implement the subject matter described herein, and changes may be made to the function and arrangement of the elements discussed without departing from the scope of this specification. Various processes or components may be omitted, substituted, or added as needed in the examples. Furthermore, features described in some examples may be combined in other examples.

[0011] Example 1: The oxygen-permeable, environmentally friendly, lightweight foamed planting material in this embodiment refers to an environmentally friendly, lightweight foamed planting material with a porous structure, used for oxygen supply and moisture retention in the root zone of plants, and whose effective permeability coefficient can be characterized by low-pressure air flux data.

[0012] The breathable, environmentally friendly, lightweight foamed planting material uses plant fiber-modified polyolefin composite material and is prepared through a supercritical nitrogen physical foaming process. In continuous discharge scenarios, the continuous discharge or mold cavity forming equipment 200 adopts a twin-screw extrusion continuous foaming production line, with the extrusion temperature set at... to The foaming pressure is set to to After foaming, a horizontal mesh belt air cooler is used for cooling. In cavity molding scenarios, continuous discharge or cavity molding equipment 200 uses a closed-type compression molding foaming mold, and the mold temperature is set to... The pressure holding and foaming time is set to After a few minutes, the oxygen-permeable, environmentally friendly, lightweight foamed planting material is removed and air-cooled.

[0013] like Figure 1 As shown, the production management system 100 interacts with the continuous discharge or mold cavity forming equipment 200, the moisture saturation and ventilation drying equipment 300, the low-pressure air flux measuring equipment 400 with a sealed ventilation fixture, the target downstream resource 500 in the downstream resource set, and the production execution terminal 600. Figure 1 The target downstream resource 500 in the diagram is a schematic object of the target downstream resource in the downstream resource set. The target downstream resource 500 is determined by the production management system 100 from the downstream resource set when performing batch sorting and resource allocation. The production management system 100 is used to establish batch-oriented production management data entities, receive low-pressure air flux data, calculate wet-dry air permeability retention rate, transfer time compensation coefficient and earliest transfer time of the batch, and generate dispatch records that cannot be automatically overwritten.

[0014] The target downstream resources in the downstream resource set correspond to the subsequent production process resources after the foaming and cooling of the oxygen-permeable, environmentally friendly, lightweight foamed planting material. Specifically, these include curing and settling stations, fixed-length cutting equipment, surface modification lines, and finished product packaging equipment. Each type of production resource contains multiple independent pieces of equipment or stations, each uniquely identified by a resource number. Their availability and standard processing time for downstream resources are pre-stored in the downstream resource set of the production management system 100. During scheduling, the production management system 100 matches allocable target downstream resources from this set, completing the binding of batches with process resources.

[0015] like Figure 2 As shown, this embodiment is executed sequentially according to steps S100 to S700. Step S100 is used to establish a batch-oriented production management data entity and bind the batch basic data containing the downstream resource set; Step S200 is used to obtain a sample of foamed planting material, and control the moisture saturation and ventilation drying equipment 300 to perform two saturation drainage operations on the sample to generate two standard wet-dry states of the same batch; Step S300 is used to measure the corresponding low-pressure air flux data using a low-pressure air flux measuring device 400 with a sealed ventilation clamp under the two standard wet-dry states; Step S400 is used to calculate the effective air permeability state coefficient of the same batch before and after wet drying to extract the wet-dry air permeability retention rate; Step S500 is used to calculate the transfer time compensation coefficient based on the wet-dry air permeability retention rate and convert it into the earliest transfer time of the batch; Step S600 is used to perform batch sorting and resource allocation to obtain the transfer start time and packaging release time of the target downstream resource in the downstream resource set; Step S700 is used to generate and lock the dispatch record and send it to the production execution terminal 600.

[0016] exist Figure 3 In one embodiment shown, a low-pressure air flux measurement device 400 with a sealed venting clamp may include a test chamber 410, a sample 420, a sealed venting clamp 430, an edge sealing ring 431, an inlet pipe 440, a low-pressure differential airflow direction indicator arrow 441, an outlet pipe 450, and an apparent air velocity and differential pressure sensor assembly 460. The sample 420 is disposed between the sealed venting clamps 430. The edge sealing ring 431 is used to restrict airflow around the edge of the sample 420. The inlet pipe 440 and the outlet pipe 450 form a preset pressure difference along the thickness direction of the sample. The apparent air velocity and differential pressure sensor assembly 460 is used to collect the initial apparent air velocity, the initial differential pressure, the subsequent apparent air velocity, and the subsequent differential pressure.

[0017] Step S100: Establish a batch-oriented production management data entity and bind it to the batch basic data containing the downstream resource set.

[0018] After receiving a bubble cooling completion signal from the continuous discharge or mold cavity forming equipment 200, the production management system 100 establishes a production management data entity bound with a batch number, treating each continuous discharge or the same mold cavity forming cycle as a batch. In the continuous discharge scenario, the preset continuous discharge batch division length in the production management system 100 is set to every... For each batch, the length is determined based on the extrusion stability of the continuous discharge production line and the single-batch processing capacity of the downstream process. The continuous discharge or cavity forming equipment 200 cuts the continuously extruded, oxygen-permeable, environmentally friendly, lightweight foamed planting material to a predetermined length. Each completed cut generates a foaming and cooling completion signal and uploads it to the production management system 100. In the cavity forming scenario, oxygen-permeable, environmentally friendly, lightweight foamed planting material that completes foaming and cooling within the same cavity forming cycle is classified as a batch. The batch number is generated by the production management system 100 and remains unique after the production management data entity is created.

[0019] After the foaming and cooling process is completed, the core layer temperature of the oxygen-permeable, environmentally friendly, lightweight foamed planting material drops to [temperature value missing]. The criteria for judgment are: surface temperature drops to room temperature and no obvious surface deformation. The continuous discharge or mold cavity forming equipment 200 collects the surface temperature and core layer temperature of the foamed material using infrared temperature sensors and implanted thermocouples, respectively. When both temperature parameters simultaneously meet the judgment conditions, a foaming cooling completion signal is generated and uploaded to the production management system 100. In the mold cavity forming scenario, the air cooling time after mold opening reaches [a certain value]. When the temperature meets the above requirements within minutes, the bubble cooling process is considered complete.

[0020] The production management data entity records the bubble cooling completion time, sample volume, sample thickness, dry bulk density, solid skeleton density, basic conditioning time, downstream resource standard processing time, and downstream resource set for this batch, serving as the batch's basic data. The bubble cooling completion time is uploaded to the production management system 100 by the continuous discharge or mold cavity forming equipment 200; the sample volume and thickness are obtained by measuring samples from the same batch; the dry bulk density is obtained by the dry mass of the sample after low-temperature constant weight and the sample volume; the solid skeleton density is measured by the skeleton density after crushing or slicing in the same batch; the basic conditioning time and downstream resource standard processing time are determined by the parameter relationships pre-stored in the production management system 100.

[0021]

[0022] In the above formula, Indicates dry bulk density. Indicates dry mass. This indicates the sample volume. If the volume density is greater than or equal to the solid skeleton density, the production management system 100 will mark the measurement data corresponding to the dry volume density or solid skeleton density as abnormal and reacquire the corresponding measurement data.

[0023] The density of the solid skeleton was measured using the gas displacement method, with high-purity helium as the test medium. Before measurement, the same batch of oxygen-permeable, environmentally friendly, lightweight foamed planting material was pulverized into particles smaller than [a certain size]. Particles, take The particles to be tested were placed in the sample chamber and tested using a fully automated true density analyzer. The test temperature was set to [temperature value missing]. The test pressure is set to The test was repeated three times, and the average value was taken as the solid skeleton density of the batch. The test results were uploaded to the production management system 100 and written into the production management data entity of the corresponding batch for the calculation of total porosity.

[0024] Basic humidification time The grading was based on the thickness and dry bulk density of the oxygen-permeable, environmentally friendly, lightweight foamed planting material. When the sample thickness was... And the dry bulk density is At that time, the basic conditioning time is set to Hours; when the sample thickness increases by 1 hour The basic conditioning time will increase accordingly. Hours; when the dry bulk density increases by 1 hour The basic conditioning time will increase accordingly. The basic conditioning time is pre-stored in the production management system 100 and is automatically bound to the production management data entity of the corresponding batch, serving as the base duration for calculating the earliest transition time of the batch.

[0025] The downstream resource set includes at least one target downstream resource capable of receiving the current scheduled batch and forming an occupied interval. The target downstream resource is an object determined by the production management system 100 within the downstream resource set; before matching, each object in the downstream resource set can participate in the calculation as a target downstream resource. Each target downstream resource has a resource number, available time, and a standard processing time corresponding to the current scheduled batch. The standard processing time of the downstream resource covers the occupied interval of the target downstream resource from the start time of the transfer to the time of packaging release.

[0026] Downstream resource standard processing time The processing time for downstream resources is set based on the process type and batch volume of the target downstream resources, with the standard processing time for downstream resources of the fixed-length cutting equipment set as per batch. The standard processing time for downstream resources of the surface modification treatment line is set at minutes per batch. The standard processing time for downstream resources of finished product packaging equipment is set at minutes per batch. Minutes. The standard processing time for downstream resources is pre-stored in the downstream resource set of the production management system 100, and is bound to the resource number of the corresponding target downstream resource, covering the total time occupied by this batch on the target downstream resource from the start of the transfer to the time of packaging and release.

[0027] Step S200: Obtain a sample of foamed planting material, control the moisture saturation and ventilation drying equipment to perform two saturation drainage operations on the sample to generate two standard wet-dry states of the same batch.

[0028] After the production management data entity is established, the production management system 100 obtains samples from the same batch of breathable, environmentally friendly, lightweight foamed planting material. The test samples are cylindrical or cuboid in shape, with the diameter of the cylindrical samples set as follows: The diameter is consistent with the effective ventilation area, and the thickness is consistent with the finished thickness of the corresponding batch of oxygen-permeable, environmentally friendly, lightweight foamed planting material; the cross-sectional dimensions of the rectangular sample are set as follows: The thickness is consistent with the finished thickness of the corresponding batch of breathable, environmentally friendly, lightweight foamed planting material. The sample was cut using a sharp blade, and after cutting, the two test surfaces of the sample remained flat and parallel, with a surface flatness deviation not exceeding [a certain value]. The edges are free of burrs and missing corners; at least one batch is prepared in the same batch. The test results of the parallel samples were averaged and then written into the production management data entity.

[0029] The production management system 100 controls the moisture saturation and ventilation drying equipment 300 to perform two saturation drainage operations on the samples. The first saturation drainage operation is used to bring the samples to the initial saturation drainage state after bubbling and cooling, and the initial saturation drainage quality is recorded. The second saturation drainage operation is used to bring the samples, after wet disturbance, to the second saturation drainage state, and the second saturation drainage quality is recorded. The two standard wet-dry states consist of the initial saturation drainage state and the second saturation drainage state.

[0030] The saturation stage in the saturation drainage operation employs a vacuum saturation method, completely immersing the sample in water. In pure water, first evacuate the saturation chamber to an absolute pressure of and maintain After 10 minutes, return to normal pressure and continue soaking. Minutes, with the difference between two consecutive weighings of the sample mass being less than [value missing]. As the criterion for determining whether saturation is complete, the first saturation drainage state and the second saturation drainage state use the exact same saturation temperature, vacuum degree, holding time and criterion to ensure the consistency of the benchmark between the two sets of saturation states.

[0031] The saturation drainage process employs a combination of hanging and surface drying. After saturation, the sample is removed from the water and hung vertically in a windless environment to drain. After 10 minutes, use qualitative filter paper to gently adhere to the entire surface of the sample to absorb the free water adhering to the surface. Do not apply any squeezing force to the sample during the operation to avoid squeezing out the water inside the pores and affecting the saturated drainage quality. Immediately after drainage, weigh the sample and record the first saturated drainage mass and the second saturated drainage mass.

[0032] After reaching the initial saturation and drainage state, the production management system 100 controls the moisture saturation and ventilation drying equipment 300 to perform a wet disturbance on the sample. The wet disturbance includes resaturation, drainage, and ventilation drying to the preset humidity conditioning endpoint. The resaturation, drainage, and ventilation drying to the preset humidity conditioning endpoint in the wet disturbance are used to create the disturbance conditions between the two saturation and drainage operations; the saturation and drainage operation re-executed after the wet disturbance is used to generate the resaturation and drainage state.

[0033] The ventilation and drying process during moisture disturbance adopts a constant temperature and humidity ventilation and drying method, with the drying environment temperature set at [temperature value missing]. The ambient relative humidity is set to Ventilation speed set to The airflow direction is parallel to the large surface of the sample. The moisture saturation and ventilation drying equipment 300 maintains stable drying conditions through its built-in temperature and humidity control module and fan module, ensuring uniform changes in the moisture content of the sample during the wet disturbance process and avoiding uneven local drying that could affect the consistency of the resaturation and drainage state.

[0034] The preset humidity conditioning endpoint includes two categories of judgment rules: sample quality stability conditions and sample moisture content conditions. Meeting either one of these conditions is sufficient to determine that the preset humidity conditioning endpoint has been reached. The sample quality stability condition is defined as every [percentage missing]. The sample is weighed once every few minutes, and the difference in mass of three consecutive weighings is less than the total mass of the sample. The sample's water content condition is that the volumetric water content of the sample decreases to a certain percentage of the total porosity. The volumetric moisture content is calculated using the formula based on the real-time weighed mass and dry mass. The production management system 100 preferentially uses the sample quality stability condition as the default judgment rule, and switches to the sample moisture content condition when rapid wet disturbance needs to be completed.

[0035]

[0036] In the above formula, Indicates volumetric moisture content. This indicates the mass measured under the corresponding conditions. Indicates dry mass. This represents the preset water density constant. represents the volume of the sample.

[0037] After recording the re-saturated drainage mass, the production management system 100 controls the sample to undergo low-temperature constant-weight treatment, and records the dry mass. The low-temperature constant-weight treatment is carried out in a forced-air drying oven, and the treatment temperature is set to , and the blast air velocity is set to ; the constant weight determination criterion is to weigh the sample once every hours, and the mass difference between two consecutive weighings is less than of the dry mass of the sample. After reaching the constant weight state, the sample is taken out and placed in a desiccator to cool to room temperature, and then the dry mass is weighed and recorded; the moisture saturation and ventilation drying equipment 300 performs the low-temperature constant-weight treatment according to the above preset conditions, so as to ensure that the moisture in the internal pores of the sample is completely removed and the solid skeleton does not undergo thermal deformation.

[0038] Step S300: Under two standard wet-dry states, a low-pressure air flux measuring device equipped with a sealed vent fixture is used to measure corresponding low-pressure air flux data.

[0039] In the first saturated drainage state, the sample 420 is placed into the sealed vent fixture 430 as shown in Figure 3 , so that the thickness direction of the sample is consistent with the indication arrow 441 for the low-pressure difference airflow direction. The edge sealing ring 431 presses against the edge area of the sample 420 to reduce the possibility of gas bypassing the effective ventilation area of the sample 420. The production management system 100 controls the low-pressure air flux measuring device 400 equipped with the sealed vent fixture to apply a preset pressure difference in the thickness direction of the sample through the air inlet pipeline 440 and the air outlet pipeline 450, and measure the first apparent air velocity and the first pressure difference after the measurement is stabilized.

[0040] The edge sealing ring 431 of the sealed vent fixture 430 is made of silicone rubber, with a circular cross-section and a cross-sectional diameter of . When the sealed vent fixture 430 is pressed, the pressing torque is controlled by a torque wrench to be , so that the edge sealing ring 431 produces uniform compressive deformation to fill the gap between the edge of the sample 420 and the sealed vent fixture 430. Before each test, a standard non-porous aluminum plate is used for leakage rate verification. When the leakage rate is lower than of the total flow, the seal is determined to be qualified, and the test of the sample 420 can be carried out; the contact width between the edge sealing ring 431 and the edge of the sample 420 is not less than , so as to restrict the airflow bypass at the edge of the sample 420 and reduce the influence of edge leakage on the test result.

[0041] The preset pressure difference applied during the low-pressure air flux measurement process is set to The preset pressure difference is the pressure difference between the inlet and outlet sides along the thickness direction of the sample. The low-pressure airflow measurement device 400 with a sealed ventilation clamp monitors the pressure difference across the sample in real time using a pressure differential sensor and adjusts the intake flow rate through a proportional control valve at the inlet end to maintain the pressure difference stably at the preset value. Measurements under the initial saturation drainage state and the subsequent saturation drainage state use the exact same preset pressure difference value to ensure the comparability of the two sets of test data.

[0042] Apparent air velocity This refers to the ratio of the volumetric flow rate of the test airflow to the effective ventilation area of ​​the sample, where the effective ventilation area is consistent with the flow cross-sectional area of ​​the sealing ventilation fixture 430; when the effective ventilation area is set to a circular cross-section, the diameter of the flow cross-section is... The effective ventilation area is calculated using the following formula:

[0043] In the above formula, Indicates the effective ventilation area. This indicates the diameter of the flow passage section. The low-pressure air flux measurement device 400 with a sealed ventilation clamp collects real-time volumetric flow rate through a built-in gas flow sensor, and calculates the initial apparent air velocity and the subsequent apparent air velocity under the corresponding conditions by combining the pre-stored effective ventilation area.

[0044] Under the condition of resaturation and drainage, sample 420 is placed in the same sealing and venting fixture 430 with the same sample thickness direction, the same preset pressure difference is applied, and the apparent air velocity and pressure difference are measured again after the measurement stabilizes. The two measurements maintain the same sample thickness direction, the same sealing and venting fixture, the same edge sealing conditions, and the same effective ventilation area to reduce the deviation of low-pressure air flux data caused by differences in clamping direction or sealing.

[0045] The preset criteria for measurement stability are: set in the production management system 100. Continuous sampling within a second sampling period For the apparent air velocity and pressure differential data, the apparent air velocity values ​​for all groups do not fluctuate within the range of the average value. Meanwhile, the pressure difference values ​​of all groups fluctuate within a range not exceeding the average value. When the above conditions are met, the measurement is determined to have reached a stable state. The production management system 100 takes the average value of all data within the sampling period as the final values ​​of the first apparent air velocity, the first differential pressure, the second apparent air velocity, and the second differential pressure.

[0046] The low-pressure air flux measuring device 400, equipped with a sealed venting clamp, also records the aerodynamic viscosity during measurement. In the aerodynamic viscosity calculation formula, a reference aerodynamic viscosity is used. Values Reference temperature Values Preset constant Values The production management system 100 adopts the Kelvin temperature measurement rule for unified processing. , and Numerical calculations for measuring temperature The temperature data is collected in real time by the built-in temperature sensor of the low-pressure air flux measurement device 400 with a sealed venting clamp and uploaded to the production management system 100. The aerodynamic viscosity under the corresponding measurement condition is calculated by substituting the data into the following formula:

[0047] In the above formula, Indicates aerodynamic viscosity, Indicates reference aerodynamic viscosity. Indicates reference temperature. Indicates the measured temperature. This represents a preset constant. The production management system 100 writes the initial apparent air velocity, initial differential pressure, secondary apparent air velocity, secondary differential pressure, and aerodynamic viscosity as low-pressure air flux data into the production management data entity.

[0048] Step S400: Based on the batch basic data and low-pressure air flux data, calculate the effective air permeability state coefficient of the same batch before and after wet drying, so as to extract the wet-dry air permeability retention rate.

[0049] The production management system 100 calculates the effective air permeability coefficient of the same batch before and after wet drying based on batch baseline data and low-pressure air flux data. To distinguish between the two standard wet-dry states, let... Indicates the initial saturated drainage state, let... This indicates a resaturated drainage state. The production management system 100 first calculates the volumetric moisture content under the two states based on the initial or resaturated drainage mass, dry mass, preset water density constant, and sample volume.

[0050]

[0051] In the above formula, This represents the volumetric water content under the two conditions. This indicates the initial saturation discharge mass or the subsequent saturation discharge mass. Indicates dry mass. This represents the preset water density constant. This indicates the sample volume. The production management system 100 uses unified measurement rules to process the initial saturation drainage mass, the re-saturation drainage mass, the dry mass, the preset water density constant, and the sample volume.

[0052] Subsequently, the production management system 100 calculates the total porosity based on the dry bulk density and the solid skeleton density.

[0053]

[0054] In the above formula, Indicates total porosity. Indicates dry bulk density. This represents the density of the solid skeleton. If a certain volume density is greater than or equal to the solid skeleton density, or if the calculated volumetric water content is greater than the total porosity, the production management system 100 will mark the corresponding measurement data as abnormal and reacquire the corresponding measurement data.

[0055] The production management system 100 calculates the effective ventilation porosity under two conditions based on the total porosity, volumetric water content, and a preset resolution lower limit constant. (Preset resolution lower limit constant) The value of is set to 0.5% of the total porosity, and its calculation expression is:

[0056] The preset resolution lower limit constant is determined based on the lowest resolution of the low-pressure air flux measurement device 400 with a sealed ventilation clamp. When the calculated effective ventilation porosity is less than the preset resolution lower limit constant, the preset resolution lower limit constant is taken as the calculated value of the effective ventilation porosity. This avoids the effective ventilation porosity from becoming zero or negative due to measurement resolution limitations or calculation rounding, ensuring that the subsequent calculation of the effective air permeability state coefficient is performed normally.

[0057]

[0058] In the above formula, Indicates the effective ventilation porosity. Indicates total porosity. Indicates volumetric moisture content. This represents the preset resolution lower limit constant.

[0059] The production management system 100 calculates the air permeability coefficient for the two sets of conditions based on the aerodynamic viscosity, sample thickness, first apparent air velocity or second apparent air velocity and the corresponding pressure difference.

[0060]

[0061] In the above formula, Indicates the air permeability coefficient. Indicates aerodynamic viscosity, Indicates the thickness of the sample. Indicates the first apparent air velocity or the second apparent air velocity. This indicates the corresponding pressure difference.

[0062] The production management system 100 calculates the effective air permeability state coefficient by combining the air permeability coefficient, sample thickness, effective air permeability porosity, total porosity, and the first minimum tolerance. The first minimum tolerance... The value of is set to one ten-thousandth of the square of the total porosity, and its calculation expression is:

[0063] The first minimum tolerance value is less than the square of the normal total porosity, and is only used when the total porosity approaches zero due to abnormal data, to avoid... As the divisor results in invalid calculations, the effect of the first minimum tolerance on the calculation of the effective permeability coefficient under normal operating conditions is negligible.

[0064]

[0065] In the above formula, Indicates the effective air permeability coefficient. Indicates the air permeability coefficient. Indicates the thickness of the sample. Indicates the effective ventilation porosity. Indicates total porosity. This represents the first minimum tolerance. The effective air permeability coefficient is used to comprehensively characterize the air permeability and conductivity of foamed planting media under corresponding wet and dry conditions, as well as the effectiveness of its pore structure. In the formula... The term is used to normalize the effect of sample thickness on air permeability. This term, based on the correlation between pore structure and permeability in seepage mechanics, is introduced to correct the contribution weight of the effective ventilation pore ratio to air permeability. The power exponent corresponds to a general empirical index for seepage in porous media.

[0066] The effective measurement range of the low-pressure air flux measuring device 400 with a sealed venting clamp is set to the lowest measurable value of the air permeability coefficient. The corresponding effective air permeability state coefficient boundary. When the effective air permeability state coefficient calculated under the initial saturated drainage state is lower than this boundary, it is determined that the low-pressure air flux data of this group exceeds the effective measurement range. The production management system 100 does not use this group of data, and controls the moisture saturation and ventilation drying equipment 300 and the low-pressure air flux measuring equipment 400 with sealed ventilation clamps to re-prepare samples and perform two saturated drainage operations and low-pressure air flux measurements until the test data falls within the effective measurement range.

[0067] The production management system 100 compares the effective air permeability state coefficients under the two sets of conditions and calculates the wet-dry air permeability retention rate. When the effective air permeability state coefficient under the initial saturated drainage condition is greater than the lower limit of the effective measurement range of the low-pressure air flux measuring device 400 with a sealed vent clamp, the production management system 100 calculates the wet-dry air permeability retention rate using the following formula:

[0068] In the above formula, Indicates the wet-dry breathability retention rate. This represents the effective air permeability coefficient under the initial saturated drainage condition. This represents the effective air permeability coefficient under the re-saturated drainage state. When the effective air permeability coefficient under the initial saturated drainage state is zero or lower than the lower limit of the effective measurement range of the low-pressure air flux measuring device 400 with a sealed venting clamp, the production management system 100 does not use this set of low-pressure air flux data and re-executes steps S200 and S300. The wet-dry air permeability retention rate is used to characterize the degree to which the effective air permeability state of the same batch is retained after wet disturbance.

[0069] When the production management system determines that data such as dry bulk density, volumetric moisture content, air permeability coefficient, effective air permeability state coefficient, or wet-dry air permeability retention rate are abnormal, it first marks the abnormal status of the corresponding data and prioritizes replacing the abnormal data with test data from parallel samples in the same batch. If the parallel sample data is also abnormal, a new sample is prepared from the corresponding batch of oxygen-permeable environmentally friendly lightweight foamed planting material, and the saturated drainage, low-pressure air flux measurement, and low-temperature constant weight treatment process is repeated. The maximum number of retries for the same batch of data is [number missing]. Next, if If the data is still abnormal after the second retry, the batch will be marked as a batch awaiting manual review, the scheduling process will be suspended, and the data will be sent to production management personnel for processing.

[0070] Step S500: Calculate the transfer time compensation coefficient based on the wet-dry air permeability retention rate and convert it into the earliest transfer time of the batch.

[0071] The production management system 100 obtains the preset lower limit of wet-dry air permeability retention rate. (Lower limit of wet-dry air permeability retention rate) Based on the classification and application of the oxygen-permeable, environmentally friendly, lightweight foamed planting material, the lower limit of the wet-dry air permeability retention rate for the standard model of oxygen-permeable, environmentally friendly, lightweight foamed planting material used for oxygen supply to the plant root zone is set as follows: The lower limit of wet and dry air permeability retention rate for the special model of oxygen-permeable, environmentally friendly, lightweight foamed planting material used in high water retention scenarios is set as follows: This lower limit is automatically matched and associated by the production management system 100 based on the model number bound to the batch, and serves as the threshold for determining whether additional turnaround time compensation is needed.

[0072] Third smallest tolerance The value of is set to one-thousandth of the lower limit of wet-dry breathability retention rate, and its calculation expression is:

[0073] The value of the third minimum tolerance is less than the value corresponding to the lower limit of the wet-dry breathability retention rate. It is only used to avoid invalid calculation results caused by zero value input in the logarithmic difference calculation when the wet-dry breathability retention rate approaches zero due to abnormal data. Under normal working conditions, the effect of the third minimum tolerance on the calculation result of the transition time compensation coefficient is negligible.

[0074] When the wet-dry air permeability retention rate is less than the lower limit of the wet-dry air permeability retention rate, the production management system 100 calculates the increased transition time compensation coefficient by performing a logarithmic difference calculation between the lower limit and the wet-dry air permeability retention rate, and combining this with the third minimum tolerance. When the wet-dry air permeability retention rate is greater than or equal to the lower limit, the transition time compensation coefficient is zero.

[0075]

[0076] In the above formula, This represents the transition time compensation coefficient. This indicates the lower limit of wet-dry breathability retention. Indicates the wet-dry breathability retention rate. This indicates the third smallest tolerance.

[0077] The production management system 100 determines the time extension factor based on the transition time compensation coefficient and uses the time extension factor to correct the basic conditioning time.

[0078]

[0079] In the above formula, Indicates the time extension factor. This represents the transition time compensation coefficient.

[0080]

[0081] In the above formula, Indicates the earliest batch transfer time. Indicates the time when the bubble cooling is complete. Indicates the basic humidification time. This indicates the time extension factor. The production management system 100 uses unified time measurement rules to process the completion time of bubble cooling, the basic conditioning time, and the earliest batch transfer time. The production management system 100 writes the earliest batch transfer time into the production management data entity. Before the earliest batch transfer time is reached, even if the target downstream resource in the downstream resource set is available, the production management system 100 will not generate the corresponding batch transfer start time.

[0082] Step S600: Based on the earliest batch transfer time, wet-dry air permeability retention rate, and the available time of the target downstream resources in the downstream resource set, perform batch sorting and resource allocation to obtain the transfer start time and packaging release time of the target downstream resources.

[0083] The production management system 100 acquires a set of batches to be scheduled that contain the same batch. Each batch in the set has completed the wet-dry breathability retention rate calculation and has not yet generated a locked dispatch record. The production management system 100 sorts the batches in ascending order by the earliest transfer time; if the times are the same, it sorts them in descending order by the wet-dry breathability retention rate; if the retention rates are the same, it sorts them in lexicographical order by the batch number, thereby generating a unique sequence to be scheduled.

[0084] To avoid ambiguity arising from identical time and identical retention rate, the production management system 100 determines identical time based on the earliest batch transfer time written to the production management data entity, and determines identical retention rate based on the wet-dry breathability retention rate value written to the production management data entity. If the production management system 100 uses a preset time precision or a preset numerical precision, then if the values ​​are equal under the preset time precision, it is determined that the time is identical; if the values ​​are equal under the preset numerical precision, it is determined that the retention rate is identical.

[0085] The production management system 100 selects the current scheduling batch according to the unique pending sequence and matches the target downstream resource in the downstream resource set that has the earliest start time for the current scheduling batch to transition. For each object in the downstream resource set that can participate in the calculation as a target downstream resource, the production management system 100 calculates the maximum value between the earliest transition time of the current scheduling batch and the current available time of the object.

[0086]

[0087] In the above formula, This indicates that the current scheduled batch is the [number]th [batch] in the downstream resource set. The start time of the transition on an object that can be used as a downstream resource for computation. Indicates the earliest batch transfer time. Indicates the first The current availability of an object that can be used as a downstream resource in the calculation. Production management system 100 will... The earliest object is identified as the target downstream resource; when multiple objects correspond to At the same time, the production management system 100 determines one of the target downstream resources according to the lexicographical order of the resource numbers. After the target downstream resource is determined, the corresponding... This is the start time of the current scheduled batch's transfer to the target downstream resources.

[0088] After identifying the target downstream resource, the production management system 100 adds the start time of the current scheduled batch's transfer on the target downstream resource to the standard processing time of the downstream resource on the target downstream resource to determine the packaging release time.

[0089]

[0090] In the above formula, Indicates the time when the packaging is released. Indicates the start time of the sequence transition. This indicates the standard processing time of the downstream resources for the current scheduled batch. After completing the resource allocation for a current scheduled batch, the production management system 100 updates the current availability time of the target downstream resources to the packaging release time of the current scheduled batch, and then performs resource allocation for the next current scheduled batch in the unique waiting sequence.

[0091] Step S700: Convert the sequence start time and packaging release time into a dispatch time field that can be executed by the equipment, generate and lock the dispatch record containing the sequence start time and packaging release time, and send it to the production execution terminal.

[0092] The production management system 100 writes the transfer start time into the transfer start time field and the packaging release time into the packaging release time field. The transfer start time field and the packaging release time field constitute the work assignment time field that the equipment can execute. The production execution terminal 600 controls the transfer or packaging release operation according to the work assignment time field.

[0093] Before generating work assignment records, the production management system 100 performs a non-overlapping interval check on each target downstream resource to ensure that the occupancy intervals of any two batches on the same target downstream resource do not intersect. For two batches assigned to the same target downstream resource, the production management system 100 makes a judgment according to the following formula:

[0094] In the above formula, and These represent the start time of batch transfer and the release time of packaging, respectively. and These represent the start time of the sequence transfer and the release time of the packaging for another batch, respectively. If the interval non-overlap verification fails, the production management system 100 uses the locked dispatch record as the unoccupiable interval, updates the current available time of the target downstream resources, and then returns to step S600 to re-execute batch sorting and resource allocation until the interval non-overlap verification passes.

[0095] After the interval non-overlap verification passes, the production management system 100 generates a verification digest based on the resource number, batch number, and system timestamp of the target downstream resource. The verification digest is generated using the SHA-256 hash algorithm. During generation, the strings are concatenated in the order of the resource number, batch number, and system timestamp of the target downstream resource. The concatenation format is "resource number + batch number + system timestamp", where the system timestamp is accurate to milliseconds. The concatenated string is then input into the SHA-256 hash algorithm for calculation, and a fixed-length hash value is obtained as the verification digest.

[0096] Each time the production management system 100 reads a work assignment record, it recalculates the verification summary according to the same rules and compares it with the verification summary in the work assignment record. If the two are inconsistent, the work assignment record is determined to have been modified, triggering an anomaly alarm and locking the work assignment record. The verification summary is used to identify whether the transfer start time field and packaging release time field in the work assignment record have been automatically overwritten or abnormally modified. The verification summary, together with the transfer start time field and packaging release time field, constitutes a work assignment record that cannot be automatically overwritten. The work assignment record must at least contain the batch number, the resource number of the target downstream resource, the transfer start time field, the packaging release time field, and the verification summary.

[0097] The production management system 100 sets the work assignment records to a locked state. Work assignment records in the locked state cannot be automatically overwritten by the production management system 100; if adjustments are needed, the production management system 100 only allows manual confirmation according to preset permissions and saves the adjustment reason, adjustment time, and personnel information. The production management system 100 sends the work assignment records to the production execution terminal 600 to trigger sequence transfer or packaging release operations. After receiving the work assignment records, the production execution terminal 600 triggers the sequence transfer operation related to the target downstream resources at the start of the sequence transfer, and triggers the packaging release operation at the packaging release time, and sends the execution results back to the production management system 100.

[0098] Example 2: In one implementation example, the continuous discharge or cavity forming equipment 200 is a continuous discharge equipment. The production management system 100 establishes a production management data entity for each continuous discharge as a batch, and binds the bubble cooling completion time, sample volume, sample thickness, dry bulk density, solid skeleton density, basic conditioning time, downstream resource standard processing time, and downstream resource set. The production management system 100 controls the moisture saturation and ventilation drying equipment 300 to perform the first saturation drainage operation on the sample, generating the first saturation drainage state and recording the first saturation drainage mass; then, wet disturbance is performed; then, a second saturation drainage operation is performed, generating a second saturation drainage state and recording the second saturation drainage mass; finally, low-temperature constant weight treatment is performed and the dry mass is recorded.

[0099] In this embodiment example, the production management system 100 controls a low-pressure air flux measuring device 400 with a sealed venting clamp to measure the initial apparent air velocity, initial pressure difference, subsequent apparent air velocity, subsequent pressure difference, and aerodynamic viscosity under both initial saturated drainage and re-saturated drainage conditions, and writes the above data as low-pressure air flux data into the production management data entity. The production management system 100 calculates the effective permeability state coefficient and wet-dry permeability retention rate, and calculates the transition time compensation coefficient and the earliest transition time of the batch.

[0100] The production management system 100 acquires a set of batches to be scheduled that contain the same batch, and generates a unique sequence to be scheduled based on the earliest batch transfer time, wet-dry air permeability retention rate, and batch number. Then, it determines the transfer start time based on the earliest batch transfer time and the current availability of the target downstream resource, and determines the packaging release time based on the transfer start time and the standard processing time of the downstream resource. After the interval non-overlap verification passes, the production management system 100 generates a dispatch record containing the transfer start time field, the packaging release time field, and the verification summary, and sends the dispatch record to the production execution terminal 600.

[0101] Therefore, this implementation converts the difference in effective air permeability coefficient of the same batch under two standard wet and dry conditions into wet-dry air permeability retention rate, then converts the wet-dry air permeability retention rate into the transfer time compensation coefficient and the earliest transfer time of the batch, and further converts it into the transfer start time and packaging release time of the target downstream resource in the downstream resource set, so that the production execution terminal 600 obtains dispatch records that cannot be automatically overwritten.

[0102] The embodiments of this example have been described above. However, this example is not limited to the specific implementation methods described above. The specific implementation methods described above are merely illustrative and not restrictive. Those skilled in the art can make many other forms based on the guidance of this example, and all of them are within the protection scope of this example.

Claims

1. A method for optimizing the production process of oxygen-permeable, environmentally friendly, lightweight foamed planting materials, applied to a production management system, wherein the production management system includes continuous discharge or mold cavity forming equipment, moisture saturation and ventilation drying equipment, a low-pressure airflow measuring device with a sealed ventilation fixture, and a production execution terminal, characterized in that... The method includes: Establish batch-oriented production management data entities and bind them to batch basic data that includes downstream resource sets; Obtain a sample of foamed planting material, and control the moisture saturation and ventilation drying equipment to perform two saturation drainage operations on the sample to generate two standard wet-dry states of the same batch; Under the two standard wet and dry conditions, the corresponding low-pressure air flux data were measured using the low-pressure air flux measuring device. Based on the batch basic data and the low-pressure air flux data, the effective air permeability state coefficient of the same batch before and after wet drying is calculated to extract the wet-dry air permeability retention rate. Calculate the transition time compensation coefficient based on the wet-dry air permeability retention rate, and convert it into the earliest transition time of the batch. Based on the earliest batch transfer time, the wet-dry breathability retention rate, and the availability time of the target downstream resources in the downstream resource set, batch sorting and resource allocation are performed to obtain the transfer start time and packaging release time of the target downstream resources. The sequence start time and the packaging release time are converted into a dispatch time field that can be executed by the equipment, a dispatch record containing the sequence start time and the packaging release time is generated and locked, and then sent to the production execution terminal.

2. The optimized production process method for oxygen-permeable, environmentally friendly, lightweight foamed planting material according to claim 1, characterized in that, Establish batch-oriented production management data entities and bind them to batch-based basic data containing downstream resource sets, including: In the production management system, each continuous output or molding cycle of the same mold cavity is considered a batch, and a production management data entity bound with a batch number is established. Record the following data for the batch under the production management data entity: bubble cooling completion time, sample volume, sample thickness, dry bulk density, solid skeleton density, basic conditioning time, downstream resource standard processing time, and the downstream resource set. These data serve as the basic data for the batch. The dry bulk density is obtained by the dry mass of the sample after it has been kept at constant weight at low temperature and the volume of the sample. The solid skeleton density is obtained by measuring the skeleton density after the same batch of samples has been crushed or sliced.

3. The optimized production process method for oxygen-permeable, environmentally friendly, lightweight foamed planting material according to claim 2, characterized in that, The moisture saturation and ventilation drying equipment is controlled to perform two saturation drainage operations on the sample, generating two standard wet-dry states for the same batch, including: The sample was brought to the first saturated drainage state after bubbling and cooling, and the mass of the first saturated drainage was recorded. After reaching the initial saturation and drainage state, the sample is subjected to a wet disturbance, which includes re-saturation, drainage, and ventilation drying to a preset humidity adjustment endpoint. After the wet disturbance, the sample is subjected to saturation drainage again to achieve a re-saturation drainage state, and the re-saturation drainage mass is recorded. The sample was subjected to low-temperature constant-weight treatment, and the dry mass was recorded.

4. The optimized production process method for oxygen-permeable, environmentally friendly, lightweight foamed planting material according to claim 3, characterized in that, Under the two standard wet-dry conditions, the corresponding low-pressure air flux data were measured using the low-pressure air flux measuring device, including: The sample in the initial saturated drainage state is placed into the sealed ventilation fixture, a preset pressure difference is applied in the thickness direction of the sample, and the initial apparent air velocity and initial pressure difference are measured after stabilization. The sample in the re-saturated drainage state is placed into the sealing and ventilating fixture in the same sample thickness direction, the preset pressure difference is applied, and the re-apparent air velocity and re-pressure difference are measured after stabilization. Record the aerodynamic viscosity at the time of measurement; The initial apparent air velocity, the initial pressure difference, the subsequent apparent air velocity, the subsequent pressure difference, and the aerodynamic viscosity are written into the production management data entity as the low-pressure air flux data.

5. The method for optimizing the production process of oxygen-permeable, environmentally friendly, lightweight foamed planting material according to claim 4, characterized in that, Calculate the effective air permeability state coefficient of the same batch before and after wet drying to extract the wet-dry air permeability retention rate, including: Based on the first saturated drainage mass or the second saturated drainage mass, the dry mass, the preset water density constant, and the sample volume, the volumetric water content under the two conditions is calculated respectively. The total porosity is calculated based on the dry bulk density and the solid skeleton density. Based on the total porosity, the volumetric water content, and the preset resolution lower limit constant, the effective ventilation porosity under the two sets of conditions is calculated respectively. Based on the aerodynamic viscosity, the sample thickness, the first apparent air velocity or the second apparent air velocity and the corresponding pressure difference, calculate the air permeability coefficient for the two sets of conditions respectively; The effective air permeability state coefficient is calculated by combining the air permeability coefficient, the sample thickness, the effective air permeability porosity, the total porosity, and the first minimum tolerance. By comparing the effective air permeability state coefficients under the two sets of conditions, the wet-dry air permeability retention rate is calculated.

6. The optimized production process method for oxygen-permeable, environmentally friendly, lightweight foamed planting material according to claim 5, characterized in that, The transfer time compensation coefficient is calculated based on the wet-dry breathability retention rate and converted into the earliest transfer time of the batch, including: Obtain the preset lower limit of wet and dry breathability retention rate; By performing a logarithmic difference calculation between the lower limit of the wet-dry breathability retention rate and the wet-dry breathability retention rate, and combining it with the third minimum tolerance, the transition time compensation coefficient that is increased when the wet-dry breathability retention rate is less than the lower limit of the wet-dry breathability retention rate is calculated. The time extension factor is determined based on the aforementioned transition time compensation coefficient; The base conditioning time is corrected using the time extension factor and added to the time when the bubble cooling is completed to determine the earliest time for the batch to switch to the next production cycle.

7. The optimized production process method for oxygen-permeable, environmentally friendly, lightweight foamed planting material according to claim 6, characterized in that, Perform batch sorting and resource allocation to determine the start time of the transordering and the release time of the package on the target downstream resource, including: Obtain a set of batches to be scheduled that include the same batch, sort them in ascending order by the earliest transfer time of the batch, sort them in descending order by the wet-dry breathability retention rate when the times are the same, and sort them in lexicographical order by the batch number when the retention rates are the same, to generate a unique sequence to be scheduled. Select the current scheduling batch according to the unique unscheduled sequence, and match the target downstream resource in the downstream resource set that makes the start time of the current scheduling batch's reordering earliest; The maximum value between the earliest transfer time of the current scheduled batch and the current availability time of the target downstream resource is calculated to determine the transfer start time; The packaging release time is determined by summing the start time of the sequence transfer and the standard processing time of the downstream resource on the target downstream resource for the current scheduled batch.

8. The optimized production process method for oxygen-permeable, environmentally friendly, lightweight foamed planting material according to claim 7, characterized in that, Converting the sequence start time and the packaging release time into a dispatch time field that can be executed by the equipment, generating and locking the dispatch record and sending it to the production execution terminal, includes: Write the sequence start time into the sequence start time field and the package release time into the package release time field; Perform interval non-overlap verification on each of the target downstream resources to ensure that the occupied intervals of any two batches on the same target downstream resource do not intersect; After the non-overlapping interval verification passes, a verification summary is generated according to the resource number of the target downstream resource, the batch number, and the system timestamp. The sequence start time field, the packaging release time field, and the verification digest are combined into a dispatch record that cannot be automatically overwritten; The dispatch record is sent to the production execution terminal to trigger a sequence transfer or packaging release operation.

Images