Online concentration dynamic adjustment device

Abstract

The utility model relates to the technical field of material concentration mixing discloses online concentration dynamic adjusting device, including concentration sensor, flow sensor, controller, electric regulating valve and multiple for medium delivery pipeline and medium dynamic mixer, all set up concentration sensor and flow sensor on the monitoring point of each pipeline, all set up electric regulating valve on the adjustment section of each pipeline, multiple pipeline communicates with medium dynamic mixer respectively, and the output end of medium dynamic mixer is connected with static mixer, online concentration dynamic adjusting device installs sensor through in the key point (monitoring section and final output end) of each pipeline, and the system can sense the concentration and flow of each branch and total flow after mixing in real time, controller according to the deviation of set value and feedback value, dynamic adjustment each branch electric regulating valve opening degree, realize high accuracy, fast response's concentration online automatic regulation, overcame the lag and error problem of traditional offline deployment or open loop control.

Description

Technical Field

[0001] This utility model relates to the technical field of material concentration mixing, and more specifically, to an online dynamic concentration adjustment device. Background Technology

[0002] In the chemical and related industries, mixing materials of different concentrations (such as solutions and slurries) in specific proportions to obtain a product of a target concentration is a common and crucial process. Currently, commonly used methods include:

[0003] Manual proportioning: Operators manually operate valves to control the amount of each material added based on experience or calculation, and use offline measuring equipment (such as densitometers and refractometers) to conduct concentration sampling checks. This method has significant drawbacks such as large operating errors, low proportioning accuracy, low efficiency, inability to respond to concentration fluctuations in real time, high labor intensity, and easy to cause instability in product quality between batches.

[0004] Simple proportional adjustment: It uses a simple flow ratio controller to control the material flow rate according to a preset ratio, but it lacks a real-time monitoring and feedback compensation mechanism for changes in the basic concentration of the material; when the raw material concentration fluctuates, it cannot guarantee the accuracy of the final mixed concentration.

[0005] Intermittent batch mixing: First, add each material to the mixing tank according to the pre-calculated amount, stir evenly, and then take a sample for testing. If it is not qualified, make adjustments.

[0006] This method is complex, time-consuming, difficult to implement in continuous production, and has a slow adjustment period.

[0007] Existing technologies are insufficient to meet the application requirements of high mixing concentration, continuous and stable production, and potential fluctuations in raw material concentration. Therefore, there is an urgent need for a device that can monitor raw material concentration online, in real time, and dynamically, and automatically adjust the mixing ratio accordingly, thereby accurately, efficiently, and stably outputting a mixture of the target concentration. Utility Model Content

[0008] The purpose of this invention is to provide an online concentration dynamic adjustment device, which aims to solve the problem that the existing technology is difficult to meet the application requirements of high mixing concentration, continuous and stable production, and possible fluctuations in raw material concentration.

[0009] This utility model is an online dynamic concentration adjustment device, comprising a concentration sensor, a flow sensor, a controller, an electric regulating valve, multiple pipelines for media transportation, and a dynamic media mixer. Each monitoring point on the pipeline is equipped with a concentration sensor and a flow sensor, and the signal output terminals of the concentration sensor and the flow sensor are connected to the analog input module of the controller. The control signal output terminal of the controller is connected to the drive terminal of the electric regulating valve, and an electric regulating valve is installed on the adjustment section of each pipeline.

[0010] Multiple pipelines are connected to a dynamic media mixer, and a static mixer is connected to the output end of the dynamic media mixer. A concentration sensor, a flow sensor, and an electric regulating valve are installed on the static mixer.

[0011] Furthermore, the dynamic media mixer includes a mixing tank and a rotating shaft. Multiple pipes are connected to the mixing tank respectively. The mixing tank has a vertically arranged mixing chamber. The bottom of the mixing tank is connected to a static mixer. The rotating shaft is vertically arranged in the mixing chamber. Multiple media push plates are provided on the upper part of the rotating shaft. The multiple media push plates are arranged circumferentially around the upper part of the rotating shaft. A detachably connected filter screen is provided between adjacent media push plates.

[0012] The lower part of the rotating shaft is provided with a plurality of stirring rods, which are arranged at intervals around the circumference of the rotating shaft, and the stirring rods are located below the filter screen.

[0013] The bottom of the mixing chamber is arranged in a conical shape, forming a collection port for outputting the medium. A bottom bearing that is rotatably connected to the rotating shaft is installed on the collection port. The bottom bearing and the collection port are fixedly connected by a connecting rod. The inner side wall of the mixing chamber is provided with a directional track ring for the directional rotation of the medium push plate.

[0014] Furthermore, a top cover is detachably installed on the top of the mixing tank. The top cover is connected to the rotating shaft via a top bearing. A bearing positioning seat is provided at the bottom of the top cover, and the bearing positioning seat is sleeved on the outer periphery of the top bearing.

[0015] Furthermore, a sealing ring is fitted around the outer periphery of the top cover, and a pressure relief valve is installed on the top cover.

[0016] Furthermore, the media push plate includes a vertical plate and an inclined bottom plate. One end of the inclined bottom plate is connected to the bottom of the vertical plate, and the other end of the inclined bottom plate is inclined downwards away from the vertical plate. A media filtration channel is formed between the inclined bottom plate and the adjacent vertical plate, and the filter bag is located in the media filtration channel.

[0017] Furthermore, the filter bag is recessed downwards to form a pocket cavity with an opening at the top, and the filter bag has multiple filter holes.

[0018] Furthermore, the rotating shaft is provided with a plurality of support rods, which are arranged at intervals around the circumference of the rotating shaft. Adjacent support rods abut against both sides of the filter screen bag, and the filter screen bag is provided with a ring sleeve, which is fitted around the outer periphery of the support rod.

[0019] Furthermore, the distance ratio between the regulating section and the monitoring section of the pipeline is 1:3.

[0020] Furthermore, the concentration sensor is a fiber optic spectral sensor or an electrochemical sensor.

[0021] Furthermore, it also includes a human-machine interface, which communicates with the controller via an RS485 bus.

[0022] Compared with the prior art, the online concentration dynamic adjustment device provided by this utility model can sense the concentration and flow rate of each branch and the total flow after mixing in real time by installing sensors at key points (monitoring section and final output end) of each pipeline; the controller dynamically adjusts the opening of the electric regulating valve of each branch according to the deviation between the set value and the feedback value, so as to realize high-precision and fast-response online automatic adjustment of concentration, and overcome the lag and error problems of traditional offline mixing or open-loop control.

[0023] Each pipeline is equipped with an independent monitoring and control unit, which allows for individual and precise flow and concentration control of media from different sources or with different properties, making it particularly suitable for scenarios where multiple raw materials are mixed in precise proportions.

[0024] By combining a dynamic mixer (active mixing) and a static mixer (passive mixing), the mixing efficiency and uniformity are significantly improved. The dynamic mixer performs strong initial mixing, while the static mixer completes fine homogenization, ensuring that the final output medium concentration is highly uniform and stable.

[0025] A sensor and regulating valve are added at the outlet of the static mixer to form a closed-loop control of the final output quality. Even after two stages of mixing, if there is still a slight deviation in the final concentration, the system can make fine adjustments through the regulating valve here or as a safety redundancy to ensure that the product concentration reaches the highest standard.

[0026] The basic framework of the device (sensing-control-execution-hybrid) is defined, which is clear in structure, easy to implement and maintain, and allows for flexible addition or reduction of the number of pipelines as needed. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the working process of the online concentration dynamic adjustment device provided by this utility model;

[0028] Figure 2 This is a front view cross-sectional structural diagram of the dynamic media mixer provided by this utility model;

[0029] Figure 3 This is a top view cross-sectional structural diagram of the dynamic media mixer provided by this utility model.

[0030] In the diagram: Controller 10, Concentration Sensor 20, Flow Sensor 30, Electric Regulating Valve 40, Pipeline 50, Dynamic Mixer 60, Static Mixer 70, Mixing Tank 61, Mixing Chamber 62, Rotating Shaft 63, Medium Push Plate 64, Filter Bag 65, Collection Port 66, Bottom Bearing 67, Top Cover 68, Top Bearing 69, Stirring Rod 610, Oriented Track Ring 611, Support Rod 631, Vertical Plate 641, Inclined Bottom Plate 642, Ring 651, Connecting Rod 671, Bearing Positioning Seat 681, Sealing Ring 682, Pressure Relief Valve 683. Detailed Implementation

[0031] To make the objectives, technical solutions, and advantages of this utility model clearer, the present utility model will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the present utility model and are not intended to limit the present utility model.

[0032] The implementation of this utility model will be described in detail below with reference to specific embodiments.

[0033] In the accompanying drawings of this embodiment, the same or similar reference numerals correspond to the same or similar components. In the description of this utility model, it should be understood that if terms such as "upper," "lower," "left," and "right" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, they are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, the terms used to describe positional relationships in the drawings are only for illustrative purposes and should not be construed as limiting this utility model. For those skilled in the art, the specific meaning of the above terms can be understood according to the specific circumstances.

[0034] Reference Figure 1-3 The image shown is a preferred embodiment of the present invention.

[0035] The online concentration dynamic adjustment device includes a concentration sensor 20, a flow sensor 30, a controller 10, an electric regulating valve 40, multiple pipelines 50 for media transportation, and a media dynamic mixer 60. Each monitoring point of each pipeline 50 is equipped with a concentration sensor 20 and a flow sensor 30. The signal output terminals of the concentration sensor 20 and the flow sensor 30 are connected to the analog input module of the controller 10. The control signal output terminal of the controller 10 is connected to the drive terminal of the electric regulating valve 40. Each regulating section of each pipeline 50 is equipped with an electric regulating valve 40.

[0036] Multiple pipes 50 are connected to a dynamic media mixer 60. A static mixer 70 is connected to the output end of the dynamic media mixer 60. A concentration sensor 20, a flow sensor 30, and an electric regulating valve 40 are installed on the static mixer 70.

[0037] The online concentration dynamic adjustment device provided above, by installing sensors at key points (monitoring section and final output end) of each pipeline 50, can sense the concentration and flow rate of each branch and the total flow after mixing in real time; the controller 10 dynamically adjusts the opening degree of the electric regulating valve 40 of each branch according to the deviation between the set value and the feedback value, so as to realize high-precision and fast-response online automatic adjustment of concentration, overcoming the lag and error problems of traditional offline mixing or open-loop control;

[0038] Each pipeline 50 is equipped with an independent monitoring and control unit, which allows for individual and precise flow and concentration control of media from different sources or with different properties, and is especially suitable for scenarios where multiple raw materials are mixed in precise proportions;

[0039] The combined use of a dynamic mixer 60 (active mixing) and a static mixer 70 (passive mixing) significantly improves mixing efficiency and uniformity; the dynamic mixer performs strong initial mixing, while the static mixer 70 completes fine homogenization, ensuring that the final output medium concentration is highly uniform and stable.

[0040] A sensor and regulating valve are added to the outlet of the static mixer 70 to form a closed-loop control of the final output quality. Even after two stages of mixing, if there is still a slight deviation in the final concentration, the system can make fine adjustments through the regulating valve here or as a safety redundancy to ensure that the product concentration reaches the highest standard.

[0041] The basic framework of the device (sensing-control-execution-hybrid) is defined, with a clear structure that is easy to implement and maintain, and the number of pipes can be flexibly increased or decreased as needed.

[0042] In this embodiment, the dynamic media mixer 60 includes a mixing tank 61 and a rotating shaft 63. Multiple pipes 50 are connected to the mixing tank 61 respectively. The mixing tank 61 has a vertically arranged mixing chamber 62. The bottom of the mixing tank 61 is connected to the static mixer 70. The rotating shaft 63 is vertically arranged in the mixing chamber 62. Multiple media push plates 64 are provided on the upper part of the rotating shaft 63. The multiple media push plates 64 are arranged circumferentially around the upper part of the rotating shaft 63. A detachably connected filter screen 65 is provided between adjacent media push plates 64.

[0043] Multiple stirring rods 610 are provided on the lower part of the rotating shaft 63. The multiple stirring rods 610 are arranged at intervals around the circumference of the rotating shaft 63, and the stirring rods 610 are located below the filter screen 65.

[0044] The bottom of the mixing chamber 62 is arranged in a conical shape, forming a collection port 66 for outputting the medium. A bottom bearing 67 that is rotatably connected to the rotating shaft 63 is installed on the collection port 66. The bottom bearing 67 and the collection port 66 are fixedly connected by a connecting rod 671. A directional track ring 611 for the directional rotation of the medium push plate 64 is provided on the inner wall of the mixing chamber 62.

[0045] High-efficiency staged mixing and filtration:

[0046] Medium pusher plate 64: Rotates with the shaft. The medium that just enters the upper part of the mixing chamber 62 will generate power (passive rotation) on the medium pusher plate 64, which will generate a strong pushing and shearing effect on the medium entering the upper part of the mixing chamber 62, realizing preliminary large-scale mixing and dispersion; directional track ring 611 guides the pusher plate to rotate in a directional manner, optimizes the flow field, and avoids disorderly splashing of the medium or the formation of dead corners.

[0047] When the fluid dynamics of the medium are insufficient, a drive motor can be used to drive the rotating shaft 63. The top of the rotating shaft 63 is extended upward to form a connecting section, which is used to connect with the drive motor to drive the rotating shaft 63 to rotate as a whole, thereby improving the mixing efficiency.

[0048] Detachable filter bag 65: Located between media push plates 64, it simultaneously intercepts any large particles, clumps or impurities that may be present in the media during the initial mixing stage, preventing them from entering the subsequent precision mixing area or clogging downstream equipment (such as static mixer 70); the detachable design facilitates cleaning or replacement.

[0049] Stirring rod 610: Located in the filtered area (below the mesh bag), it further stirs and homogenizes the pre-mixed and filtered medium to ensure better uniformity before entering the conical bottom.

[0050] Smooth transport and prevention of sedimentation:

[0051] Conical bottom: guides the medium to flow naturally towards the central collection port 66, conforming to fluid dynamics characteristics and reducing medium retention and deposition at the bottom.

[0052] Bottom bearing 67 is fixed to connecting rod 671: providing stable support for the bottom of rotating shaft 63 and ensuring smooth rotation; at the same time, the fixing method of connecting rod 671 avoids the bearing directly bearing the weight or impact of the medium, extending its service life; the structure of the collecting flow port 66 ensures smooth discharge.

[0053] Compact structure and integrated functions: The mixing chamber 62 integrates coarse mixing, online filtration, fine mixing and bottom guide material collection functions, with a compact structure and high mixing efficiency.

[0054] In this embodiment, a top cover 68 is detachably installed on the top of the mixing tank 61. The top cover 68 is connected to the rotating shaft 63 through a top bearing 69. A bearing positioning seat 681 is provided at the bottom of the top cover 68, and the bearing positioning seat 681 is sleeved on the outer periphery of the top bearing 69.

[0055] Easy maintenance: The removable top cover 68 facilitates cleaning, inspection or replacement of parts inside the mixing chamber 62 (such as the medium push plate 64, filter screen 65, stirring rod 610, and chamber wall), greatly reducing maintenance difficulty and downtime.

[0056] Reliable support and sealing: The top bearing 69 provides stable support for the upper end of the rotating shaft 63; the bearing positioning seat 681 precisely fixes the bearing position, ensuring the coaxiality and rotational stability of the rotating shaft 63, and reducing vibration and wear.

[0057] In this embodiment, a sealing ring 682 is fitted around the outer periphery of the top cover 68, and a pressure relief valve 683 is installed on the top cover 68.

[0058] Reliable sealing: The sealing ring 682 ensures that the top of the mixing chamber 62 remains sealed during operation, preventing media leakage, external contamination, or pressure loss.

[0059] Safety assurance: The pressure relief valve 683 automatically opens when the pressure in the mixing chamber 62 rises abnormally (such as during gas production or temperature increase) to release pressure, prevent equipment from being damaged by overpressure or causing danger, and improve system safety.

[0060] In this embodiment, the media push plate 64 includes a vertical plate 641 and an inclined bottom plate 642. One end of the inclined bottom plate 642 is connected to the bottom of the vertical plate 641, and the other end of the inclined bottom plate 642 is inclined downwards away from the vertical plate 641. A media filtering channel is formed between the inclined bottom plate 642 and the adjacent vertical plate 641, and the filter bag 65 is located in the media filtering channel.

[0061] Optimize flow and filtration:

[0062] Inclined base plate 642: Its inclined design is to allow the medium to better contact the vertical plate 641 and the inclined base plate 642 during the process of the medium entering the mixing chamber 62 under high pressure, and push them to drive the rotating shaft 63 to rotate. The medium flows downward under the push of the medium push plate 64, rather than splashing horizontally, which promotes the medium to pass smoothly through the filter bag 65 below and flow to the lower part of the mixing chamber 62.

[0063] Media filtration channel: clearly defines the path that the media must flow through the filter bag 65 under the action of the media pusher plate 64, ensuring that all media are effectively filtered; the channel space prevents the filter bag 65 from being compressed and becoming ineffective.

[0064] Improved mixing efficiency: The combination of vertical plate 641 and inclined plate generates more complex shear and turbulence while pushing the medium, thus enhancing the initial mixing effect.

[0065] In this embodiment, the filter bag 65 is recessed downward to form a pocket cavity with a top opening, and the filter bag 65 has multiple filter holes.

[0066] Increased filtration area and capacity: The recessed pocket structure significantly increases the effective filtration area and can temporarily hold more trapped impurities, slowing down the clogging speed of the mesh and extending the single use time.

[0067] Smooth slag discharge guidance: The top opening and downward concave design facilitates the concentration of trapped impurities towards the bottom of the bag under gravity or media scouring, making it easy to clean later by disassembly and preventing impurities from accumulating at the top of the mesh bag.

[0068] In this embodiment, a plurality of support rods 631 are provided on the rotating shaft 63. The plurality of support rods 631 are arranged at intervals around the circumference of the rotating shaft 63. Adjacent support rods 631 abut against the two sides of the filter screen bag 65 respectively. The filter screen bag 65 is provided with a ring 651, which is fitted on the outer periphery of the support rods 631.

[0069] Stable and reliable fixation: The support rod 631 presses against the net bag from both sides, and the ring 651 is fitted onto the rod to ensure that the net bag remains stable, does not shift, does not overturn, and does not detach under high-speed rotation and media impact, resulting in high operational reliability.

[0070] Easy to install and remove: The looping method between the ring 651 and the support rod 631 makes the installation and removal of the net bag simple and quick, and convenient to remove for cleaning or replacement during maintenance.

[0071] In this embodiment, the distance ratio between the regulating section and the monitoring section of the pipeline 50 is 1:3.

[0072] Optimized response and control accuracy: This specific ratio setting is the result of empirical optimization; the longer distance from the monitoring section to the regulating section (3 times) provides sufficient response time and space for fluid flow and concentration changes, enabling the changes detected by the sensor to more accurately reflect the fluid state that is about to reach the regulating valve; avoiding the controller 10 from overreacting (oscillation) to instantaneous disturbances due to too close a distance, or the control from being too far away (untimely adjustment); the 1:3 ratio helps to achieve more stable and accurate dynamic control.

[0073] In this embodiment, the concentration sensor 20 is a fiber optic spectral sensor or an electrochemical sensor.

[0074] High precision and applicability:

[0075] Fiber optic spectral sensors are suitable for detecting the concentration of media (such as liquid chemicals and slurries) through optical properties (such as absorbance and reflectance); they offer non-contact or immersion measurement with fast response, high accuracy, low contamination, and corrosion resistance.

[0076] Electrochemical sensors: suitable for detecting the concentration of media based on electrochemical principles (such as pH, ion concentration, conductivity); they have good selectivity and high sensitivity.

[0077] Adaptable to diverse media: By clearly defining these two high-performance sensor types, the device can be widely applied to various industries requiring precise concentration control, such as chemical, pharmaceutical, food and beverage, and environmental water treatment, as well as media with different physicochemical properties, thereby improving the device's versatility and reliability.

[0078] In this embodiment, a human-machine interface is also included, which communicates with the controller 10 via an RS485 bus.

[0079] User-friendly operation and monitoring: The HMI provides operators with a graphical user interface for easy parameter setting (target concentration, flow rate, etc.), start / stop control, and mode selection.

[0080] Real-time status display: Centrally displays key parameters such as real-time concentration, flow rate, valve opening, and alarm information of each pipeline and the final output, making the operating status clear at a glance.

[0081] Data recording and analysis: Typically integrates data recording functions to facilitate tracking production history, analyzing trends, quality traceability, and process optimization.

[0082] Reliable communication: The RS485 bus has strong anti-interference capabilities, long transmission distance, and supports multi-point communication, making it very suitable for stable connection between controller 10 and HMI in industrial environments.

[0083] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. An online concentration dynamic adjustment device, characterized in that, The system includes a concentration sensor, a flow sensor, a controller, an electric regulating valve, multiple pipelines for media transport, and a dynamic media mixer. Each monitoring point on the pipeline is equipped with a concentration sensor and a flow sensor. The signal output terminals of the concentration sensor and the flow sensor are connected to the analog input module of the controller. The control signal output terminal of the controller is connected to the drive terminal of the electric regulating valve. Each regulating section of the pipeline is equipped with an electric regulating valve. Multiple pipelines are connected to a dynamic media mixer, and a static mixer is connected to the output end of the dynamic media mixer. A concentration sensor, a flow sensor, and an electric regulating valve are installed on the static mixer.

2. The online concentration dynamic adjustment device as described in claim 1, characterized in that, The dynamic media mixer includes a mixing tank and a rotating shaft. Multiple pipes are connected to the mixing tank. The mixing tank has a vertically arranged mixing chamber. The bottom of the mixing tank is connected to a static mixer. The rotating shaft is vertically arranged in the mixing chamber. Multiple media push plates are provided on the upper part of the rotating shaft. The multiple media push plates are arranged circumferentially around the upper part of the rotating shaft. A detachably connected filter screen is provided between adjacent media push plates. The lower part of the rotating shaft is provided with a plurality of stirring rods, which are arranged at intervals around the circumference of the rotating shaft, and the stirring rods are located below the filter screen. The bottom of the mixing chamber is arranged in a conical shape, forming a collection port for outputting the medium. A bottom bearing that is rotatably connected to the rotating shaft is installed on the collection port. The bottom bearing and the collection port are fixedly connected by a connecting rod. The inner side wall of the mixing chamber is provided with a directional track ring for the directional rotation of the medium push plate.

3. The online concentration dynamic adjustment device as described in claim 2, characterized in that, A top cover is detachably installed on the top of the mixing tank. The top cover is connected to the rotating shaft through a top bearing. A bearing positioning seat is provided at the bottom of the top cover and is sleeved on the outer periphery of the top bearing.

4. The online concentration dynamic adjustment device as described in claim 3, characterized in that, A sealing ring is fitted around the outer periphery of the top cover, and a pressure relief valve is installed on the top cover.

5. The online concentration dynamic adjustment device as described in claim 4, characterized in that, The media push plate includes a vertical plate and an inclined bottom plate. One end of the inclined bottom plate is connected to the bottom of the vertical plate, and the other end of the inclined bottom plate is inclined downwards away from the vertical plate. A media filtration channel is formed between the inclined bottom plate and the adjacent vertical plate, and the filter bag is located in the media filtration channel.

6. The online concentration dynamic adjustment device as described in claim 5, characterized in that, The filter bag is recessed downwards to form a pocket cavity with an opening at the top, and the filter bag has multiple filter holes.

7. The online concentration dynamic adjustment device as described in claim 6, characterized in that, The rotating shaft is provided with a plurality of support rods, which are arranged at intervals around the circumference of the rotating shaft. Adjacent support rods abut against the two sides of the filter screen bag. The filter screen bag is provided with a ring sleeve, which is fitted around the outer periphery of the support rod.

8. The online concentration dynamic adjustment device according to any one of claims 1 to 7, characterized in that, The distance ratio between the regulating section and the monitoring section of the pipeline is 1:

3.

9. The online concentration dynamic adjustment device as described in claim 8, characterized in that, The concentration sensor is either a fiber optic spectral sensor or an electrochemical sensor.

10. The online concentration dynamic adjustment device according to any one of claims 1 to 7, characterized in that, It also includes a human-machine interface, which communicates with the controller via an RS485 bus.

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