CN110427684B - Research and development method of high-viscosity fluid filling and cap screwing integrated equipment - Google Patents
Research and development method of high-viscosity fluid filling and cap screwing integrated equipment Download PDFInfo
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Abstract
The invention discloses a research and development method of high-viscosity fluid filling and cap screwing integrated equipment in the field of filling devices. This design has overcome and has glued thick raw materials filling initial stage, and the inside temperature that the content fermentation arouses increases progressively and leads to the container to warp, packaging material is decomposed a little, the content emptys not smooth and filling mouth attachment arouses difficult problems such as oxidation pollution, proposes the novel structure packaging technology based on viscous food and sauce material system, and the research is solved high thick sauce material structure packing lid adhesion nature, is emptyd methods such as smoothness nature and leak protection sealed effect, realizes the whole line balance and the stability of filling process.
Description
Technical Field
The invention relates to the field of filling devices, in particular to a research and development method of high-viscosity fluid filling and cap screwing integrated equipment.
Background
In foreign countries, a relatively perfect industrial system has been formed in the filling device machinery industry, and plays an important role in the development of the packaging machinery manufacturing industry. Foreign filling machines are developed in more mature countries such as the united states, germany, japan, italy and the united kingdom, where there are many professional manufacturers who produce such machines. The electronic capacity type filling system is mainly adopted, and a filling valve provided with an electronic flowmeter is used for metering and cutting, so that the purpose of controlling the filling quantity is achieved. Such as CBIALFILL, miguerre, italy, sprague, etc. However, foreign filling devices are mainly used for filling beverages or low-viscosity materials, and are not urgently improved in the aspects of reducing metering errors, leakage, dropping and the like.
The piston type filling method is mainly adopted in China, and when the filled object reaches a certain volume, the piston is used for injecting materials into the container, so that the problems that the materials are adhered to the surface of the piston, powder is generated due to friction of the piston and the like are caused, and the consequences of low production efficiency, inaccurate metering, food pollution and the like are directly caused. In the aspect of filling devices, a high-viscosity fluid filling technology which is suitable for filling bottles and bottle caps with various shapes is not solved.
Through literature search, only a few papers at home and abroad are researched on the viscosity test of the viscous food. The research mainly takes a macromolecular chain structure, a motion mechanism, an interface action, a pipeline structure, a pipeline size, a temperature, a pressure, a flow rate and the like in the viscous food as research objects, achieves the purposes of controlling the flow resistance of the viscous food in a pipeline, reducing the relaxation time of the viscous food, improving the flow-off effect, eliminating the defects of metering error, dropping liquid, food pollution and the like by optimizing parameters, provides a theoretical basis for pipeline type high-speed flow-off filling equipment, and has no public report in similar research.
In the field of filling equipment, countries such as europe and the united states of america have formed relatively perfect industrial systems, mainly adopt electronic capacity type filling systems to control filling quantity, but the existing filling devices mainly aim at beverages or medium and low viscosity materials, and meanwhile, need to be improved in the aspects of reducing metering errors, leakage flows, dropping liquid and the like. At present, the piston type filling method is mainly adopted in China, the problems of low production efficiency, inaccurate metering, food pollution and the like caused by the fact that materials are adhered to the surface of a piston and powder is generated due to friction generally exist, and meanwhile, in the aspect of filling equipment, a high-viscosity fluid filling technology suitable for filling containers in various shapes is not solved.
Disclosure of Invention
In order to solve the above problems, it is an object of the present invention to provide a design of a high viscosity fluid filling apparatus.
In order to achieve the purpose, the technical scheme of the invention is as follows: modeling by using rheological characteristics of thick sauce and viscous food, researching a flow breaking mechanism of the viscous food, obtaining a viscosity change curve of the food and a relaxation time spectrum of the food, optimizing the design of the inner wall of a discharge pipeline, and finally obtaining an optimal design scheme of the whole equipment.
After the scheme is adopted, the following beneficial effects are realized: 1. the rapid metering filling and sterile filling of viscous food are always difficult problems to overcome internationally due to the limitation of variety of food, process equipment and the like. The project breaks through the technologies of aseptic butt joint of complex procedures, multi-machine cooperative control, high-viscosity fluid filling suitable for filling bottles and bottle caps with various shapes and the like, develops high-viscosity fluid filling and cap screwing integrated complete equipment, and realizes the automation of the whole process of filling thick sauce and viscous food.
2. The method solves the problems that the inner temperature is gradually increased due to the content physical property fermentation to cause the deformation of a container, the micro decomposition of a packaging material, the unsmooth dumping of the content, the oxidation pollution caused by the attachment of a filling opening and the like in the initial filling stage of the viscous raw material, provides a novel structure packaging technology based on viscous food and a sauce system, researches and solves the problems of the adhesion of a packaging cover body, the dumping smoothness, the leakage-proof sealing effect and the like of a high-viscosity sauce structure, and realizes the whole line balance and stability of the filling process.
Further, the method comprises the following steps:
when the flow breaking mechanism of the viscous food is researched, the method mainly comprises the following steps;
(1) Modeling rheological properties of viscous food and thick paste;
(2) Generating a relaxation time spectrum of the fluid and a viscosity change curve of the fluid;
(3) Forecasting different material formulas according to the mode, and providing a basis for intelligent filling pipeline design;
(4) Optimizing the parameters of the pipeline in an actual test;
(5) The surface structure and the inner wall material of the tapping pipe are analyzed and researched for the action mechanism of the viscous food interface.
Modeling rheological characteristics of viscous food and thick sauce, and establishing a relation model of viscosity, solvent molecular weight, solid content, temperature, pressure and shearing rate according to viscosity characteristics of the viscous food and the thick sauce by referring to a Cross-Arrhenius viscosity model:
in the formula eta 0 -zero shear viscosity, pas;
b-zero shear viscosity η 0 Level of (2), molecular weight M with solvent w 3.4 And the volume fraction V of the solid filler in the food is in direct proportion, pa.s;
τ * -shear stress level, pa, of viscous food and puree rheology from newtonian transition zone to power law zone;
T b —η 0 sensitivity to temperature T, K;
β—η 0 sensitivity to pressure, m 2 /N；
n-flow index, and molecular weight M of the solvent w 3.4 And the volume fraction V of solid filler in the food product.
And further correcting the model according to thick sauce, viscous food, viscosity characteristics and special working condition conditions of food filling, developing a packaging container capable of realizing hot filling for realizing high-speed filling, considering the requirement of food quality on processing temperature, and determining the maximum filling temperature as T:
in the formula eta T -zero shear viscosity at filling temperature T, pa · s;
b-level of zero shear viscosity, pa · s;
τ * -the shear stress level, pa, of the thick paste and viscous food product rheology from the newtonian transition zone to the power law zone;
β—η 0 sensitivity to filling pressure, m 2 /N；
n-flow index.
The storage modulus G' (w) of the thick sauce and the viscous food is expressed by 5 Maxwell motion unit numbers by adopting a generalized Maxwell model j ) And dissipation modulus G' (w) j )：
In the formula: w is a j For shear oscillation frequency, 5 sets (. Lamda.) i ,g i ) Constituting a discrete relaxation time spectrum of the puree and the viscous food product.
(2) According to a capillary rheometer and a rotary rheometer, shear rate-viscosity data static viscosity data and dynamic viscosity curves of viscous food and thick sauce fluid are obtained through testing, and according to a rheological characteristic mathematical model, the test data curves are fitted according to a least square method to obtain viscosity pressure coefficients, shear stress levels, viscosity sensitivity to filling pressure, flow indexes and other coefficients in the model at a specific filling temperature, and a viscosity change curve is fitted; and measuring the storage modulus and the energy consumption modulus under different frequencies according to a rotational rheometer, and calculating a fluid discrete relaxation time spectrum by adopting a linear regression analysis method.
(3) Predicting different material formulas according to the chart, and providing a basis for intelligent filling pipeline design;
(4) Optimizing the parameters of the pipeline in an actual test;
(5) The surface structure of the tapping pipe and the mechanism of action of the inner wall material on the viscous food interface are analyzed and studied.
The technical scheme has the following beneficial effects:
1. researching the mutual winding, bonding and adsorption mechanism among macromolecular chains, chain segments and functional groups in the thick sauce and the viscous food, analyzing the rheological characteristics of the thick sauce and the viscous food, establishing a mathematical model, and determining a relaxation time spectrum and a viscosity change curve of the fluid; the influence of the pipe diameter size, the shape, the fluid speed, the pressure, the temperature and the like on the viscosity and the relaxation time of the viscous food is researched, the influence mechanism is analyzed, the parameters are optimized, and the purpose of controlling the viscosity and the relaxation time is achieved;
2. the method is characterized by researching the action mechanism of the wall material and the surface structure in the pipe on the interface of the viscous food, mainly researching the action modes and the action forces between different medium materials and macromolecules such as protein, sugar, grease, starch and the like, designing the surface of the micro-nano structure, researching the adsorption effects of the sizes, the shapes and the like of different micro-nano structures on different macromolecules, and achieving the purposes of reducing the flow resistance of the viscous food in the pipeline and improving the flow cutoff effect through material selection and structural design. And a theoretical research basis is provided for the design and optimization of the key structure of the filling machine.
3. The control technology and the implementation scheme of quantitative filling precision are researched for soybean paste, chili paste, tomato paste and other paste foods which contain particles or do not contain particles and have certain viscosity.
4. According to the conditions of food flow detection equipment, intelligent filling equipment, online operation and traceable equipment development, the integrated technology of thick sauce and thick food intelligent packaging equipment is researched, and a coordinated monitoring and intelligent optimization scheduling decision system of a distributed network is developed. The system and the method can be used for filling materials in different forms such as tablets, capsules, granules, liquid and the like, and the demonstration production and the application of novel intelligent packaging and filling equipment for series materials are developed. Establishing a domestic leading filling demonstration production line with the maximum filling yield of more than 36000 bottles/hour.
Further, in the step (1), the modeling of the rheological properties of the thick paste and the thick sauce is mainly to establish a mathematical model for predicting the rheological properties of the thick paste and the thick sauce according to the polymerization degree, the branch chain degree and the functional group of macromolecules of the thick paste and the thick paste as parameters and the apparent viscosity and the relaxation time as unknowns. And theoretical research foundation and data foundation are provided for the design and optimization of the key structure of the filling machine.
Further, the relaxation time spectrum of the fluid and the viscosity change curve of the fluid are generated in the step (2), and the static viscosity data and the dynamic viscosity curve of the filling fluid are obtained through testing by a capillary rheometer and a rotational rheometer, and the data fitting is carried out on the test data curve according to the rheological characteristic mathematical model determined in the step (1), so as to determine the viscosity pressure coefficient, the shear stress level and the sensitivity of the viscosity to the filling pressure in the model at the specific filling temperature and generate the viscosity change curve; fitting a fluid discrete relaxation time spectrum according to the storage modulus and the energy consumption modulus under different frequencies; establishing a prediction curve of the relaxation time and viscosity of the fluid and the temperature, pressure and flow speed state of the fluid.
Further, establishing physical models of different pipeline structures and sizes in the step (3), and researching the viscosity and relaxation time of the thick sauce and the viscous food under different temperatures, pressures and flow rates; meanwhile, super-hydrophobic micro-nano structures are designed on the surfaces of different pipeline materials, contact angles and adhesion properties of thick sauce and viscous food on the surfaces are researched, and the pipeline material with the smallest material apparent viscosity and the smallest relaxation time is selected after statistics.
The surface of the micro-nano structure is designed, the adsorption effect of different micro-nano structure sizes, appearances and the like on different macromolecules is researched, and the purposes of reducing the flow resistance of viscous food in a pipeline and improving the flow cutoff effect are achieved through material selection and structural design.
Drawings
FIG. 1 is a design flow chart of an embodiment of the present invention.
Detailed Description
The following is further detailed by way of specific embodiments:
the embodiment is basically as shown in the attached figure 1: a research and development method of high-viscosity fluid filling and cap screwing integrated equipment comprises the following steps:
the method comprises the following steps of constructing a data base, researching the mutual winding, bonding and adsorption mechanisms among macromolecular chains, chain segments and functional groups in thick sauce and viscous food, analyzing the rheological characteristics of the thick sauce and the viscous food, and establishing a mathematical model.
In a second step, the relaxation time spectrum and the viscosity profile of the fluid are determined.
Thirdly, material selection of the discharge pipe is constructed, influences of the pipe diameter size, the shape, the fluid speed, the pressure, the temperature and the like on the viscosity and the relaxation time of the viscous food are researched, the influence mechanism is analyzed, parameters are optimized, and the purpose of controlling the viscosity and the relaxation time is achieved; the method is characterized by researching the action mechanism of the wall material and the surface structure in the pipe on the interface of the viscous food, mainly researching the action modes and the acting forces between different medium materials and macromolecules such as protein, sugar, grease, starch and the like, designing the surface of a micro-nano structure, researching the adsorption effects of the sizes, the appearances and the like of different micro-nano structures on different macromolecules, and achieving the purposes of reducing the flow resistance of the viscous food in a pipeline and improving the flow cutoff effect through material selection and structural design. And a theoretical research basis is provided for the design and optimization of the key structure of the filling machine.
Fourthly, optimizing parameters, researching the influence of the pipe diameter size, the shape, the fluid speed, the pressure, the temperature and the like on the viscosity and the relaxation time of the viscous food, analyzing the influence mechanism, optimizing the parameters and achieving the purpose of controlling the viscosity and the relaxation time;
and fifthly, analyzing and researching the surface structure and the inner wall of the discharge pipe and the action mechanism of a material viscous food interface.
And sixthly, designing a micro-nano structure, researching the action mechanism of the wall material and the surface structure in the pipe on the interface of the viscous food, mainly researching the action modes and the action forces between different medium materials and macromolecules such as protein, sugar, grease, starch and the like, designing the surface of the micro-nano structure, researching the adsorption effects of different micro-nano structure sizes, appearances and the like on different macromolecules, and achieving the purposes of reducing the flow resistance of the viscous food in a pipeline and improving the flow cutoff effect through material selection and structural design.
Seventhly, developing complete equipment, researching a control technology and an implementation scheme of quantitative filling precision aiming at soy sauce foods such as soybean paste, chili paste and tomato paste which contain particles or do not contain particles and have certain viscosity, and designing a high-viscosity filling valve system;
the foregoing is merely an example of the present invention and common general knowledge of known specific structures and features of the embodiments is not described herein in any greater detail. It should be noted that, for those skilled in the art, without departing from the structure of the present invention, several changes and modifications can be made, which should also be regarded as the protection scope of the present invention, and these will not affect the effect of the implementation of the present invention and the practicability of the patent. The scope of the claims of the present application shall be defined by the claims, and the description of the embodiments and the like in the specification shall be used to explain the contents of the claims.
Claims (5)
1. A research and development method of high-viscosity fluid filling and cap screwing integrated equipment is characterized by comprising the following steps: modeling by using rheological characteristics of thick sauce and viscous food, researching a flow breaking mechanism of the viscous food, obtaining a viscosity change curve of the food and a relaxation time spectrum of the food, optimizing the design of the inner wall of a discharge pipeline, and finally obtaining an optimal design scheme of the whole equipment.
2. The method of claim 1, wherein the apparatus further comprises: when the flow breaking mechanism of the viscous food is researched, the method mainly comprises the following steps;
(1) Modeling rheological properties of viscous food and thick paste; modeling rheological characteristics of viscous food and thick sauce, and establishing a relation model of viscosity, solvent molecular weight, solid content, temperature, pressure and shearing rate according to viscosity characteristics of the viscous food and the thick sauce by referring to a Cross-Arrhenius viscosity model:
in the formula eta 0 -zero shear viscosity, pas;
b-zero shear viscosity eta 0 Level of (2), molecular weight M with solvent w 3.4 And the volume fraction V of the solid filler in the food is in direct proportion, pas;
τ * -shear stress level, pa, of viscous food and puree rheology from newtonian transition zone to power law zone;
T b —η 0 sensitivity to temperature T, K;
β—η 0 sensitivity to pressure, m 2 /N；
n-flow index, and molecular weight M of the solvent w 3.4 And the volume fraction V of solid filler in the food is inversely proportional;
and further correcting the model according to thick sauce, viscous food, viscosity characteristics and special working condition conditions of food filling, developing a packaging container capable of realizing hot filling for realizing high-speed filling, considering the requirement of food products on processing temperature, and determining the maximum filling temperature to be T:
in the formula eta T -zero shear viscosity at filling temperature T, pa s;
b-level of zero shear viscosity, pa s;
τ * -shear stress level, pa, of the thick paste and viscous food product rheology from newtonian transition zone to power law zone;
β—η 0 sensitivity to filling pressure, m 2 /N；
n-the flow index;
the storage modulus G' (w) of the thick sauce and the viscous food is expressed by 5 Maxwell motion unit numbers by adopting a generalized Maxwell model j ) And dissipation modulus G' (w) j )：
In the formula: w is a j For shear oscillation frequency, 5 sets (. Lamda.) i ,g i ) Forming a discrete relaxation time spectrum of the thick paste and the viscous food;
(2) According to a capillary rheometer and a rotary rheometer, shear rate-viscosity data static viscosity data and dynamic viscosity curves of viscous food and thick sauce fluid are obtained through testing, and according to a rheological characteristic mathematical model, a test data curve is fitted according to a least square method to obtain a viscosity pressure coefficient, a shear stress level, the sensitivity of viscosity to filling pressure and a flow index coefficient in the model at a specific filling temperature, and a viscosity change curve is fitted; measuring the storage modulus and the energy consumption modulus under different frequencies according to a rotational rheometer, and calculating a fluid discrete relaxation time spectrum by adopting a linear regression analysis method;
(3) Predicting different material formulas according to the mode to provide basis for intelligent filling pipeline design;
(4) Optimizing the parameters of the pipeline in an actual test;
(5) The surface structure of the tapping pipe and the mechanism of action of the inner wall material on the viscous food interface are analyzed and studied.
3. The method for developing a high-viscosity fluid filling and cap screwing integrated device according to claim 2, wherein: in the step (1), the modeling of the rheological properties of the thick paste and the thick sauce is mainly to establish a mathematical model for predicting the rheological properties of the thick paste and the thick sauce by taking the polymerization degree, the branching degree and the functional group of macromolecules of the thick paste and the thick paste as parameters and the apparent viscosity and the relaxation time as unknowns.
4. The development method of the high-viscosity fluid filling and cap screwing integrated equipment according to claim 2, characterized in that: generating a relaxation time spectrum of the fluid and a viscosity change curve of the fluid in the step (2) mainly comprises the steps of obtaining static viscosity data and a dynamic viscosity curve of the filling fluid through testing by a capillary rheometer and a rotary rheometer, performing data fitting on the test data curve according to the rheological characteristic mathematical model determined in the step (1), determining a viscosity pressure coefficient, a shear stress level and the sensitivity of the viscosity to the filling pressure in the model at a specific filling temperature, and generating the viscosity change curve; fitting a fluid discrete relaxation time spectrum according to the storage modulus and the energy consumption modulus under different frequencies; establishing a prediction curve of the relaxation time and viscosity of the fluid and the temperature, pressure and flow speed state of the fluid.
5. The method for developing a high-viscosity fluid filling and cap screwing integrated device according to claim 2, wherein: establishing physical models of different pipeline structures and sizes in the step (3), and researching the viscosity and relaxation time of the thick sauce and the viscous food under different temperatures, pressures and flow rates; meanwhile, super-hydrophobic micro-nano structures are designed on the surfaces of different pipeline materials, contact angles and adhesion properties of thick sauce and viscous food on the surfaces are researched, and the pipeline material with the smallest material apparent viscosity and the smallest relaxation time is selected after statistics.
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