An acrylic matting resin production system

Abstract

The application relates to an acrylic matt resin production system, which comprises a reaction kettle, a recovery tank, a by-product detection module and a control module. The system takes the condensate output rate as an indirect evaluation parameter of the heat release trend in the reaction kettle. The control module judges whether the output rate and the real-time temperature respectively reach the preset rate and the preset monitoring temperature. When both reach the standard, it is determined that there is an excessive heat release trend, and the control module links to enhance the cooling power of the heat exchange regulation unit and increase the rotating speed of the variable frequency stirring unit to accelerate the heat removal; if both do not reach the standard, the current state is maintained. The application improves the defects of the current prior art, such as the heat removal response lag caused by single temperature detection, and the defects of easy blocking of the production line and easy excessive cooling of materials caused by the lack of dynamic self-adaptive linkage between the upstream and the downstream.

Description

Technical Field

[0001] This application relates to the field of chemical polymer material production equipment and automatic control, and in particular to an acrylic matte resin production system. Background Technology

[0002] Acrylic matte resin is an important additive in powder coatings. Its production process usually involves multiple steps, including batch polymerization reaction, discharge, steel strip cooling, and subsequent warehousing and packaging.

[0003] The polymerization of acrylic monomers is a typical exothermic process. Currently, the industry commonly uses temperature sensors, such as thermocouples, inserted into the reactor to monitor the temperature of the reactants and adjust the cooling medium flow rate of the jacket accordingly. However, due to the rapid increase in viscosity of the resin reaction system in the later stages of polymerization, coupled with the need for a protective sleeve on the outside of the temperature probe, there is a significant hysteresis in heat conduction, i.e., thermal inertia. By the time the temperature sensor detects an abnormal temperature rise and feeds back to the control system, local overheating or even excessive exothermic reaction has often already occurred in the reactor. This delayed heat release response can easily lead to the risk of explosive polymerization and can also cause uneven distribution of resin molecular weight, affecting the matting properties of the final product.

[0004] On the other hand, most existing resin production lines adopt a unidirectional open-loop control mode, lacking effective data interaction and coordination between upstream and downstream equipment. The downstream packaging process and the upstream material discharge and flake forming processes often operate at their own fixed rates. When the packaging machine experiences a decrease in processing speed due to material jams, malfunctions, or throughput fluctuations, the upstream system cannot detect this in time and continues to discharge and flake at the original rate. This not only easily leads to material accumulation or even overflow in the intermediate silo, forcing the production line to shut down urgently, but also causes the material remaining on the steel strip flake forming machine to become severely brittle due to excessive cooling time during the emergency shutdown, seriously affecting product quality and production continuity.

[0005] The inventors believe that the existing technology has the defects of delayed heat release response due to single temperature detection, and the lack of dynamic adaptive linkage between upstream and downstream leads to easy blockage of production lines and overcooling of materials. Summary of the Invention

[0006] In order to improve the shortcomings of the existing technology, such as the lag in heat release response caused by single temperature detection, and the easy blockage of production line and overcooling of materials due to the lack of dynamic adaptive linkage between upstream and downstream, this application provides an acrylic matte resin production system.

[0007] The acrylic matte resin production system provided in this application adopts the following technical solution: An acrylic matte resin production system, comprising: The reactor is equipped with a heat exchange regulating unit, a frequency conversion stirring unit, and a temperature detection device for acquiring the real-time temperature inside the reactor. A recovery tank, connected to the exhaust end of the reactor, is used to collect the condensate from the volatile byproducts in the reactor. A byproduct detection module is installed on the recovery tank to detect the change in the amount of condensate within a cycle time. The lower discharge unit is located at the lower end of the reactor and is used to transport the product output from the reactor and package the product. It is also equipped with a back-end detection module, which is used to detect the operating data of the lower discharge unit. The control module is communicatively connected to the by-product detection module, temperature detection element, heat exchange adjustment unit, lower discharge unit and frequency conversion stirring unit respectively; The control module (7) is configured to: acquire the real-time temperature inside the reactor collected by the temperature detection device, acquire the change in the output of condensate collected by the by-product detection module within a cycle time, and calculate the output rate of condensate. When the output rate exceeds the preset rate, the temperature detection process is executed after a preset time. When the real-time temperature inside the reactor of the temperature detection process exceeds the preset monitoring temperature, an enhanced cooling command is sent to the heat exchange regulation unit, and an increased speed command is sent to the variable frequency stirring unit to accelerate the heat removal rate of the reaction system inside the reactor. Meanwhile, the control module collects the operating data detected by the back-end detection module, and adjusts the feeding and discharging rates of the lower discharge unit based on the operating data and the instantaneous output rate of condensate.

[0008] By adopting the above technical solution, the control module synchronously acquires the real-time temperature inside the reactor collected by the temperature detection device and the condensate production rate calculated by the by-product detection module, and performs dual threshold judgment. Only when the temperature inside the reactor reaches the monitored temperature and the production rate exceeds the preset threshold will the system activate and enhance the heat exchange and variable frequency stirring power to accelerate the heat removal rate. This solution introduces the condensate production rate as an indirect evaluation parameter, realizing multi-source data verification of the exothermic trend of the polymerization reaction. It improves the situation of large heat conduction lag and slow heat removal response faced by traditional production relying solely on contact temperature measurement. This helps to improve the temperature controllability and safety stability of the polymerization reaction process, reduce the risk of explosive polymerization caused by local overheating of materials, and thus reduce the resulting product quality fluctuations.

[0009] Preferably, the lower discharge unit includes: Steel strip flaking machine, equipped with a flaking variable frequency motor; The hopper is located downstream of the steel strip sheeter; A packaging machine is located downstream of the hopper; The backend detection module includes: The discharge adjustment unit is installed on the discharge pipe of the reactor and located upstream of the steel strip flaking machine, and is used to adjust the discharge flow rate of the reactor. Material level detection devices are installed on the silo; The counting and detection unit is located on the packaging machine conveyor belt; The control module is communicatively connected to the discharge adjustment unit, the flaking frequency conversion motor, the material level detection device, and the counting detection device, respectively. The control module is configured to: obtain the hopper filling rate from the material level detection device, obtain the packaging machine throughput from the counting detection device, compare and calculate the hopper filling rate and the packaging machine throughput to obtain the downstream equipment's retention risk coefficient, and issue instructions to adjust the speed of the slagging frequency converter motor and the discharge flow rate of the discharge adjustment unit accordingly.

[0010] By adopting the above technical solution, the control module compares and calculates the silo filling rate obtained by the material level detection device with the packaging machine throughput obtained by the counting detection device to obtain the downstream equipment's retention risk coefficient. Based on this, the speed of the flake variable frequency motor and the discharge flow rate of the discharge adjustment unit are dynamically adjusted in reverse. This solution establishes a data interaction and capacity adaptive matching mechanism between upstream and downstream equipment in the production line. It improves the situation in traditional production lines where data from each section is isolated, and when downstream packaging slows down or congestion occurs, it is easy to cause intermediate silo overflow and forced unplanned shutdowns of the entire line. This helps maintain the dynamic balance of the continuous resin production process and the smoothness of material flow, and reduces equipment losses caused by emergency shutdowns.

[0011] Preferably, the heat exchange regulating unit includes a proportional regulating valve installed on the cooling medium pipeline of the reactor jacket, the variable frequency stirring unit includes a variable frequency stirring motor connected to the stirring shaft of the reactor, and the by-product detection module is a continuous radar level gauge or mass flow meter installed on the recovery tank. The continuous radar level gauge or mass flow meter is used to collect the liquid level height of the by-product condensate or the cumulative mass of the by-product at a high frequency with a second-level cycle.

[0012] By adopting the above technical solution, a continuous radar level gauge or mass flow meter with second-level high-frequency acquisition capability is set as the by-product detection module, and a proportional control valve and a variable frequency stirring motor are used as the execution units for heat exchange and stirring, respectively. This solution provides the control system with high-frequency front-end data sensing capability and smooth back-end execution capability, improving the detection blind zone caused by low data acquisition frequency in traditional production equipment, and the coarse control action and easy overshoot oscillation caused by the use of on / off valves or fixed frequency motors. It helps to further improve the agility and stability of the entire reactor temperature control system.

[0013] Preferably, the reactor is further equipped with a vacuum degassing unit, which is connected to the control module. The control module is configured to: after determining that the polymerization reaction has completed the main reaction stage and entered the cooling or heat preservation stage, issue a command to the vacuum degassing unit to start negative pressure degassing, so as to establish a negative pressure environment in the reactor when the temperature of the reaction system is at a safe temperature threshold, and extract residual low molecular weight volatiles. During the start-up of the vacuum degassing unit, the control module suspends the determination of the exothermic trend based on the condensate production rate, or marks the condensate production rate collected in this stage as degassing stage data.

[0014] By adopting the above technical solution, the vacuum degassing unit is activated during the cooling or heat preservation stage after the polymerization reaction to extract residual low-molecular-weight volatiles. During this period, the over-trend judgment based on the condensate production rate is simultaneously suspended. This solution effectively removes residual impurities in the reaction system through negative pressure, improving the purity and environmental performance of the resin product. On the other hand, through dynamic switching of operating logic, it cleverly eliminates control logic interference caused by the instantaneous surge of condensate due to vacuum suction. This improves the situation where small molecules easily remain in the resin and affect the final quality in conventional processes, and the situation where the introduction of negative pressure operation causes sudden changes in sensor data in the linkage control system, leading to misjudgment, false alarms, and incorrect heat removal actions in the control system. It ensures the self-consistency and operational stability of the system control logic under complex operating conditions.

[0015] Preferably, the by-product detection module, the heat exchange adjustment unit, the variable frequency stirring unit, the material level detection element, the counting detection element, and the flaking variable frequency motor are all connected to the control module via an industrial bus protocol; the control module is a distributed control system or a programmable logic controller.

[0016] Preferably, the by-product detection module performs high-frequency continuous acquisition of the liquid level or cumulative mass of the condensate in the recovery tank 5 at a rate of seconds; the control module obtains the change in liquid level or cumulative mass within adjacent acquisition cycles, and divides the change by the corresponding acquisition time interval to calculate the condensate production rate.

[0017] By adopting the above technical solution, the by-product detection module performs high-frequency continuous data acquisition at a rate of seconds, and the control module calculates the instantaneous output rate of the condensate by dividing the cumulative difference between adjacent acquisition cycles by the time interval. At the algorithm level, this solution transforms the conventional static liquid level or total mass into a dynamic rate that directly reflects the intensity of the system, giving the system the ability to keenly capture and mathematically quantify minute abnormal heat release fluctuations. This improves upon the traditional monitoring logic that relies solely on absolute liquid level threshold alarms or simple manual observation of cumulative amounts, which leads to a sluggish perception of sudden overreaction trends and an extremely compressed prediction time window. This helps the system to perceive the phase change acceleration trend within the vessel with extremely low latency, thus gaining a crucial response advantage for executing subsequent heat removal intervention commands.

[0018] Preferably, the step of the control module calculating the retention risk coefficient includes: obtaining the current inventory of the silo from the material level detection device, and calculating the ratio of the current inventory to the rated capacity of the silo as the filling rate; counting the number of packages per unit time from the counting detection device to obtain the current packaging throughput; performing a fusion calculation on the filling rate and the current packaging throughput to obtain the retention risk coefficient; if the retention risk coefficient exceeds a preset risk threshold, the control module issues an instruction to reduce the speed of the flaking frequency converter motor and the discharge flow rate of the discharge adjustment unit, and coordinates to issue an instruction to the heat exchange adjustment unit to maintain or reduce the temperature inside the reactor; if the retention risk coefficient does not exceed the preset risk threshold, an instruction to maintain the current discharge state and flaking speed is issued.

[0019] By adopting the above technical solution, the control module integrates the material filling rate and the throughput of the packaging machine to calculate the retention risk coefficient. When this coefficient exceeds the limit, a comprehensive intervention command is issued to reduce the speed of the flake motor, reduce the discharge flow, and adjust or maintain the temperature inside the reactor. This solution establishes a balanced early warning model at the algorithm level, realizing flexible matching of the entire process capacity from the back-end packaging to the front-end reactor. It improves the passive protection of traditional production lines that rely solely on forced shutdown when the material is full when encountering downstream congestion. This avoids situations where high-temperature materials retained in the reactor deteriorate due to long-term accumulation, materials on the steel belt dry out excessively due to cooling, and frequent start-ups and shutdowns of the entire line cause significant mechanical shock to the equipment. It helps to ensure the quality consistency of the entire batch of resin products under unstable operating conditions and improves the fault tolerance and operational continuity of complex linkage production lines.

[0020] Preferably, the steps of the control module adjusting the heat exchange regulating unit and the variable frequency stirring unit include: obtaining the difference between the condensate production rate and the preset rate, and calculating the ratio of the difference to the preset rate as a rate deviation coefficient; multiplying the rate deviation coefficient by the pre-stored first proportional adjustment coefficient and the second proportional adjustment coefficient respectively to obtain the positive adjustment amount of the proportional regulating valve opening and the increase amount of the variable frequency stirring motor frequency; the control module determines the new target valve opening and the target stirring speed based on the above adjustment amount, and sends the corresponding instructions to the heat exchange regulating unit and the variable frequency stirring unit.

[0021] By adopting the above technical solution, the control module calculates the rate deviation coefficient of the condensate production rate relative to the preset threshold, and uses the pre-stored first and second proportional adjustment coefficients for mathematical quantification to obtain the specific positive adjustment amount of the heat exchange regulating valve opening and the frequency of the variable frequency motor. This solution introduces a proportional adaptive adjustment mechanism based on the severity of the deviation at the algorithm level, enabling the system to output a heat removal intervention action of corresponding intensity according to the specific magnitude of the abnormal heat release trend in the reactor, achieving dynamic and precise matching between heat removal power and heat accumulation rate. This improves the situation where over-adjustment caused by the mismatch between the intervention intensity and the actual working condition under traditional nonlinear switch control or fixed step adjustment methods leads to violent temperature fluctuations in the reactor, or insufficient adjustment leading to untimely heat removal. This helps to make the temperature intervention process of the polymerization reaction system smoother and more precise.

[0022] Preferably, the steel strip flake machine is also equipped with a cooling water valve, which is connected to the control module. When the retention risk coefficient exceeds a preset risk threshold, the control module sends a command to reduce the speed of the flake-forming variable frequency motor and a command to reduce the opening of the cooling water valve at the same time, in order to compensate for the extended cooling time of the resin material caused by the reduction in the running speed of the steel strip, thereby maintaining the unit cooling intensity of the resin by the steel strip flake machine within a preset range to avoid the material becoming too brittle.

[0023] By adopting the above technical solution, this application, through the control module, simultaneously sends a command to the cooling water valve to reduce the opening degree when issuing a command to reduce the speed of the variable frequency motor of the flake forming machine; this solution establishes a dynamic compensation mechanism for cooling intensity based on material residence time, so that the total cooling capacity of the steel belt for the material can be adaptively reduced with the running speed, which improves the situation in the traditional flake forming process where the resin is cooled for too long on the steel belt due to the production line slowing down and stagnating, which leads to excessive drying, brittleness, yellowing and quality deterioration of the material, and helps to ensure the uniformity of resin flake morphology and physicochemical properties even under non-stable feeding conditions.

[0024] In summary, this application includes at least one of the following beneficial technical effects: This application synchronously acquires the real-time temperature inside the reactor and the condensate production rate through a control module and performs dual threshold judgments. Furthermore, it introduces a proportional adaptive adjustment mechanism based on the severity of deviation at the algorithm's underlying level, achieving precise matching between multi-source verification of exothermic trends and the intensity of intervention actions. This scheme improves upon the traditional approach that relies solely on contact temperature measurement, which suffers from large thermal inertia, delayed heat removal response, and the tendency for nonlinear switching control to easily cause severe temperature fluctuations inside the reactor. This approach helps to enhance the safety and stability of the polymerization system and reduce the risk of localized overheating and explosive polymerization of materials.

[0025] This application calculates the retention risk coefficient by fusing the filling rate obtained from the material level detection device and the packaging throughput obtained from the counting detection device. Based on this coefficient, it dynamically adjusts the downstream discharge flow rate, flake rotation speed, and even collaboratively reduces the temperature inside the reactor. This solution constructs a flexible capacity matching and adaptive throttling mechanism for the entire production line, which improves the situation in traditional production lines where data from each section is isolated, and downstream congestion can easily lead to overflow of intermediate silos, long-term accumulation and deterioration of high-temperature materials, and forced emergency shutdown of the entire line. It maintains the dynamic balance of continuous production and the smoothness of material flow.

[0026] This application features synergistic optimization in hardware architecture and operating condition shielding logic. It establishes high-speed, interference-resistant underlying communication through continuous high-frequency sensors and an industrial bus, and dynamically isolates easily mutated condensate indicators during the vacuum degassing stage. It is also supplemented by a dynamic compensation mechanism for the cooling intensity of the condensation. This integrated architecture improves the problems of excessive drying due to abnormal material retention in traditional processes, as well as the susceptibility to sensor false alarms and system interference malfunctions under complex operating conditions such as negative pressure degassing. It further ensures the consistency of the physicochemical properties of the resin product and the logical self-consistency of the control system under complex operating conditions. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the structure of an acrylic matte resin production system according to an embodiment of this application.

[0028] Figure 2 This is a process flow diagram of an acrylic matte resin production system according to an embodiment of this application.

[0029] Explanation of reference numerals in the attached drawings: 1. Reactor; 2. Heat exchange regulating unit; 21. Proportional regulating valve; 3. Variable frequency stirring unit; 4. Temperature detection element; 5. Recovery tank; 6. By-product detection module; 7. Control module; 8. Discharge regulating unit; 9. Steel strip flake machine; 91. Flake flake variable frequency motor; 92. Cooling water valve; 10. Hopper; 11. Packaging machine; 12. Vacuum degassing unit; 13. Counting detection element; 14. Material level detection element. Detailed Implementation

[0030] The following is in conjunction with the appendix Figure 1-2This application will be described in further detail.

[0031] This application discloses an acrylic matte resin production system. (Refer to...) Figure 1-2 An acrylic matte resin production system includes a reactor 1 equipped with a heat exchange regulating unit 2, a frequency conversion stirring unit 3, and a temperature detection element 4 for acquiring the real-time temperature inside the reactor 1; a recovery tank 5 connected to the exhaust end of the reactor 1 for collecting condensate from the volatilized by-products inside the reactor 1; a by-product detection module 6 installed on the recovery tank 5 for detecting the change in condensate volume over a period of time; a lower discharge unit located at the lower end of the reactor for transporting and packaging the product output from the reactor, and also equipped with a back-end detection module for detecting the operating data of the lower discharge unit; and a control module 7 connected to the by-product detection module 6, the temperature detection element 4, the heat exchange regulating unit 2, the lower discharge unit, and the frequency conversion stirring unit. The stirring unit 3 is connected for communication; the control module 7 is configured to: acquire the real-time temperature inside the reactor 1 collected by the temperature sensor 4, and acquire the change in the output of condensate within a cycle time collected by the by-product detection module 6, and calculate the output rate of condensate; when the output rate exceeds the preset rate, execute the temperature detection process after a preset time; when the real-time temperature inside the reactor 1 in the temperature detection process exceeds the preset monitoring temperature, send an enhanced cooling command to the heat exchange adjustment unit 2 and an increased speed command to the variable frequency stirring unit 3 to accelerate the heat removal rate of the reaction system inside the reactor 1; at the same time, the control module 7 will collect the operating data detected by the back-end detection module, and adjust the feeding and discharging rates of the lower discharge unit according to the operating data and the instantaneous output rate of condensate.

[0032] The lower discharge unit includes: a steel strip flaking machine 9, equipped with a flaking variable frequency motor 91; a hopper 10, located downstream of the steel strip flaking machine 9; and a packaging machine 11, located downstream of the hopper 10. The rear detection module includes: a discharge adjustment unit 8, installed on the discharge pipe of the reactor 1 and located upstream of the steel strip flaking machine 9, used to adjust the discharge flow rate of the reactor 1; a material level detection element 14, installed on the hopper 10; and a counting detection element 13, located on the conveyor belt of the packaging machine 11. The control module 7 is communicatively connected to the discharge adjustment unit 8, the flaking variable frequency motor 91, the material level detection element 14, and the counting detection element 13. The control module 7 is configured to obtain the hopper filling rate from the material level detection element 14 and the packaging machine throughput from the counting detection element 13. The control module 7 compares and calculates the hopper filling rate and the packaging machine throughput to obtain the retention risk coefficient of the downstream equipment, and issues instructions to adjust the speed of the slagging frequency converter motor 91 and the discharge flow rate of the discharge adjustment unit 8 accordingly.

[0033] The heat exchange regulating unit 2 includes a proportional regulating valve 21 installed on the jacket cooling medium pipeline; the variable frequency stirring unit 3 includes a variable frequency stirring motor connected to the stirring shaft; the by-product detection module 6 is a continuous radar level gauge or mass flow meter installed on the recovery tank 5; the continuous radar level gauge or mass flow meter is used to collect the liquid level height of the by-product condensate or the cumulative mass of the by-product at a high frequency with a second-level cycle; the recovery tank 5 is a cylinder with a uniform cross-section.

[0034] Based on this, the control module 7 determines the new target valve opening and target stirring speed, and sends the corresponding instructions to the heat exchange adjustment unit 2 and the frequency conversion stirring unit 3 to accelerate the heat removal rate of the reaction system in the reactor 1.

[0035] A vacuum degassing unit 12 is also provided on the reactor 1. The vacuum degassing unit 12 is connected to the control module 7. The control module 7 is configured to: after determining that the polymerization reaction in the reactor 1 has completed the main reaction stage and entered the cooling or heat preservation stage, issue a command to the vacuum degassing unit 12 to start the negative pressure degassing, so as to establish a negative pressure environment in the reactor 1 when the temperature of the reaction system is at a safe temperature threshold, and extract residual low molecular weight volatiles. During the start-up of the vacuum degassing unit 12, the control module 7 suspends the determination of the exothermic overheating trend based on the condensate production rate, or marks the condensate production rate collected in this stage as degassing stage data.

[0036] The by-product detection module 6, heat exchange adjustment unit 2, variable frequency stirring unit 3, material level detection element 14, counting detection element 13, and flaking variable frequency motor are all connected to the control module 7 via industrial bus protocol; the control module 7 is a distributed control system or a programmable logic controller.

[0037] The by-product detection module 6 continuously collects the liquid level or cumulative mass of the condensate in the recovery tank 5 at a high frequency with a period of seconds; the control module 7 obtains the change in liquid level or cumulative mass within adjacent collection cycles, divides the change by the corresponding collection time interval, and calculates the condensate production rate.

[0038] In some implementations, the byproduct detection module 6 is a continuous radar level gauge: During the aggregation phase, the control module operates on a time cycle. Obtain the liquid level change in recovery tank 5 and calculate the condensate production rate. : ; In the formula, The first level obtained by continuous radar level gauge Instantaneous volumetric production rate of condensate at any given time, in units , The unit is the internal cross-sectional area of ​​recycling tank 5. , The liquid level height at the current sampling time , The liquid level height in the previous collection cycle, in units. , The time interval between adjacent data collection times is expressed in seconds (s).

[0039] In some implementations, the byproduct detection module 6 is a mass flow meter: During the aggregation phase, the control module operates on a time cycle. Obtain the mass change of recovery tank 5 and calculate the condensate production rate. : ; In the formula, The first obtained by mass flow meter Instantaneous mass production rate of condensate at any given time, in g / s. This represents the current cumulative reading of the mass flow meter, in grams. This represents the cumulative mass reading from the previous acquisition cycle, in grams.

[0040] in and The instantaneous condensate production rate at time t can be calculated by mutual conversion. : ; In the formula, ρ is the density of the by-product condensate.

[0041] When the instantaneous condensate production rate exceeds a preset threshold, a positive value is taken; otherwise, it is set to zero to avoid negative interference during normal reaction. A rate deviation coefficient is then calculated. : ; In the formula, This is the rate deviation coefficient, reflecting the relative extent to which the output rate exceeds the threshold. The preset rate is set for the instantaneous output rate of condensate, in units. .

[0042] It is not a fixed constant, but an empirical upper limit value obtained by statistical analysis of different production formulas, feed amounts, reaction temperature ranges, and historical stable batch data. This upper limit is determined when the conditions are met for multiple consecutive data collection periods. > When the real-time temperature inside reactor 1 reaches the preset monitoring temperature, the control module 7 determines that the polymerization reaction inside reactor 1 has an exothermic overheating trend and enters the adjustment mode.

[0043] Similarly, when the real-time temperature inside reactor 1 reaches or exceeds the preset monitoring temperature, a positive value is taken; otherwise, it is set to zero, and the temperature deviation coefficient is calculated. : ; In the formula, This is the temperature deviation coefficient, reflecting the relative extent to which the real-time temperature exceeds the monitored temperature; For the first The real-time temperature inside reactor 1, measured in °C, is constantly collected by temperature sensor 4. This is the preset monitoring temperature threshold, in °C.

[0044] A two-parameter weighted intervention index is constructed by weighting and fusing rate deviation and temperature deviation: ; ; In the formula, It is a two-parameter weighted intervention index that comprehensively quantifies the degree of abnormal heat release inside the vessel. , These are the weighting coefficients for rate deviation and temperature deviation, respectively. It is recommended to take... =0.7、 =0.3, with byproduct rate as a leading indicator given a higher weight, and temperature deviation as an auxiliary verification quantity given a lower weight. Only when > and ≥ At the same time, and All are positive values. Only a valid positive value is taken to trigger an intervention action, consistent with the system's dual threshold criteria; if either criterion fails to reach the threshold... When the temperature approaches zero, the system does not perform heat removal intervention.

[0045] Control module 7 based on Calculate the relationship between the opening increment of the heat exchange regulating valve and the frequency increment of the variable frequency stirring motor: ; ; In the formula, This is the positive adjustment amount of the opening of the proportional control valve 21; This is the pre-stored first proportional adjustment coefficient; This represents the increase in frequency of the variable frequency mixing motor, expressed in Hz. This is the pre-stored second proportional adjustment coefficient.

[0046] The value of is positively correlated with the rated heat exchange area of ​​heat exchange regulating unit 2 and the design flow rate of cooling medium, and is an engineering conversion coefficient characterizing the valve opening degree to the heat removal capacity. The coefficients are positively correlated with the rated power curve of the motor in variable frequency stirring unit 3. Before the system is put into operation, the above coefficients are calibrated by step response tests during the no-load or aqueous phase trial operation of the equipment and are pre-stored in the control module 7.

[0047] The formula for calculating the reduction in the opening degree of the cooling water valve 92 is as follows: ; In the formula, This is the amount by which the opening of the cooling water valve 92 is reduced; The reduction in operating frequency of the 91-type variable frequency motor is expressed in Hz. This is a buffer parameter for molding speed.

[0048] Among them, the molding speed buffer parameter The compensation ratio characterizing the efficiency of heat dissipation from the material due to the decrease in steel belt drive speed is determined based on the specific heat capacity of a specific resin formulation and the thermal conductivity of the steel belt material. Preferably, the... The value range is set to [1.2, 2.5].

[0049] The steps for the control module 7 to calculate the retention risk coefficient include: obtaining the current inventory of the silo 10 from the material level detection device 14, and calculating the ratio of the current inventory to the rated capacity of the silo 10 as the filling rate; counting the number of packages per unit time from the counting detection device 13 to obtain the current packaging throughput; performing a fusion calculation between the filling rate and the current packaging throughput to obtain the retention risk coefficient; if the retention risk coefficient exceeds the preset risk threshold, the control module 7 issues an instruction to reduce the speed of the caking frequency converter motor 91 and the discharge flow rate of the discharge adjustment unit 8, and coordinates with the heat exchange adjustment unit 2 to issue an instruction to maintain or reduce the temperature inside the reactor 1; if the retention risk coefficient does not exceed the preset risk threshold, an instruction to maintain the current discharge state and the caking speed is issued.

[0050] Get the real-time fill rate of silo 10 and the real-time processing throughput of terminal packaging machine 11 The system calculates the material retention risk coefficient in real time. : ;

[0051] In the formula, The material retention risk coefficient ranges from 0 to 1. The current inventory of silo 10 is obtained from the material level detection component 14; The rated capacity of the silo is 10. This is a packaging processing weighting constant; This represents the real-time throughput of packaging machine 11, in units of pieces / min.

[0052] The steps of the control module 7 in adjusting the heat exchange regulating unit 2 and the variable frequency stirring unit 3 include: obtaining the difference between the condensate production rate and the preset rate, and calculating the ratio of the difference to the preset rate as the rate deviation coefficient; multiplying the rate deviation coefficient by the pre-stored first proportional adjustment coefficient and the second proportional adjustment coefficient respectively to obtain the positive adjustment amount of the opening of the proportional regulating valve 21 and the increase in the frequency of the variable frequency stirring motor; the control module 7 determines the new target valve opening and the target stirring speed based on the above adjustment amount, and sends the corresponding instructions to the heat exchange regulating unit 2 and the variable frequency stirring unit 3.

[0053] The steel strip flaking machine 9 is also equipped with a cooling water valve 92, which is connected to the control module 7. When the retention risk coefficient exceeds the preset risk threshold, the control module 7 sends a command to reduce the speed of the flaking variable frequency motor 91 and a command to reduce the opening of the cooling water valve 92 at the same time to compensate for the extended cooling time of the resin material caused by the reduction of the steel strip running speed, thereby maintaining the unit cooling intensity of the resin by the steel strip flaking machine 9 within the preset range to avoid the material becoming too brittle.

[0054] when When the preset risk threshold is exceeded, a global flexible speed reduction mechanism is triggered, which reduces the running speed of the steel belt in the sheeter using the following formula. Simultaneously, the discharge flow rate of the discharge adjustment unit 8 is reduced: ; In the formula, The baseline velocity is expressed in m / min. This is a buffer parameter for molding speed. And 0 ≤ <1. At the same time, the control module 7 sends a command to the steel strip cooling water valve 92 to reduce the opening degree in order to compensate for the extended cooling time of the resin material caused by the reduction of the steel strip running speed, thereby maintaining the unit cooling intensity of the resin by the steel strip sheeter 9 within the preset range to avoid the material becoming too brittle.

[0055] In some implementations, regarding the two-parameter weighted intervention index Rate deviation weighting coefficient Weighting coefficient for temperature deviation Its value follows > The setting principle is based on the fact that the byproduct condensate production rate is a priori physical quantity reflecting the intensity of the reaction system, while the temperature change inside reactor 1 is a consequential physical quantity with thermal inertia and physical hysteresis. To achieve proactive early warning and intervention, the system assigns higher decision weights to the priori quantities. Preferably, The value range is [0.6, 0.8]. The value range of is [0.2, 0.4], and satisfies . + =1.

[0056] For the reverse linkage operation downstream of the production system, control module 7 performs feedback adjustment based on the calculated retention risk coefficient. When the retention risk coefficient exceeds the preset risk threshold, control module 7 issues a command to reduce the operating frequency of the sheet-forming variable frequency motor 91 of the steel strip sheet-forming machine 9. To prevent the resin material from becoming too brittle due to prolonged cooling time on the cooling belt caused by a decrease in the running speed of the steel belt, control module 7 synchronously calls the molding speed buffer parameter to reduce the opening of cooling water valve 92.

[0057] In a specific engineering application embodiment, this system is equipped with a 5000L reactor 1, and a steel strip sheeter 9 with an effective length of 12m is used in the sheet-forming section. After equipment trial operation and calibration, the first proportional adjustment coefficient K1 = 15.5 and the second proportional adjustment coefficient K2 = 0.85 are pre-stored in the control module 7. In a certain production batch, when the throughput of the packaging machine 11 decreases, causing the retention risk coefficient to exceed the limit, the control module 7 reduces the operating frequency of the sheet-forming variable frequency motor 91 by 5Hz, at which time the preset forming speed buffer parameter is invoked. =1.8, calculated as follows =1.8×5=9. Based on this instruction, control module 7 reduces the opening of cooling water valve 92 by 9% simultaneously, reducing front-end capacity while maintaining the flexibility of the material sheeting.

[0058] The implementation principle of the acrylic matte resin production system in this application embodiment is as follows: This system achieves collaborative operation of each production section by establishing a closed-loop control architecture covering the entire process of upstream polymerization reaction, midstream flake formation and downstream packaging.

[0059] During the polymerization reaction stage, the system synchronously acquires the real-time temperature and instantaneous output rate of condensate in the reactor 1 through the temperature detection device 4 and the by-product detection module 6; the control module 7 dynamically calculates and outputs the heat exchange valve opening degree and variable frequency stirring speed command based on the dual threshold criteria and the proportional deviation algorithm.

[0060] When the instantaneous output rate of condensate exceeds the preset rate threshold and the real-time temperature inside reactor 1 reaches or exceeds the preset monitoring temperature, control module 7 sends an enhanced cooling command to heat exchange adjustment unit 2 and an increased speed command to variable frequency stirring unit 3. If the system is in a special stage such as cooling and degassing, control module 7 automatically executes the working condition isolation logic to ensure that the condensate disturbance caused by degassing is not misjudged as abnormal heat release, thereby ensuring the robustness of the control action.

[0061] When the instantaneous output rate of condensate collected and calculated by the by-product detection module 6 does not exceed the preset rate threshold, the control module 7 determines that the current operating condition does not meet the triggering conditions for the exothermic trend, and maintains the current cooling power of the heat exchange adjustment unit 2 and the current stirring speed of the frequency conversion stirring unit 3, so that the polymerization reaction in the reactor 1 continues to run according to the current process parameters.

[0062] When the instantaneous output rate of condensate exceeds the preset rate threshold, the control module 7 executes the temperature detection process after a preset time. If the real-time temperature inside the reactor 1 collected by the temperature detection element 4 does not reach the preset monitoring temperature, the control module 7 determines that the current operating condition does not simultaneously meet the dual-parameter intervention conditions, and maintains the current cooling power of the heat exchange adjustment unit 2 and the current stirring speed of the variable frequency stirring unit 3; if the real-time temperature inside the reactor 1 reaches the preset monitoring temperature, the control module 7 sends an enhanced cooling command to the heat exchange adjustment unit 2 and an increased speed command to the variable frequency stirring unit 3 to improve the heat removal rate of the reaction system.

[0063] During the discharge and sheeting stages, the control module 7 assesses the overall line's congestion risk coefficient in real time based on the fusion calculation results of the silo 10 filling rate and the packaging machine 11 throughput. When a potential processing bottleneck is predicted downstream, the system triggers a reverse linkage adjustment mechanism: on the one hand, it reduces the flow rate of the discharge adjustment unit 8 and the variable frequency speed of the steel strip sheeter 9 to alleviate the inventory pressure in the silo 10; on the other hand, it simultaneously and dynamically reduces the opening of the cooling water valve 92 of the steel strip sheeter 9 to compensate for the excessive brittleness that may be caused by the prolonged cooling time of the material on the steel strip due to the reduction in production capacity, ensuring the consistency of the material output quality.

[0064] When the retention risk coefficient calculated by control module 7 based on the fusion of the filling rate of silo 10 and the throughput of packaging machine 11 does not exceed the preset risk threshold, it indicates that the downstream material handling capacity of the current production line can match the upstream discharge rate, and the inventory of silo 10 is within a safe and controllable dynamic balance range, with no risk of overflow or blockage. At this time, control module 7 does not perform speed reduction and throttling intervention, maintaining the current discharge flow rate of discharge adjustment unit 8, the speed of the sheet-forming variable frequency motor 91 of steel strip sheeter 9, and the current opening degree of cooling water valve 92, so that the production line continues to operate stably along the existing set parameters to ensure maximum production efficiency and equipment utilization.

[0065] Through the synergy of the above logic, this system not only achieves precise and real-time intervention in the deheating process of polymerization reactor 1, but also opens up a reverse feedback path from the end of the production line to the source, enabling the entire device to adaptively optimize process parameters under external operating condition fluctuations. This ensures the smooth operation of continuous production and the uniformity of product physicochemical properties while guaranteeing the safety and controllability of the polymerization process.

[0066] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A production system for acrylic matte resin, characterized in that: include: The reactor (1) is equipped with a heat exchange regulating unit (2), a frequency conversion stirring unit (3), and a temperature detection device (4) for obtaining the real-time temperature inside the reactor (1); The recovery tank (5) is connected to the exhaust end of the reactor (1) and is used to collect the condensate from the volatile by-products in the reactor (1). A byproduct detection module (6) is installed on the recovery tank (5) to detect the change in the amount of condensate within a cycle time. The lower discharge unit is located at the lower end of the reactor and is used to transport the product output from the reactor and package the product. It is also equipped with a back-end detection module, which is used to detect the operating data of the lower discharge unit. The control module (7) is connected in communication with the by-product detection module (6), temperature detection element (4), heat exchange adjustment unit (2), lower discharge unit and frequency conversion stirring unit (3), respectively. The control module (7) is configured to: acquire the real-time temperature inside the reactor (1) collected by the temperature detection element (4), acquire the change in the output of condensate collected by the by-product detection module (6) within a cycle time, and calculate the output rate of condensate. When the output rate exceeds the preset rate, the temperature detection process is executed after a preset time. When the real-time temperature inside the reactor (1) of the temperature detection process exceeds the preset monitoring temperature, an enhanced cooling command is sent to the heat exchange regulating unit (2), and an increased speed command is sent to the variable frequency stirring unit (3) to accelerate the heat removal rate of the reaction system inside the reactor (1). At the same time, the control module (7) will collect the operating data detected by the back-end detection module, and adjust the feeding and discharging rates of the lower discharge unit according to the operating data and the instantaneous output rate of condensate.

2. The acrylic matte resin production system according to claim 1, characterized in that: The lower discharge unit includes: A steel strip slagging machine (9) is equipped with a slagging variable frequency motor (91); The hopper (10) is located downstream of the steel strip slab forming machine (9); Packaging machine (11) is located downstream of the hopper (10); The backend detection module includes: The discharge adjustment unit (8) is installed on the discharge pipeline of the reactor (1) and is located upstream of the steel strip slagging machine (9) to adjust the discharge flow rate of the reactor (1); A material level detection device (14) is installed on the silo (10); The counting and detection unit (13) is located on the conveyor belt of the packaging machine (11); The control module (7) is communicatively connected to the discharge adjustment unit (8), the slagging frequency converter (91), the material level detection device (14), and the counting detection device (13), respectively. The control module (7) is configured to: obtain the hopper filling rate by the material level detection device (14), obtain the packaging machine throughput by the counting detection device (13), compare and calculate the hopper filling rate and the packaging machine throughput to obtain the retention risk coefficient of the downstream equipment, and issue instructions to adjust the speed of the slagging frequency conversion motor (91) and the discharge flow rate of the discharge adjustment unit (8) accordingly.

3. The acrylic matte resin production system according to claim 1, characterized in that: The heat exchange regulating unit (2) includes a proportional regulating valve (21) installed on the cooling medium pipeline of the jacket of the reactor (1), the variable frequency stirring unit (3) includes a variable frequency stirring motor connected to the stirring shaft of the reactor (1), and the by-product detection module (6) is a continuous radar level gauge or mass flow meter installed on the recovery tank (5). The continuous radar level gauge or mass flow meter is used to collect the liquid level height of the by-product condensate or the cumulative mass of the by-product at a high frequency with a second-level cycle.

4. The acrylic matte resin production system according to claim 3, characterized in that: A vacuum degassing unit (12) is also provided on the reactor (1), and the vacuum degassing unit (12) is connected to the control module (7). The control module (7) is configured to: after determining that the polymerization reaction in the reactor (1) has completed the main reaction stage and entered the cooling or heat preservation stage, issue a command to the vacuum degassing unit (12) to start negative pressure degassing, so as to establish a negative pressure environment in the reactor (1) when the temperature of the reaction system is at a safe temperature threshold, and extract residual low molecular weight volatiles. During the start-up of the vacuum degassing unit (12), the control module (7) suspends the determination of the exothermic overheating trend based on the condensate production rate, or marks the condensate production rate collected in this stage as degassing stage data.

5. The acrylic matte resin production system according to claim 2, characterized in that: The by-product detection module (6), the heat exchange adjustment unit (2), the frequency conversion stirring unit (3), the material level detection element (14), the counting detection element (13), and the flaking frequency conversion motor (91) are all connected to the control module (7) via an industrial bus protocol; the control module (7) is a distributed control system or a programmable logic controller.

6. The acrylic matte resin production system according to claim 3, characterized in that: The byproduct detection module (6) continuously collects the liquid level or cumulative mass of the condensate in the recovery tank (5) at a high frequency with a second-level cycle; the control module (7) obtains the change in liquid level or cumulative mass in adjacent collection cycles, and divides the change by the corresponding collection time interval to calculate the condensate production rate.

7. The acrylic matte resin production system according to claim 2, characterized in that: The steps of the control module (7) in calculating the retention risk coefficient include: obtaining the current inventory of the silo (10) by the material level detection device (14), and calculating the ratio of the current inventory to the rated capacity of the silo (10) as the filling rate; counting the number of packages per unit time by the counting detection device (13) to obtain the current packaging throughput; performing a fusion calculation on the filling rate and the current packaging throughput to obtain the retention risk coefficient; if the retention risk coefficient exceeds the preset risk threshold, the control module (7) issues an instruction to reduce the speed of the slagging frequency converter motor (91) and the discharge flow rate of the discharge adjustment unit (8), and coordinates to issue an instruction to the heat exchange adjustment unit (2) to maintain or reduce the temperature inside the reactor (1); if the retention risk coefficient does not exceed the preset risk threshold, an instruction to maintain the current discharge state and slagging speed is issued.

8. The acrylic matte resin production system according to claim 3, characterized in that: The steps of the control module (7) in adjusting the heat exchange regulating unit (2) and the variable frequency stirring unit (3) include: obtaining the difference between the condensate production rate and the preset rate, and calculating the ratio of the difference to the preset rate as a rate deviation coefficient; multiplying the rate deviation coefficient by the pre-stored first proportional regulation coefficient and the second proportional regulation coefficient respectively to obtain the positive adjustment amount of the opening of the proportional regulating valve (21) and the increase in the frequency of the variable frequency stirring motor; the control module (7) determines the new target valve opening and the target stirring speed based on the above adjustment amount, and sends the corresponding instructions to the heat exchange regulating unit (2) and the variable frequency stirring unit (3).

9. The acrylic matte resin production system according to claim 2, characterized in that: The steel strip slagging machine (9) is also equipped with a cooling water valve (92), which is connected to the control module (7). When the retention risk coefficient exceeds the preset risk threshold, the control module (7) issues a command to reduce the speed of the slagging variable frequency motor (91) and at the same time issues a command to reduce the opening of the cooling water valve (92) to compensate for the extended cooling time of the resin material caused by the reduction of the running speed of the steel strip, thereby maintaining the unit cooling intensity of the steel strip slagging machine (9) on the resin within the preset range to avoid the material becoming too brittle.

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