CN113144997B - Method and system for determining critical fluctuation rate and judging mixing uniformity in resonant sound mixing - Google Patents
Method and system for determining critical fluctuation rate and judging mixing uniformity in resonant sound mixing Download PDFInfo
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
- B01F35/00—Accessories for mixers; Auxiliary operations or auxiliary devices; Parts or details of general application
- B01F35/20—Measuring; Control or regulation
- B01F35/21—Measuring
- B01F35/211—Measuring of the operational parameters
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
- B01F31/00—Mixers with shaking, oscillating, or vibrating mechanisms
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
- B01F2215/00—Auxiliary or complementary information in relation with mixing
- B01F2215/04—Technical information in relation with mixing
- B01F2215/0413—Numerical information
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
- B01F2215/00—Auxiliary or complementary information in relation with mixing
- B01F2215/04—Technical information in relation with mixing
- B01F2215/0413—Numerical information
- B01F2215/0436—Operational information
- B01F2215/0477—Numerical time values
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
- B01F2215/00—Auxiliary or complementary information in relation with mixing
- B01F2215/04—Technical information in relation with mixing
- B01F2215/0413—Numerical information
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Abstract
The invention discloses a method and a system for determining critical fluctuation rate and judging mixing uniformity in resonant sound mixing, wherein the method comprises the following steps: acquiring the resonant sound mixed acceleration of the mixed sample according to the time sequence to obtain an acceleration sample set; dividing samples in the acceleration sample set into a plurality of sample subsets according to a time sequence, wherein each sample subset comprises N continuous acceleration values; calculating the acceleration fluctuation rate of each sample subset, determining the corresponding acceleration fluctuation rate when the mixed samples are uniformly mixed as the critical acceleration fluctuation rate through sampling physical and chemical analysis, acquiring the acceleration fluctuation rate of each sample subset in real time for the samples to be mixed, and stopping mixing when k continuous acceleration fluctuation rates are less than or equal to the critical fluctuation rate, wherein k is more than or equal to 2, and the samples to be mixed reach a uniform state.
Description
Technical Field
The invention belongs to the technical field of material mixing degree detection, relates to resonance sound mixing uniformity detection, and particularly relates to a method and a system for determining critical fluctuation rate and judging mixing uniformity in resonance sound mixing.
Background
The resonant sound mixing technology is a technology based on vibration macro mixing and sound field micro mixing coupling action, which is based on the low frequency (about 60 Hz) and the large acceleration (100g, g = 9.8m/s) of resonant sound mixing equipment 2 ) And (5) vibrating in a reciprocating manner. Under the condition of low-frequency large acceleration vibration, the material to be mixed is fluidized to generate macroObserving a vibration mixing vortex; meanwhile, the large acceleration vibration excites a sound field (pressure wave) at the bottom of the mixing container, and the sound field generates a couple effect on the materials when propagating inside the materials to form micro-scale mixing (the scale is less than 50 um). The resonance sound mixing has the advantages of whole-field mixing, no paddle intervention, high mixing efficiency and the like, so that the resonance sound mixing is widely applied to aspects of energetic materials, foods, pharmacy, chemical eutectic and the like, and compared with a traditional mixing mode, the mixing efficiency can be improved by 2-10 times.
The same as the problems faced by all mixing modes, the resonance sound mixing also faces the problem of evaluating the mixing uniformity so as to accurately judge the mixing end point and prevent resource waste caused by insufficient mixing or over mixing. The characterization modes of the mixing uniformity comprise a direct sampling component test, a sampling electron microscope observation, an indirect sampling density test, a sampling hardness test, a sampling chromaticity test and the like. However, there are three main problems brought by sampling test, the first is long period of off-line sampling test, the second is large error of sampling test, and the third is that the local sampling point is used for judging the whole mixing uniformity, which has a certain limitation.
In order to improve the efficiency and accuracy of the mixing uniformity judgment, an online mixing uniformity judgment method is always an object of the efforts of scientific researchers. At the present stage, a better online mixing uniformity determination method is developed and is a near infrared spectroscopy method, the uniformity is determined by utilizing different material states in the mixing process and different degrees of reflection and absorption of the near infrared spectrum, and when the reflection and absorption parameters of the spectrum are consistent, the mixing is considered to be uniform, so that the method is more applied to the pharmaceutical industry. However, there are certain limitations to the application of near infrared spectroscopy to some industrial applications, and three main aspects are presented. Firstly, the near-infrared device is sensitive to environmental influence, the noise, temperature and humidity, vibration and the like of an installation occasion of the near-infrared device are stable, and otherwise, the test accuracy is influenced; secondly, the near-infrared emitting and receiving device must be installed within 2cm of the surface of the measured material, and a sapphire glass window is needed, so that the installation process is complex and the cost is high; third, the uniformity of the near infrared spectroscopy detection is only in response to the surface of the material, since light cannot penetrate the interior of the material, the detection may be affected by the material being stuck to the surface of the sapphire glass window.
The resonance sound mixing is characterized by large acceleration mixing, and the process mainly has three problems in the aspect of uniformity detection: firstly, the mixing speed is high, generally 10-20min, and for materials such as liquid phase, powder and the like, the time for achieving uniform mixing is only minutes or tens of seconds, so that the offline detection is extremely inconvenient for judging the uniformity; secondly, the mixing process container is vibrated with large amplitude and large acceleration, the installation of the near-infrared device is inconvenient, and the test accuracy is difficult to ensure.
Disclosure of Invention
In order to solve the defects in the prior art, the invention provides a method and a system for determining the critical fluctuation rate and judging the mixing uniformity in resonant sound mixing, and solves the defects of long period and large error in the traditional sampling uniformity judgment, harsh installation conditions, obvious environmental influence on the testing accuracy and the like in the online method.
In order to solve the technical problems, the invention adopts the following technical scheme:
the method for determining the critical fluctuation rate in the resonant sound mixing comprises the following steps:
G i1 for the first acceleration value in the ith subset of samples,
is the average of the accelerations in the ith subset of samples; g imax Is the maximum value of acceleration, G, in the ith subset of samples imin Is the minimum of the accelerations in the ith subset of samples;
is the jth acceleration value;
generating an acceleration fluctuation rate curve by the acceleration fluctuation rate values of all the sample subsets;
Preferably, the number n of the acceleration samples is more than or equal to 10, and the sampling step length of the acceleration is 1-10 s.
Preferably, in the step 2, N is more than or equal to 3 and less than or equal to 6.
Preferably, in the step 5, k is more than or equal to 5 and less than or equal to 15.
The invention also discloses a method for judging the mixing uniformity of the resonance sound, which comprises the following steps: acquiring acceleration in real time in the mixing process of the materials to be mixed to obtain an acceleration data set; then calculating the acceleration fluctuation rate according to the method from the step 2 to the step 3, and when k continuous acceleration fluctuation rates are less than or equal to the critical fluctuation rate delta c And when k is more than or equal to 2, stopping mixing when the mixed sample reaches a uniform state.
The invention also discloses a system for judging the mixing uniformity of the resonance sound, which comprises: an acceleration acquisition module, a data processing module, an acceleration fluctuation rate curve generation module and a mixed state judgment module, wherein,
the acceleration acquisition module is used for acquiring the resonance sound mixed acceleration of the mixed sample in real time to obtain an acceleration data set;
the data processing module comprises a data dividing module and an acceleration fluctuation rate calculating module;
the data dividing module is used for dividing data in the acceleration data set into a plurality of sample subsets according to a time sequence, each sample subset comprises N continuous acceleration values, and the ith sample subset is { G } j ,G j+1 ,...,G j+N-1 J =1, 2., N +1-N, i = j, N ≧ 2, N is the number of samples;
the acceleration fluctuation rate calculation module is used for calculating the acceleration fluctuation rate delta of each sample subset i Calculated by any one of the formulas (1) to (3),
G i1 for the first acceleration value in the ith subset of samples,
is the average of the accelerations in the ith subset of samples; g imax Is the maximum value of acceleration, G, in the ith subset of samples imin Is the minimum of the accelerations in the ith sample subset;
is the jth acceleration value;
the acceleration fluctuation rate curve generation module is used for generating an acceleration fluctuation rate curve from the acceleration fluctuation rate values of all the sample subsets;
the mixing state judgment module is used for judging whether the resonant sound mixed material is uniform or not according to the acceleration fluctuation rate and the critical acceleration fluctuation rate, and when the k continuous acceleration fluctuation rates are delta i Less than or equal to the critical acceleration fluctuation rate delta c When k is more than or equal to 2, the resonant sound mixed material reaches a uniform state, and the mixing is stopped.
Specifically, the acceleration acquisition module adopts an acceleration sensor installed on the mixing container to perform acquisition.
Preferably, the number n of the acceleration data of the acceleration acquisition module is more than or equal to 10, and the sampling step length of the acceleration is 1-10 s.
Preferably, in the data division module, N is more than or equal to 3 and less than or equal to 6.
Preferably, in the mixed state judgment module, k is greater than or equal to 5 and less than or equal to 15.
Compared with the prior art, the invention has the beneficial effects that:
the method of the invention combines the parameter acceleration of the resonance sound mixing process to judge the uniformity of the mixed material, and has the advantages of on-line, real-time and accuracy; the system is simple and reliable and is not influenced by environments such as vibration, temperature and humidity and the like because third-party test equipment is not introduced; the method of the invention judges the uniformity of the whole mixed flow field, and avoids the influence of wall surfaces, sampling areas and the like on the uniformity judgment of local sampling, near infrared and other methods.
Drawings
Fig. 1 is a graph of the acceleration and its fluctuation rate acquired in example 1.
Fig. 2 is a graph of the acceleration and its fluctuation rate acquired in example 2.
Fig. 3 is a graph of the acceleration and its fluctuation rate acquired in example 3.
Detailed Description
The resonant sound mixing mode has a remarkable characteristic that the vibration acceleration along with the whole mixing process is obviously influenced by the material state besides the material quality, the material type, the input energy and the like. When the mass, the type and the input energy of the materials are fixed, the change of the material state is the only factor influencing the mixing acceleration. In the initial stage of mixing, the materials are uneven, the state change is obvious along with the mixing, and the fluctuation of the mixing acceleration is severe; along with the mixing, the materials are gradually uniform, the state tends to be consistent and stable, and the fluctuation of the mixing acceleration is reduced, so that the vibration acceleration is used as the index for judging the mixing uniformity. On the basis, the resonance sound mixing uniformity judgment method based on the acceleration fluctuation rate is provided, the method firstly needs to determine the critical fluctuation acceleration, and specifically comprises the following steps of 1-4:
G i1 the first acceleration value in the ith sample subset is used, so that each acceleration sample can only participate in the calculation of the primary fluctuation rate;
the average value of the acceleration in the ith sample subset is the sum of all acceleration values in the ith sample subset divided by N; g imax Is the maximum value of the acceleration in the ith sample subset; g imin Is the minimum of the accelerations in the ith sample subset;
is the jth acceleration value and the value is located in the ith sample subset, the acceleration fluctuation rate delta in the formula (3) i Is the standard deviation of the samples of the acceleration in the ith subset of samples.
Generating an acceleration fluctuation rate curve from the acceleration fluctuation rate values of all the sample subsets;
sequentially sampling at different sampling times to perform physical and chemical analysis until a time point of uniform mixing is determined, and taking the time point as a critical time point; according to the acceleration fluctuation rate curve, taking the acceleration fluctuation rate corresponding to the critical time point as the critical acceleration fluctuation rate delta c 。
After the critical fluctuation rate of the acceleration is obtained, when the mixing uniformity of other samples is judged, the following method is adopted for judging, specifically:
for a certain sample to be mixed, acquiring acceleration in real time in the mixing process to obtain an acceleration data set; then calculating the acceleration fluctuation rate according to the method from the step 2 to the step 3, and when k continuous acceleration fluctuation rates are less than or equal to the critical fluctuation rate delta c When k is more than or equal to 2, preferably, k is more than or equal to 5 and less than or equal to 15, which indicates that the sample to be mixed reaches a uniform state, and the mixing can be stopped.
The sample material to be mixed in the present invention is the same as the sample material to be mixed.
An example of a specific cluster analysis method employed by the present invention is given below. It should be noted that the present invention is not limited to the following embodiments, and all equivalent changes based on the technical solutions of the present application fall into the protection scope of the present invention.
Example 1
The embodiment discloses a process for determining critical fluctuation rate in resonant sound mixing based on acceleration fluctuation rate, which specifically comprises the following steps:
the mixed material in the embodiment is a poured PBX explosive with 84% of solid content, an acceleration sensor arranged on mixing equipment is adopted to acquire acceleration, the sampling step length delta t of the mixing acceleration is =2s, and the total number of samples n =182;
dividing the sample set into a plurality of sample subsets, each sample subset consisting of 3 acceleration samples, i.e. N =3, the sample subset being { G } 1 ,G 2 ,G 3 },{G 2 ,G 3 ,G 4 },…,{G 180 ,G 181 ,G 182 }。
Acceleration fluctuation rate delta of each sample subset i Calculated according to the following formula:
at acceleration fluctuation rate delta i In the calculation, only the primary fluctuation rate calculation is performed according to each acceleration sample in the embodiment, for example, for the first sample subset, the acceleration sample is included as G 1 、G 2 、G 3 In the calculation of the acceleration fluctuation rate, only G is used 1 Making a difference value with the average value; for the second acceleration cell, the sample containing acceleration is G 2 、G 3 、G 4 In the calculation of the acceleration fluctuation ratio, only G is used 2 The difference is made from the average.
The solid line in fig. 1 is an acceleration fluctuation rate curve of N = 3. Through sampling test, the time point of uniform mixing is obtainedAbout 280 s; determining the corresponding fluctuation rate of about 0.02 on the fluctuation rate curve, and setting the critical fluctuation rate delta c ＝0.02。
In the same manner as described above, the acceleration fluctuation rate is calculated once more with N =6, and the dashed dotted line in fig. 1 is an acceleration fluctuation rate curve with N = 6. Likewise, the corresponding critical fluctuation ratio is 0.02.
The test material of this example is also a cast PBX explosive with 84% solids; in the mixing process, acquiring acceleration in real time according to the above thought, dividing samples and calculating the fluctuation rate of the acceleration; when the 5 consecutive acceleration fluctuation rates (i.e., k = 5) are equal to or less than 0.02, the mixing is stopped, corresponding to approximately 286s in fig. 1. It can also be seen from fig. 1 that when the mixing time reaches around 280s, the acceleration fluctuation becomes significantly smaller, tending to a steady value.
Example 2
The mixed material in the embodiment is a poured PBX explosive with 84% of solid content, the sampling step length delta t =2s of the mixing acceleration in the resonant sound mixing process, and the total number of samples n =182; each acceleration unit consists of 3 acceleration samples, i.e. N =3; acceleration fluctuation rate delta of each sample subset i Calculated according to the following formula:
in the same manner, the acceleration fluctuation rate was calculated again in accordance with N = 6.
Fig. 2 shows the acceleration and the acceleration fluctuation rate thereof in the present embodiment, where the solid line shows the acceleration fluctuation rate of N =3, and the dashed dotted line shows the acceleration fluctuation rate of N = 6.
Through sampling test, the time point of uniform mixing is about 280s, the fluctuation rate corresponding to the point is determined to be about 0.05 on the fluctuation rate curve, and the critical fluctuation rate delta is set c ＝0.05。
In this embodiment, if the fluctuation rate of 5 continuous accelerations (i.e. k = 5) is less than or equal to 0.05, the mixture is uniform, and the corresponding time in 2 is about 290s.
Example 3
The mixed material in the embodiment is a poured PBX explosive with 84% of solid content, the sampling step length delta t =2s of the mixing acceleration in the resonant sound mixing process, and the total number of samples n =182; each acceleration unit consists of 3 acceleration samples, i.e. N =3; fluctuation rate δ of acceleration of each sample subset i Is the standard deviation of the samples for that subset of samples,
at acceleration fluctuation rate delta i During calculation, only the first time fluctuation rate calculation is involved in each acceleration sample in this embodiment, for example, for the first sample subset, the acceleration sample G is included 1 、G 2 、G 3 In the calculation of the acceleration fluctuation ratio, only G is used 1 Making a difference value with the average value; for the second acceleration cell, the sample containing acceleration is G 2 、G 3 、G 4 In the calculation of the acceleration fluctuation rate, only G is used 2 The difference is made from the average.
In the same manner, N =6 was used to calculate the acceleration fluctuation rate again.
Fig. 3 shows the acceleration and the acceleration fluctuation rate thereof in the present embodiment, where the solid line shows the acceleration fluctuation rate of N =3, and the dashed dotted line shows the acceleration fluctuation rate of N = 6.
Through sampling test, the time point of uniform mixing is about 280s, the fluctuation rate corresponding to the time point is determined to be about 1.4 on the fluctuation rate curve, and the critical fluctuation rate delta is set c ＝1.4。
In this embodiment, if k =5 continuous fluctuation ratios are equal to or less than 1.4, the mixture is uniform, and the corresponding time in fig. 3 is about 290s.
Example 4
The embodiment discloses a resonance sound mixing uniformity judgment system based on acceleration fluctuation rate, which comprises: an acceleration acquisition module, a data processing module, an acceleration fluctuation rate curve generation module and a mixed state judgment module, wherein,
the acceleration acquisition module is used for acquiring the resonant sound mixed acceleration of the mixed sample according to the time sequence to obtain an acceleration data set; specifically, the sampling is performed using an acceleration sensor mounted on the mixing container. The acceleration sampling step length of the present embodiment is 1 to 10s.
The data processing module comprises a data dividing module and an acceleration fluctuation rate calculating module; specifically, the data dividing module is configured to divide samples in the acceleration sample set into a plurality of sample subsets according to a time sequence, where each sample subset includes N consecutive acceleration values, and an ith sample subset is { G } j ,G j+1 ,…,G j+N-1 J =1,2, \8230, N +1-N, i = j, in this embodiment, N is greater than or equal to 3 and less than or equal to 6, N is the sampling number;
the acceleration fluctuation rate calculation module is used for calculating the acceleration fluctuation rate delta of each sample subset i The calculation formula adopts any one of formulas (1) to (3);
the acceleration fluctuation rate curve generation module is used for generating an acceleration fluctuation rate curve from the acceleration fluctuation rate values of all the sample subsets and displaying the curve;
the mixing state judgment module is used for judging whether the resonant sound mixed material is uniform or not according to the acceleration fluctuation rate and the critical acceleration fluctuation rate, and particularly when k acceleration fluctuation rates delta are continuous i Less than or equal to the critical acceleration fluctuation rate delta c When the material is mixed, the resonance sound is generated, and the material is in a uniform state; k is more than or equal to 2, preferably, k is more than or equal to 5 and less than or equal to 15. And then according to the judgment instruction output by the module, ending the resonance mixing process of the mixing container.
Claims (8)
1. The method for determining the critical fluctuation rate in the resonant sound mixing is characterized by comprising the following steps of:
step 1, acquiring resonance sound mixed acceleration of a mixed sample according to a time sequence to obtain an acceleration sample set;
step 2, dividing the samples in the acceleration sample set into a plurality of sample subsets according to the time sequence, wherein each sample subset comprises N continuous acceleration values,the ith sample subset is { G } j ,G j+1 ,...,G j+N-1 J =1, 2., N +1-N, i = j, N ≧ 2, N being the number of samples;
step 3, calculating the acceleration fluctuation rate delta of each sample subset i Acceleration fluctuation rate delta i Calculated by any one of the formulas (1) to (3),
G i1 for the first acceleration value in the ith subset of samples,
is the average of the accelerations in the ith subset of samples; g imax Is the maximum value of the acceleration, G, in the ith sample subset imin Is the minimum of the accelerations in the ith sample subset;
is the jth acceleration value;
generating an acceleration fluctuation rate curve by the acceleration fluctuation rate values of all the sample subsets;
step 4, determining a corresponding time point when the mixed sample is uniformly mixed through sampling physical and chemical analysis, and taking the time point as a critical time point; according to the acceleration fluctuation rate curve, taking the acceleration fluctuation rate corresponding to the critical time point as the critical acceleration fluctuation rate delta c 。
2. The method for determining the critical fluctuation rate in resonant acoustic mixing according to claim 1, wherein in the step 1, the number n of acceleration samples is greater than or equal to 10, and the sampling step length of the acceleration is 1-10 s.
3. The method for determining a critical fluctuation rate in a resonant acoustic mixing according to claim 1, wherein in the step 2, N is 3. Ltoreq. N.ltoreq.6.
4. The method for determining the mixing uniformity of the resonant sound is characterized by comprising the following steps: acquiring acceleration in real time in the mixing process of the materials to be mixed to obtain an acceleration data set; the acceleration fluctuation rate and the critical fluctuation rate δ are then calculated according to the method of claim 1 c When k successive acceleration fluctuation rates less than or equal to a critical fluctuation rate delta occur c When k is more than or equal to 5 and less than or equal to 15, the mixing is stopped when the sample to be mixed reaches a uniform state.
5. A system for determining the uniformity of a mixture of resonant sounds, comprising: an acceleration acquisition module, a data processing module, an acceleration fluctuation rate curve generation module and a mixed state judgment module, wherein,
the acceleration acquisition module is used for acquiring the resonance sound mixed acceleration of the mixed sample in real time to obtain an acceleration data set;
the data processing module comprises a data dividing module and an acceleration fluctuation rate calculating module;
the data dividing module is used for dividing data in the acceleration data set into a plurality of sample subsets according to a time sequence, each sample subset comprises N continuous acceleration values, and the ith sample subset is { G } j ,G j+1 ,...,G j+N-1 J =1, 2., N +1-N, i = j, N ≧ 2, N being the number of samples;
the acceleration fluctuation rate calculation module is used for calculating the acceleration fluctuation rate delta of each sample subset i Calculated by any one of the formulas (1) to (3),
G i1 for the first acceleration value in the ith subset of samples,
is the average of the accelerations in the ith subset of samples; g imax Is the maximum value of acceleration, G, in the ith subset of samples imin Is the minimum of the accelerations in the ith sample subset;
is the jth acceleration value;
the acceleration fluctuation rate curve generation module is used for generating acceleration fluctuation rate curves from the acceleration fluctuation rate values of all the sample subsets;
the mixing state judgment module is used for judging whether the resonant sound mixed material is uniform or not according to the acceleration fluctuation rate and the critical acceleration fluctuation rate, and when the acceleration fluctuation rates are continuous for k times, the mixing state judgment module judges whether the resonant sound mixed material is uniform or not i Less than or equal to the critical acceleration fluctuation rate delta c When k is more than or equal to 5 and less than or equal to 15, the resonance sound is used for mixing the materials to be uniform, and the mixing is stopped.
6. The system for determining the uniformity of a resonant acoustic mixing according to claim 5, wherein the acceleration acquisition module acquires the signals using an acceleration sensor mounted on the mixing container.
7. The system for determining the uniformity of mixing of resonant sound according to claim 5, wherein the number n of acceleration data of the acceleration acquisition module is not less than 10, and the sampling step length of the acceleration is 1-10 s.
8. The resonant acoustic mixing uniformity determination system of claim 5, wherein in the data partitioning module, N is 3. Ltoreq. N.ltoreq.6.
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