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CN-121979061-A - Intelligent regulation and control system and method for accurate preparation of solid sample

CN121979061ACN 121979061 ACN121979061 ACN 121979061ACN-121979061-A

Abstract

The invention discloses an intelligent regulation and control system and method for accurately preparing a solid sample, which relate to the field of automatic control of systems and comprise an accurate feeding system, an accurate press forming system, a grading sorting discharging system and an intelligent regulation and control core module, wherein all subsystems are sequentially distributed along the flow direction of the sample, a double-data interaction link is established with the intelligent regulation and control core module to form a closed-loop regulation and control system, the accurate feeding system can realize pretreatment of the temperature and the humidity of the sample, the accurate press forming system has the functions of accurate press forming and full-parameter monitoring, the grading sorting discharging system integrates the functions of multidimensional nondestructive testing and intelligent sorting, the intelligent regulation and control core module adopts an MCU main control and deep learning edge processing unit architecture to prestore multidimensional preparation parameter libraries, and the preparation parameters are dynamically optimized by analyzing multisource feedback data through an improved closed-loop control algorithm, so that the whole-flow self-adaption accurate control is realized, and the preparation quality and efficiency are ensured.

Inventors

  • SUN XIUPING
  • LUO BIN
  • YANG YI
  • LI ZHIGUO

Assignees

  • 重庆市生态环境监测中心
  • 成都康霖科技有限责任公司

Dates

Publication Date
20260505
Application Date
20260202

Claims (10)

  1. 1. The intelligent regulation and control system for accurately preparing the solid sample is characterized by comprising an accurate feeding system, an accurate press-fit forming system, a grading sorting discharging system and an intelligent regulation and control core module, wherein the accurate feeding system, the accurate press-fit forming system and the grading sorting discharging system are sequentially distributed along the flow direction of the sample and establish a wired and wireless double-data interaction link with the intelligent regulation and control core module to form a closed-loop regulation and control system; The accurate feeding system comprises a storage bin, a variable-frequency screw feeding device, a conveying channel, a temperature and humidity integrated sensing assembly and an ultrasonic heat pump dual-mode humidity regulation device, wherein the temperature and humidity integrated sensing assembly is used for synchronously collecting temperature and humidity feedback signals of a solid sample and transmitting the temperature and humidity feedback signals to an intelligent regulation core module; The precise press-fit forming system comprises a forming cavity, a high-precision servo press-fit machine, a ceramic liquid-cooling composite temperature control system and a press-fit full-parameter monitoring assembly, wherein the ceramic liquid-cooling composite temperature control system and an intelligent regulation core module form a temperature control closed loop, the press-fit full-parameter monitoring assembly acquires pressure, displacement and forming cavity temperature signals in the press-fit process in real time, and the high-precision servo press-fit machine outputs precise press force and stroke according to control instructions; The grading sorting discharging system comprises an intelligent sorting mechanism, a tracing conveying line and a multidimensional nondestructive testing module, wherein the multidimensional nondestructive testing module integrates the functions of size visual detection, density detection and surface defect identification and outputs a quality detection feedback signal to an intelligent regulation core module; The intelligent regulation and control core module adopts a mixed control architecture of an MCU main control and deep learning edge processing unit, prestores a multi-dimensional preparation parameter library based on different sample types, analyzes multi-source feedback data acquired by each system in real time, dynamically optimizes and cooperatively adjusts feeding quantity, a pressing pressure curve, forming cavity temperature and humidity regulation and control parameters by using an improved closed-loop control algorithm, and realizes self-adaptive accurate control of the whole preparation process.
  2. 2. The intelligent regulation and control system for accurately preparing the solid sample according to claim 1, wherein the temperature and humidity integrated sensing assembly adopts a high-precision capacitive composite sensor, the temperature detection range is-10 ℃ to 60 ℃, the humidity detection range is 0-95% RH, the humidity precision is +/-1.8% RH, the temperature precision is +/-0.3 ℃, and a continuous temperature and humidity feedback signal is output; the ultrasonic heat pump dual-mode humidity control device integrates an ultrasonic atomization humidifier and a heat pump dehumidifier, and forms a linkage control link with a frequency conversion control module of the frequency conversion screw feeding device; The intelligent regulation and control core module intelligently switches the following control modes through a multi-dimensional logic judgment algorithm based on the temperature and humidity feedback signal and the difference value and the change rate of the preset adaptive temperature and humidity: The first mode of high-temperature high-humidity working condition control is that when the ambient temperature is more than 32 ℃ and the sample humidity is more than the adaptive humidity and is +6%RH, the intelligent regulation core module outputs an intermittent heat pump dehumidification instruction and a pulse ultrasonic humidification fine adjustment instruction, and simultaneously outputs a deceleration instruction to the variable-frequency screw feeding device, so that the retention time of the sample is prolonged and uniform temperature and humidity regulation is realized; The second mode is the control of the working condition of high temperature and low humidity, namely when the ambient temperature is more than 32 ℃ and the sample humidity is less than the adaptive humidity-6%RH, the intelligent regulation core module outputs a low-power continuous ultrasonic humidification instruction, and simultaneously outputs a rotating speed fine adjustment instruction to the variable-frequency screw feeding device, and the shaping cavity is matched for preheating to realize shaping optimization; And controlling the working conditions of low temperature and high humidity, namely when the ambient temperature is less than 12 ℃ and the sample humidity is more than the adaptive humidity and is less than 6% RH, the intelligent regulation core module outputs a preheating instruction to the ceramic liquid cooling composite temperature control system, and after the temperature of the forming cavity reaches a preset threshold value, outputs a feeding control instruction to the accurate feeding system, and simultaneously starts the low-power operation of the heat pump dehumidifier to avoid condensation and adhesion of the sample.
  3. 3. The intelligent regulation and control system for accurately preparing the solid sample according to claim 1, wherein a feeding double-dimensional rechecking module is arranged at the joint of the conveying channel and the forming cavity, and comprises a high-precision weighing sensor and a volume detection sensor, and is used for carrying out weight-volume double-parameter detection on the sample before entering the forming cavity and outputting a feedback signal; After the intelligent regulation and control core module receives the feedback signal, the deviation of the feeding amount is judged through a double-parameter error compensation algorithm, and if the deviation exists, a parameter adjustment instruction is output: And compensating feeding time/variable frequency rotating speed in the next feeding period, or dynamically fine-adjusting parameters of pressing pressure and pressure maintaining time in the pressing process, so as to realize real-time closed-loop compensation of feeding deviation.
  4. 4. The intelligent regulation and control system for accurately preparing the solid sample according to claim 1, wherein a pressing full-parameter monitoring assembly is arranged in the molding cavity, and the pressing full-parameter monitoring assembly integrates a high-response-speed pressure sensor, a high-precision displacement sensor and a multi-point temperature sensor and is used for collecting pressure, displacement and temperature three-dimensional curves in the whole pressing process in real time; The intelligent regulation core module compares the acquired three-dimensional curve with a standard curve of the corresponding sample type in the parameter library for analysis; If the curve is abnormal, the system can judge that the material is unevenly distributed, the state of the forming cavity is changed or the temperature and humidity are fluctuated, and immediately take corrective action.
  5. 5. The intelligent regulation and control system for accurately preparing the solid sample according to claim 1, wherein the ceramic liquid cooling composite temperature control system comprises ceramic heating elements, a spiral liquid cooling pipeline and a multi-point optical fiber temperature sensor embedded into the wall of a molding cavity, wherein the ceramic heating elements, the spiral liquid cooling pipeline and the multi-point optical fiber temperature sensor are uniformly arranged around the molding cavity, and the multi-point optical fiber temperature sensor is used for monitoring temperatures of different areas in the molding cavity in real time to realize differential accurate temperature control: For a high-adsorptivity soil sample, the temperature reference control interval of the forming cavity is 38-48 ℃, if the actual humidity of the sample fed back by the accurate feeding system is higher than the adaptive humidity by 4% RH or more, the intelligent regulation core module automatically regulates the temperature by 3-4 ℃, and the residual heat of the forming cavity is utilized to assist in water evaporation, so that the sample stabilizing time is shortened; For mineral powder samples, the temperature reference control interval of the forming cavity is 20-27 ℃, the temperature reference control interval can be dynamically adjusted according to the working condition of the ultrasonic heat pump dual-mode humidity control device, the temperature reference control interval can be moderately preheated according to the instruction of the intelligent control core module under the low-temperature high-humidity working condition, the sample condensation is avoided, a cooling medium is introduced through a liquid cooling pipeline under the high-temperature environment, the reference temperature interval is maintained, and the particle oxidation or lattice change caused by high temperature is prevented.
  6. 6. The intelligent regulation and control system for accurately preparing solid samples according to claim 1, wherein the deep learning edge processing unit of the intelligent regulation and control core module is based on MindSporeLite frames, a preparation process prediction and optimization model based on deep learning is built in the intelligent regulation and control core module, and the preparation process prediction and optimization model can analyze the latest 150-250 groups of complete preparation data in real time and has the following functions: Predicting trend, namely when detecting that the qualification rate of a certain type of sample is continuously reduced by 3 groups or the single qualification rate is lower than 92%, the deep learning edge processing unit can predict potential process drift in advance and actively trigger multi-parameter coupling adjustment; the multi-parameter coupling optimization comprises the steps of carrying out cooperative optimization on the parameters of feeding quantity, temperature and humidity, forming cavity temperature, pressing pressure and dwell time based on a model in an adjustment process, and searching a global optimal solution; And after the self-learning updating, if the comprehensive qualification rate of 12 groups of continuous samples is more than or equal to 96%, the new optimized parameters are used as dynamic reference parameters of the samples, updated to a sample preparation parameter library, and continuous self-learning and performance improvement of the system are realized.
  7. 7. The intelligent regulation and control system for accurately preparing the solid sample according to claim 1, wherein the intelligent regulation and control core module is further provided with a redundancy backup and intelligent fault self-healing module, and the comprehensive fault identification and intelligent processing are realized through sensor redundancy configuration, equipment state real-time monitoring and AI fault mode identification: monitoring data of each sensor in real time, and immediately judging the sensor as a sensor fault if the data is suddenly changed, the data exceeds a reasonable range, no feedback signal or signal drift exceeds a threshold value; Fault classification and intelligent processing: the system automatically switches to a standby sensor, and meanwhile, the average value of 15 groups of recent historical data of the sensor is called, data fusion and cross verification are carried out by combining the data of other related sensors, trusted data are generated, the system continues to run, fault logs are recorded in the background, and a user is prompted to calibrate through a human-computer interaction interface; And immediately starting a safe shutdown program, displaying detailed fault types, positions and possible reasons by a touch screen, alarming through a buzzer and a three-color indicator lamp, and simultaneously encrypting and uploading fault information to a cloud database, and attaching a remote diagnosis guide and maintenance step visual file, so that remote diagnosis and quick investigation are supported, and the shutdown time is reduced to the greatest extent.
  8. 8. The intelligent regulation and control system for accurately preparing the solid sample according to claim 1, further comprising a sample full life cycle double-traceability unit, wherein the sample full life cycle double-traceability unit comprises a miniature RFID chip implantation device, an ultraviolet code sprayer, a local encryption storage module and a cloud data interaction interface; The miniature RFID chip implantation device is used for implanting a unique miniature RFID chip into each qualified sample, the ultraviolet code sprayer is used for generating a unique two-dimensional code on the surface of the sample, and the chip and the two-dimensional code are associated with the same identification ID and comprise batch, preparation time, equipment number and operator information; The local encryption storage module is synchronized with the intelligent regulation core module in real time, and records a full-preparation process parameter chain corresponding to the unique ID, wherein the parameter chain comprises a feeding parameter, temperature and humidity regulation data, a pressing curve and a detection result; The sample full life cycle double-traceability unit supports seamless connection with a laboratory information management system, and realizes full-link data traceability and reverse inquiry generated from sample preparation, analysis and detection report generation.
  9. 9. An intelligent regulation and control method for accurately preparing a solid sample is characterized by being used for the system as claimed in any one of claims 1-8, and comprises the following steps: S1, initializing intelligent parameters, namely automatically identifying the sample type by a system through a raw material batch identification module or selecting the sample type by a user through a man-machine interaction interface of an intelligent regulation core module, automatically calling basic parameters in a pre-stored multi-dimensional preparation parameter library by the system, and performing intelligent fine adjustment on initial parameters of the current batch according to preparation data and an optimization result of the previous batch to support manual modification of key parameters by the user based on experience; S2, precisely and quantitatively feeding, wherein an intelligent regulation core module drives a variable-frequency screw feeding device of a precise feeding system to operate, solid samples in a storage bin are conveyed to a conveying channel, feeding quantity is calculated through variable-frequency rotating speed and preset flow coefficient, when the samples are conveyed to an inlet of a forming cavity, weight-volume double-parameter detection is completed through a feeding double-dimensional rechecking module, a feeder is stopped when the target feeding quantity is reached, and if feeding quantity deviation is detected, the system drives the feeder to conduct micro feeding or parameter compensation in the next period; s3, dynamic temperature and humidity regulation and feedback, namely detecting the temperature and humidity of the sample in real time by the temperature and humidity integrated sensing assembly, dynamically selecting and executing an optimal temperature and humidity regulation mode by the intelligent regulation core module according to the difference value between the detection result and the preset adaptive temperature and humidity, continuously monitoring the temperature and humidity change rate in the regulation process, and feeding back to the ceramic liquid cooling composite temperature control system in real time to provide a preheating/cooling decision basis for the ceramic liquid cooling composite temperature control system; S4, the prepressing detection and the intelligent temperature control are cooperated, namely, a temperature and humidity standard sample is sent into a forming cavity, and an intelligent control core module starts a ceramic liquid cooling composite temperature control system according to the final temperature and humidity value and the sample type fed back in the step S3, so that the temperature of the forming cavity is accurately increased to a dynamically optimized target temperature and is stable; Then driving the high-precision servo press-fit machine to drive the upper press head to descend with the pre-pressing pressure, detecting the pre-pressing process by the press-fit full-parameter monitoring assembly, and if the sample distribution is judged to be uneven, controlling the lower press head to slightly vibrate and adjust at 8-12Hz until the sample distribution is even; S5, closed-loop compression molding, namely driving the high-precision servo press-fit machine to descend according to the optimized target press-fit pressure curve by the intelligent regulation core module, compacting a sample in a molding cavity, keeping the preset pressure maintaining time, detecting final molding parameters by the press-fit full-parameter monitoring component, comparing an actual pressure-displacement-temperature three-dimensional curve with a standard curve by the system, and self-adaptively adjusting the pressure, stroke or pressure maintaining time parameters of next compression if a small deviation is found, so as to form closed-loop optimization; S6, multidimensional nondestructive testing and shunting, namely, detecting the dimensional accuracy, density and surface defects of the molded sample, if the molded sample is qualified, entering the next step, if the molded sample is unqualified, sending the molded sample to a waste channel by an intelligent sorting mechanism, and recording the unqualified reason; s7, sample double-traceability codes, namely synchronously working a miniature RFID chip implantation device and an ultraviolet code spraying device of a sample full life cycle double-traceability unit, implanting an RFID chip in a qualified sample, spraying and printing a two-dimensional code on the surface, associating the codes with all process parameters of the steps S2 to S5 by a local encryption storage module, encrypting and storing the codes, and uploading the codes to a cloud; And S8, intelligent discharging and continuous circulation, wherein the intelligent control core module drives the intelligent sorting mechanism to eject samples qualified in coding, the samples are sent to a designated collecting device through a traceability conveying line with coding identification, the system immediately and automatically triggers the next round of preparation flow, and the steps S2-S8 are repeated, so that continuous and unattended automatic production is realized.
  10. 10. The method for accurately preparing the intelligent regulation and control of the solid sample according to claim 9, wherein in the step S3, if the absolute difference between the humidity of the sample and the adaptive humidity is more than 6% RH, the intelligent regulation and control core module simultaneously starts the corresponding regulating device and the variable-frequency screw feeding device to run at a low speed so as to regulate the temperature and the humidity of the sample uniformly; if the absolute difference value of RH is less than or equal to 3 percent and less than or equal to 6 percent RH, starting the low-power operation of the regulating device; If the absolute difference value is less than 3% RH, only the temperature and humidity integrated sensing assembly is kept for monitoring, and the adjusting device is not started.

Description

Intelligent regulation and control system and method for accurate preparation of solid sample Technical Field The invention relates to the field of automatic control of systems, in particular to an intelligent regulation and control system and method for accurately preparing a solid sample. Background In the sample pretreatment links in the fields of heavy metal analysis, geological detection and the like, solid samples such as soil, mineral powder and the like are required to be prepared into a formed part (such as a wafer) with fixed specification, and then subsequent detection and analysis can be performed. The semi-manual or simple automatic preparation mode commonly adopted in the prior art has a plurality of defects: 1. The lack of an integrated cooperative control mechanism, namely that links such as feeding, pressing, discharging and the like are mutually independent, parameter adjustment depends on manual experience, and self-adaptive optimization cannot be realized according to the state of a sample and environmental changes, so that the stability of the preparation process is poor; 2. The temperature and humidity control precision is insufficient, namely only humidity or temperature is controlled singly, temperature and humidity cooperative regulation is not formed, the sensing precision is low, the regulation mode is single, the sample is easy to dew, crack or adhere, and the molding quality is influenced; 3. The matching degree of the feeding and the pressing parameters is low, namely the feeding quantity is checked by adopting a single weighing mode, the deviation compensation mode is single, the pressing process only monitors the pressure and the displacement, the non-combination temperature parameters are subjected to cooperative optimization, and the size consistency and the internal density of the sample are poor; 4. the fault tolerance and self-learning capability are lacking, namely the sensor is required to be shut down for maintenance when in fault, the self-healing of the fault cannot be realized, the system performance cannot be continuously optimized through operation data, and the precision is reduced after long-term use; 5. The traceability system is imperfect, only partial preparation parameters are recorded, the traceability of the whole-flow data is lacked, and the quality control requirement of a third-party detection mechanism cannot be met. Aiming at the problems, the invention provides an intelligent regulation and control system and method for accurately preparing a solid sample, which realize the automatic, high-precision and self-adaptive control of the whole process of preparing the solid sample and solve the defects of the prior art by constructing a closed-loop control system of temperature and humidity cooperative regulation, multi-parameter coupling optimization, fault self-healing and full-link tracing. Disclosure of Invention The invention overcomes the defects of the prior art and provides an intelligent regulation and control system and method for accurately preparing a solid sample. The technical scheme includes that the intelligent regulation and control system for accurately preparing the solid sample comprises an accurate feeding system, an accurate press-fit forming system, a grading sorting discharging system and an intelligent regulation and control core module, wherein the accurate feeding system, the accurate press-fit forming system and the grading sorting discharging system are sequentially distributed along the flow direction of the sample and establish a wired and wireless double-data interaction link with the intelligent regulation and control core module to form a closed-loop regulation and control system; The accurate feeding system comprises a storage bin, a variable-frequency screw feeding device, a conveying channel, a temperature and humidity integrated sensing assembly and an ultrasonic heat pump dual-mode humidity regulation device, wherein the temperature and humidity integrated sensing assembly is used for synchronously collecting temperature and humidity feedback signals of a solid sample and transmitting the temperature and humidity feedback signals to an intelligent regulation core module; The precise press-fit forming system comprises a forming cavity, a high-precision servo press-fit machine, a ceramic liquid-cooling composite temperature control system and a press-fit full-parameter monitoring assembly, wherein the ceramic liquid-cooling composite temperature control system and an intelligent regulation core module form a temperature control closed loop, the press-fit full-parameter monitoring assembly acquires pressure, displacement and forming cavity temperature signals in the press-fit process in real time, and the high-precision servo press-fit machine outputs precise press force and stroke according to control instructions; The grading sorting discharging system comprises an intelligent sorting mechanism, a tracing conveying li