CN117906716A - Foam detection method, visual identifier and defoaming system - Google Patents
Foam detection method, visual identifier and defoaming system Download PDFInfo
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Abstract
The invention provides a foam detection method, a visual identifier and a defoaming system, and relates to the technical field of fermentation production, wherein the foam detection method comprises the steps of acquiring a liquid level real-time image in a fermentation tank and a tank wall image of the fermentation tank; calibrating the height of the fermentation tank in the tank wall image to obtain a limit height value and a height scale mark of the fermentation tank; inputting the liquid level real-time image into an identification model, and identifying a pure liquid level area and a foam surface area; according to the height scale marks, the number of the pure liquid surface areas and the number of the foam surface areas, determining a pure liquid surface height value and a foam surface height value, and eliminating the influence of liquid surface fluctuation; according to the pure liquid level height value, the foam surface height value and the limit height value, the determined foam quantity is more attached to the real situation, and the detection result is more accurate; according to the foam quantity and a preset foam threshold value, a control signal is generated, defoaming operation is guided more accurately, and the adding time and the adding parameters of the defoaming agent are controlled, so that the final product meets the requirements.
Description
Technical Field
The invention relates to the technical field of fermentation production, in particular to a foam detection method, a visual identifier and a defoaming system.
Background
In the fermentation process, foam is normal, but excessive persistent foam brings a lot of adverse effects to fermentation, can reduce the filling coefficient of a fermentation tank, and can cause a large amount of escape of foam from an exhaust pipe or the foam can possibly leak out from an axle seal when the foam is not controlled, so that the probability of contaminating miscellaneous bacteria is increased. When the foam is serious, the normal operation of ventilation stirring can be influenced, thereby preventing the respiration of beneficial bacteria and causing abnormal metabolism or autolysis of bacteria. Thus, there is a need to control the volume of foam in a timely manner.
In the fermentation process, the foam volume is detected firstly, so that the foam can be controlled at proper time, and in the prior art, an ultrasonic liquid level meter, a radar level meter or a capacitive defoaming electrode can be used for detecting the foam. However, as the form, color and penetrability of the fermentation liquid of different products and the foam generated in different fermentation stages are different, interference is generated on the reflection of ultrasonic waves or radar waves, and foam detection data are distorted; meanwhile, due to ventilation and mechanical stirring in the fermentation tank, the liquid level of the fermentation liquid fluctuates, ultrasonic waves or radar waves are scattered, so that interference is generated on the detection of fermentation foam, and the detection result is inaccurate. In addition, when a large amount of viscous foam is generated in the fermentation liquid, the phenomena of hanging materials and scaling can occur on the detection rod of the capacitive defoaming electrode, and the probe is easy to generate larger measurement errors, so that the electrode detection is even completely distorted. The distortion of foam detection can cause serious misleading to the foam control process, even can lead to mass production failure, and cause great loss to enterprises.
Disclosure of Invention
The invention aims to solve the problems that the detection data of the existing foam detection method is easy to distort, foam control is misled, and mass production fails.
To solve the above problems, in a first aspect, the present invention provides a foam detection method, including:
Acquiring a liquid level real-time image in a fermentation tank and a tank wall image of the fermentation tank;
calibrating the height of the fermentation tank in the tank wall image to obtain a limit height value and a height scale mark of the fermentation tank;
inputting the liquid level real-time image into an identification model, and identifying a pure liquid level area and a foam surface area;
Determining a pure liquid level height value and a foam surface height value according to the height scale marks, the number of pure liquid level areas and the number of foam surface areas;
determining the foam amount according to the pure liquid level height value, the foam surface height value and the limit height value;
and generating a control signal according to the foam quantity and a preset foam threshold, wherein the control signal is used for controlling the on-off of a defoaming agent adding pipeline and the adding parameters of the defoaming agent.
Optionally, the determining the pure liquid level value and the foam surface height value according to the height scale line, the number of pure liquid level areas and the number of foam surface areas includes:
when the number of the pure liquid level areas is equal to 1 and the number of the foam surface areas is 0, positioning the positions of the height scale marks corresponding to the pure liquid level areas to obtain the pure liquid level height value, and enabling the foam surface height value to be equal to the pure liquid level height value.
Optionally, the determining the pure liquid level value and the foam surface height value according to the height scale line, the number of pure liquid level areas and the number of foam surface areas includes:
Analyzing whether there is the pure liquid surface area in contact with the tank wall of the fermenter among the plurality of pure liquid surface areas when the number of the pure liquid surface areas is greater than or equal to 1 and the number of the foam surface areas is greater than or equal to 1;
When the pure liquid surface areas contacted with the tank wall of the fermentation tank exist in the pure liquid surface areas, positioning the positions of the height scale marks corresponding to the pure liquid surface areas contacted with the tank wall of the fermentation tank to obtain the pure liquid surface height value;
When there is no pure liquid surface area in contact with the tank wall of the fermentation tank in a plurality of pure liquid surface areas, optionally one pure liquid surface area, and determining the pure liquid surface height value according to the installation position of the image acquisition device and the selected position of the pure liquid surface area;
and obtaining the foam surface height value according to the position of the height scale mark corresponding to the foam surface area.
Optionally, the determining the pure liquid level value and the foam surface height value according to the height scale line, the number of pure liquid level areas and the number of foam surface areas includes:
When the number of the pure liquid level areas is 0 and the number of the foam surface areas is equal to 1, obtaining the foam surface height value according to the positions of the height scale marks corresponding to the foam surface areas;
and taking the last pure liquid level value determined before the current time point as the pure liquid level value of the current time point.
Optionally, said determining the amount of foam based on said pure liquid level value, said foam level value, and said limit height value comprises:
determining a difference value between the foam surface height value and the pure liquid surface height value, and marking the difference value as a first difference value;
Determining the difference between the limit height value and the pure liquid level height value, and recording the difference as a second difference;
and dividing the first difference value by the second difference value to obtain the foam quantity.
In a second aspect, the present invention also provides a visual identifier comprising a memory, a processor and a computer program stored on the memory and executable on the processor, which when executed by the processor implements the foam detection method as above.
In a third aspect, the invention also provides a defoaming system, which comprises the visual identifier, an atomizer, a first self-control valve and a defoaming agent adding pipeline, wherein the visual identifier is used for determining the foam amount of the surface of fermentation liquor in a fermentation tank and outputting a control signal; the first self-control valve is arranged on the defoamer adding pipeline; the atomizer is used for setting up the inside of fermentation cylinder, the atomizer with the one end of defoaming agent adds the pipeline links to each other, the other end of defoaming agent adds the pipeline and is used for letting in aseptic defoaming agent.
Optionally, the defoaming system further comprises a second self-control valve, a first remote thermometer, a first steam valve and a first steam pipeline; the second self-control valve is arranged on the defoamer adding pipeline and is connected with one end, far away from the fermentation tank, of the first self-control valve; the first remote thermometer is arranged on the defoaming agent adding pipeline between the first self-control valve and the fermentation tank and is used for measuring the temperature in the defoaming agent adding pipeline, and the control signal output end of the first remote thermometer is respectively connected with the control end of the first steam valve and the control end of the first self-control valve; one end of the first steam pipeline is communicated with the defoaming agent adding pipeline between the first self-control valve and the second self-control valve, the other end of the first steam pipeline is used for introducing clean steam, and the first steam valve is arranged on the first steam pipeline.
Optionally, the defoaming system further comprises a second remote thermometer, a third steam valve, a second steam pipeline, an exhaust pipeline and a first exhaust valve; the second remote-transmission thermometer is arranged on the defoamer adding pipeline between the second self-control valve and the sterile defoamer inlet and is used for measuring the temperature in the defoamer adding pipeline, and the control signal output end of the second remote-transmission thermometer is respectively connected with the control end of the third steam valve and the control end of the first exhaust valve; the third steam valve is arranged on the second steam pipeline, one end of the second steam pipeline is communicated with the defoamer adding pipeline between the second remote thermometer and the sterile defoamer inlet, and the other end of the second steam pipeline is used for introducing the clean steam; one end of the exhaust pipeline is communicated with one end of the second self-control valve, which is far away from the first self-control valve, and the first exhaust valve is arranged on the exhaust pipeline.
Optionally, the defoaming system further comprises a second steam valve, a fourth steam valve and a second exhaust valve, wherein the second steam valve is installed on the first steam pipeline, the fourth steam valve is installed on the second steam pipeline, the second exhaust valve is installed on the exhaust pipeline, and the control signal output end of the first remote thermometer is connected with the control end of the second steam valve; and the control signal output end of the second remote thermometer is respectively connected with the control end of the fourth steam valve and the control end of the second exhaust valve.
Compared with the prior art, the invention has the following beneficial effects:
The invention provides a foam detection method, a visual identifier and a defoaming system, which are used for acquiring a liquid level real-time image in a fermentation tank and a tank wall image of the fermentation tank; firstly, calibrating the height of the fermentation tank in the tank wall image to obtain a limit height value and a height scale mark of the fermentation tank so as to position the height of the liquid level in subsequent production; the liquid level real-time image is input into the recognition model, and the recognition model can accurately recognize the pure liquid level area and the foam surface area because the foam surface is obviously different from the pure liquid level; according to the identified pure liquid level area and foam surface area, a pure liquid level height value and a foam surface height value can be positioned corresponding to the height scale mark, even if the liquid level fluctuates at this time, the pure liquid level height value and the foam surface height value can synchronously change, according to the pure liquid level height value and the limit height value, the residual space except the space occupied by the fermentation liquid in the fermentation tank at this time can be analyzed, according to the pure liquid level height value and the foam surface height value, the space occupied by the foam can be analyzed, the influence of the fluctuation of the liquid level can be eliminated, the influence on the analysis of the foam quantity is not large, the determined foam quantity is more fit with the real situation, the detection result is more accurate, a control signal is generated according to the foam quantity and the preset foam threshold value, the defoaming operation is guided more accurately, the adding time and the throwing parameter of the defoaming agent are controlled, and the final product meets the requirements.
Drawings
FIG. 1 is a schematic flow chart of a foam detection method according to an embodiment of the present invention;
FIG. 2 is a schematic diagram showing the structure of a visual identifier according to an embodiment of the present invention;
Fig. 3 shows a schematic structural diagram of a defoaming system according to an embodiment of the present invention.
Reference numerals illustrate:
1. A fermentation tank; 2. an atomizer; 3. a visual identifier; 4. a first self-control valve; 5. a second self-control valve; 6. a first steam valve; 7. a second steam valve; 8. a first exhaust valve; 9. a second exhaust valve; 10. a third steam valve; 11. a fourth steam valve; 12. a first remote thermometer; 13. a second remote thermometer.
Detailed Description
In order that the above objects, features and advantages of the invention will be readily understood, a more particular description of the invention will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings.
It is noted that the terms "first," "second," and the like in the description and claims of the invention and in the foregoing figures are used for distinguishing between similar objects and not necessarily for describing a particular sequential or chronological order. It is to be understood that the data so used may be interchanged where appropriate such that the embodiments of the invention described herein may be implemented in sequences other than those illustrated or otherwise described herein.
In the description of the present specification, the descriptions of the terms "embodiment," "one embodiment," and the like mean that a particular feature, structure, material, or characteristic described in connection with the embodiment or embodiment is included in at least one embodiment or implementation of the present invention. In this specification, schematic representations of the above terms do not necessarily refer to the same examples or implementations. Furthermore, the particular features, structures, materials, or characteristics may be combined in any suitable manner in any one or more embodiments or implementations.
Fig. 1 shows a schematic flow chart of a foam detection method according to an embodiment of the present invention, where the foam detection method includes:
S1: and acquiring a liquid level real-time image in the fermentation tank and a tank wall image of the fermentation tank.
Specifically, as shown in fig. 3, a fermenter 1 is an apparatus for a microbial fermentation process for producing various biological products such as alcohol, yogurt, soy sauce, etc. It provides an environment that controls the temperature, oxygen and nutrient supply to promote the growth and metabolic activity of microorganisms. Fermentation broth refers to the liquid used in the fermentation process. Fermentation broths can be produced by growth and propagation of microorganisms (e.g., yeasts) in a suitable environment. These microorganisms decompose organic substances and produce useful compounds such as alcohol, lactic acid, acetic acid, etc. Fermentation broths are widely used in the food and beverage industry, for example, for brewing beer, wine, yogurt, soy sauce, and the like. Aeration agitation and partial metabolites of the microorganisms in the fermentation are responsible for foam generation. Foam is a colloidal system in which a gas is dispersed in a small amount of liquid. Depending on the nature of the fermentation broth, there are two types of foam, one type being present on the surface of the broth, the proportion of the gas phase being particularly high, and there being a distinct boundary between the foam and the liquid below it; the other is in the viscous fermentation liquor, the foam is uniform and fine in surface and relatively stable, and the proportion of the gas phase is gradually increased from bottom to top. The foam amount referred to below refers to the amount of foam present on the surface of the fermentation broth. The liquid level in the fermentation tank 1 is monitored in real time, the liquid level in the fermentation tank is photographed through the camera, a liquid level real-time image is obtained, meanwhile, in the initial stage of monitoring, a tank wall image of the fermentation tank is required to be photographed and obtained, so that the height scale is calibrated on the tank wall, and when the height scale is calibrated, the same height can be calibrated on the periphery of the tank wall to form a circular scale mark, namely, each height is provided with a circular scale mark attached to the tank wall.
S2: and calibrating the height of the fermentation tank in the tank wall image to obtain the limit height value and the height scale mark of the fermentation tank.
Specifically, the scale mark in the height direction is marked on the tank wall image so as to facilitate the subsequent recognition of the liquid level height, in addition, the mark can be marked on other parts fixed in the tank body besides the height recognition on the tank wall image, but the tank body of the fermentation tank is equipment necessary for fermentation, so that the height scale mark is marked on the tank wall image of the fermentation tank uniformly so as to facilitate uniform management and height data extraction.
S3: and inputting the liquid level real-time image into a recognition model to recognize the pure liquid level region and the foam surface region.
Specifically, the recognition model may be a deep neural network model, and for different products, training of the recognition model is required before the fermenter and its corresponding recognition model are put into use for the first time. Acquiring a pure liquid level image, a pure foam surface image and a part of foam surface image in the production process of the product to form a training set, and marking a pure liquid level area and a foam surface area of each image in the training set; and training the recognition model by adopting a training set, updating parameters of the recognition model so that errors between recognition results output by the recognition model and the actual marking area are within a preset error range, thus obtaining the trained recognition model, and then putting the recognition model into use to recognize a pure liquid level area and a foam surface area in the liquid level real-time image.
S4: and determining a pure liquid level height value and a foam surface height value according to the height scale marks, the number of the pure liquid level areas and the number of the foam surface areas.
Specifically, since no bubbles are generated in the fermentation tank at first in the fermentation process of the product, the bubbles are pure liquid level, but as the fermentation advances, the liquid level starts to generate bubbles, but the bubbles appear randomly, so that the bubbles can be generated in one area, and the bubbles can be generated in a plurality of areas sequentially or simultaneously, a plurality of bubble surface areas can appear at the moment, and the bubble surface areas can divide the pure liquid level into a plurality of areas until the whole liquid level is filled with the bubbles, and only the pure bubble surface is left. According to the positions of the scale marks corresponding to the foam surface area and the pure liquid surface area, the pure liquid surface height value and the foam surface height value can be obtained.
S5: and determining the foam amount according to the pure liquid level height value, the foam surface height value and the limit height value.
In particular, since excessive foam amount may cause foam overflow, increasing the probability of contamination by bacteria, it is necessary to control the continued increase of foam amount in time. The residual space except the space occupied by the fermentation liquid in the fermentation tank at the moment can be analyzed according to the pure liquid level height value and the limit height value, and the space occupied by the foam can be analyzed according to the pure liquid level height value and the foam surface height value. Because the foam surface is obviously different from the pure liquid surface, the pure liquid surface area and the foam surface area are accurately identified by the identification model, the pure liquid surface height value and the foam surface height value can be correspondingly positioned according to the identified pure liquid surface area and the foam surface area, even if the liquid surface fluctuates at the moment, the pure liquid surface height value and the foam surface height value can synchronously change, the influence of the fluctuation of the liquid surface can be eliminated when the residual space in the fermentation tank and the space occupied by the foam are analyzed, the influence on the analysis of the foam quantity is not great, the detected foam quantity is more attached to the real condition, the detection result is more accurate, the follow-up more accurate guide defoaming control is convenient, and the final product meets the requirements.
S6: and generating a control signal according to the foam quantity and a preset foam threshold, wherein the control signal is used for controlling the on-off of a defoaming agent adding pipeline and the adding parameters of the defoaming agent.
Specifically, when the foam amount is greater than a preset foam threshold, a control signal is generated, wherein the control signal comprises a signal for controlling the on-off of the defoaming agent adding pipeline and parameters for controlling the adding speed and the adding time of the defoaming agent. When the foam amount is smaller than or equal to a preset foam threshold value, a control signal is not generated, the current defoaming agent adding pipeline is kept in a closed state, and no defoaming agent is added.
In the embodiment, acquiring a real-time image of the liquid level in the fermentation tank and a tank wall image of the fermentation tank; firstly, calibrating the height of the fermentation tank in the tank wall image to obtain a limit height value and a height scale mark of the fermentation tank so as to position the height of the liquid level in subsequent production; inputting the liquid level real-time image into an identification model, and accurately identifying a pure liquid level area and a foam surface area by the identification model because the foam surface is obviously different from the pure liquid level; according to the identified pure liquid level area and foam surface area, a pure liquid level height value and a foam surface height value can be positioned corresponding to the height scale mark, even if the liquid level fluctuates at this time, the pure liquid level height value and the foam surface height value can synchronously change, according to the pure liquid level height value and the limit height value, the residual space except the space occupied by the fermentation liquid in the fermentation tank at this time can be analyzed, according to the pure liquid level height value and the foam surface height value, the space occupied by the foam can be analyzed, the influence of the fluctuation of the liquid level can be eliminated, the influence on the analysis of the foam quantity is not large, the determined foam quantity is more fit with the real situation, the detection result is more accurate, a control signal is generated according to the foam quantity and the preset foam threshold value, the defoaming operation is guided more accurately, the adding time and the throwing parameter of the defoaming agent are controlled, and the final product meets the requirements.
In one embodiment of the present invention, the determining the pure liquid level value and the foam level value according to the height tick mark, the number of pure liquid level regions, and the number of foam level regions includes:
when the number of the pure liquid surface areas is equal to 1 and the number of the foam surface areas is 0, the fact that no foam is generated at the moment is indicated, the pure liquid surface areas are in contact with the height scale marks marked on the tank wall, the positions of the height scale marks corresponding to the pure liquid surface areas can be positioned, the pure liquid surface height value is obtained, and the fact that no foam exists indicates that the foam quantity is 0. At this time, the foam surface height value can be equal to the pure liquid surface height value, and the foam volume can be calculated to be 0 when the space occupied by the foam obtained by subtracting the pure liquid surface height value from the foam surface height value is 0.
In one embodiment of the present invention, the determining the pure liquid level value and the foam level value according to the height tick mark, the number of pure liquid level regions, and the number of foam level regions includes:
When the number of the pure liquid level areas is greater than or equal to 1 and the number of the foam surface areas is greater than or equal to 1, the fact that foam is generated in the fermentation process is indicated, and foam floats out of the liquid level in one or more places.
When the pure liquid surface areas contacted with the tank wall of the fermentation tank exist in the pure liquid surface areas, the positions of the height scale marks corresponding to the pure liquid surface areas contacted with the tank wall of the fermentation tank can be directly positioned, and the pure liquid surface height value is obtained.
When there is no pure liquid surface area in contact with the tank wall of the fermentation tank in the plurality of pure liquid surface areas, optionally one pure liquid surface area, determining the pure liquid surface height value according to the installation position of the image acquisition device and the selected position of the pure liquid surface area.
Specifically, since the pure liquid level is not in contact with the height scale line, the pure liquid level value cannot be directly read out from the photographed photo or cannot be analyzed through a simple image, at this time, a pure liquid level area can be selected, a measurement point can be projected to the selected pure liquid level area through a distance sensor to obtain the distance between the measurement point and the distance sensor, then the distance between the measurement point and the tank wall is analyzed from the acquired image, the distance sensor can be embedded in a visual identifier, and the current pure liquid level value is analyzed through the installation position of the visual identifier or the distance sensor, the distance between the measurement point and the tank wall and the limit height value. In addition, if no other liquid or substance is injected into the fermenter during the fermentation, some fermentation liquid is consumed during the fermentation, but the consumption of fermentation liquid can be estimated approximately based on the fermentation time, so that the current pure liquid level value of fermentation liquid can be analyzed.
And obtaining the foam surface height value according to the position of the height scale mark corresponding to the foam surface area. Because the foam floats on the fermentation broth and is not shielded, the height value of the foam surface can be directly observed or projected and analyzed from the acquired image.
In one embodiment of the present invention, the determining the pure liquid level value and the foam level value according to the height tick mark, the number of pure liquid level regions, and the number of foam level regions includes:
when the number of the pure liquid level areas is 0 and the number of the foam surface areas is equal to 1, the pure liquid level is not present, the whole fermentation liquid level is filled with foam, after the foam is filled, the foam which is regenerated later is crushed or the foam begins to accumulate and continuously ascend to the top end of the fermentation tank, and the foam surface height value is obtained according to the position of the height scale mark corresponding to the foam surface area.
And taking the last pure liquid level value determined before the current time point as the pure liquid level value of the current time point. The foam shields the whole liquid level of the fermentation liquid, so that the liquid level value cannot be obtained directly from the acquired image, and the last analyzed pure liquid level value can be picked up at the moment, or the current pure liquid level value can be deduced according to the initial value of the pure liquid level value, the fermentation time and the amount of consumed fermentation liquid in unit time.
In one embodiment of the invention, said determining the amount of foam based on said pure liquid level value, said foam level value and said limit height value comprises:
and determining the difference between the foam surface height value and the pure liquid level height value, and marking the difference as a first difference value, wherein the first difference value represents the space occupied by the foam.
And determining the difference between the limit height value and the pure liquid level value, and recording the difference as a second difference value, wherein the second difference value represents the residual space in the fermentation tank.
And dividing the first difference value by the second difference value to obtain the foam quantity, wherein the foam quantity represents how much percent of the space occupied by the foam is the residual space in the fermentation tank, 0% represents the minimum foam quantity allowed by the process, 100% represents the maximum foam quantity allowed by the process, and judgment and early warning are timely made on the fermentation foam of the specific product under the specific process condition according to the foam quantity.
Fig. 2 shows a schematic structural diagram of a visual identifier according to an embodiment of the present invention, where the visual identifier includes a memory 100, a processor 200, and a computer program stored on the memory 100 and executable on the processor, and when the processor 200 executes the computer program, the above foam detection method is implemented.
The visual identifier establishes a customized mathematical model and a database of a specific product with specific process conditions, the visual identifier continuously monitors and collects images in the fermentation process, the image processing capacity is utilized to compare the mathematical model with the characteristics of the foam in the fermentation process, the deep learning technology is utilized to realize automatic classification and identification of the images by constructing a deep neural network model (identification model), and then the numerical value of the foam quantity (0% represents the minimum foam quantity allowed by the process and 100% represents the maximum foam quantity allowed by the process) is output to represent the state of the fermentation foam, so that judgment and early warning are timely made on the fermentation foam of the specific product with specific process conditions. The output value of the customized mathematical model can be corresponding to the adding mode of the defoaming agent formulated in the database, and the corresponding adding mode of the defoaming agent is called according to the output result of the data model, so that the automatic control program forms linkage control to control the defoaming process. In addition, as shown in fig. 3, the visual identifier 3 is positioned outside the fermentation tank 1 and is not in contact with the fermentation liquid, so that the influence of hanging materials and scaling caused by foam on the detection result can be completely avoided. The visual identifier in this embodiment is similar to the technical effects of the above foam detection method, and will not be described here again.
FIG. 3 shows a schematic structural diagram of a defoaming system in an embodiment of the present invention, wherein the defoaming system comprises the visual identifier 3, the atomizer 2, the first self-control valve 4 and the defoamer adding pipeline, and the visual identifier 3 is used for determining the foam amount of the surface of the fermentation liquid in the fermentation tank 1 and outputting a control signal; the first self-control valve 4 is arranged on the defoamer adding pipeline; the atomizer 2 is used for being arranged in the fermentation tank 1, the atomizer 2 is connected with one end of the defoaming agent adding pipeline, and the other end of the defoaming agent adding pipeline is used for being introduced with a sterile defoaming agent.
In this embodiment, the tank top pressure of the fermenter in the fermentation culture process may be set to 0.01MPa-0.13MPa, the material pressure of the side of the defoamer adding pipeline away from the fermenter may be set to 0.15 MPa-0.25 MPa, and the fermentation tank may be supplemented with the sterile defoamer by means of the pressure difference between the two sides of the first self-control valve 4. When the visual identifier 3 identifies fermentation foam, and after the foam quantity exceeds the standard, a control signal is generated, the control signal is sent to the first automatic control valve 4, the first automatic control valve 4 responds to the control signal, the first automatic control valve 4 is opened, the sterile defoaming agent starts to be fully atomized in the space of the upper end socket of the fermentation tank through the atomizer 2, the defoaming agent is enabled to be in uniform contact with the surface of the fermentation broth, the defoaming effect is improved, the stirring effect of a stirrer in the fermentation tank can be further improved, the mass transfer efficiency is improved better, the sufficient mixing of the defoaming agent and the fermentation broth is realized, and the efficient foam elimination function is realized. The adding mode of the defoaming agent is automatically controlled, the process of adding the sterile defoaming agent into the fermentation broth is controlled in a small quantity and multiple times or continuous low flow mode, the one-time excessive addition of the defoaming agent is avoided, the local excessive addition of the defoaming agent can be effectively prevented, the foam is effectively eliminated, the consumption of the defoaming agent is low, the difficulty of a subsequent extraction section is reduced, and the production cost is reduced. When the visual identifier 3 identifies that the fermentation foam is below the preset foam threshold, the first self-control valve 4 is closed and the sterile antifoaming agent stops adding the fermentation broth through the atomizer 2. The visual identifier 3 and the first automatic control valve 4 form a first connecting loop, and the sterile defoamer is added into the surface of the fermentation broth through the atomizer 2 to realize the function of eliminating the foam of the fermentation broth. The atomizer 2 may be configured in a single group or in multiple groups according to the actual situation.
In one embodiment of the present invention, as shown in fig. 3, the defoaming system further comprises a second self-control valve 5, a first remote thermometer 12, a first steam valve 6 and a first steam pipeline; the second self-control valve 5 is arranged on the defoamer adding pipeline, and the second self-control valve 5 is connected with one end of the first self-control valve 4, which is far away from the fermentation tank 1; the first remote thermometer 12 is installed on the defoamer adding pipeline between the first self-control valve 4 and the fermentation tank 1 and is used for measuring the temperature in the defoamer adding pipeline, and the control signal output end of the first remote thermometer 12 is respectively connected with the control end of the first steam valve 6 and the control end of the first self-control valve 4; one end of the first steam pipeline is communicated with the defoamer adding pipeline between the first self-control valve 4 and the second self-control valve 5, the other end of the first steam pipeline is used for introducing clean steam, and the first steam valve 6 is arranged on the first steam pipeline.
In this embodiment, the first remote thermometer 12 forms a second interlocking loop with the first steam valve 6 and the first self-control valve 4. Before adding the defoaming agent, a defoaming agent adding pipeline is required to be sterilized, a first steam valve 6 and a first self-control valve 4 are sequentially and automatically opened in the sterilization process, a first remote thermometer 12 is used as a sterilization temperature indication, and automatic timing is started after the monitoring temperature of the first remote thermometer 12 reaches the sterilization temperature required by the process; when the timing reaches the time required by the process, the first self-control valve 4 and the first steam valve 6 are sequentially and automatically closed, and the timing is finished, so that the defoaming agent adding pipeline of the second self-control valve 5, which is close to one side of the fermentation tank, is sterilized, and the sterile feeding function is realized. If the detected temperature of the first remote thermometer 12 is lower than the process requirement sterilization temperature in the sterilization process, the timing is automatically stopped until the detected temperature of the first remote thermometer 12 reaches the process requirement sterilization temperature again after the fault is removed, and the timing is restarted to ensure the sterilization effect.
In one embodiment of the present invention, as shown in fig. 3, the defoaming system further comprises a second remote thermometer 13, a third steam valve 10, a second steam line, an exhaust line and a first exhaust valve 8; the second remote thermometer 13 is installed on the defoamer adding pipeline between the second automatic control valve 5 and the sterile defoamer inlet and is used for measuring the temperature in the defoamer adding pipeline, and the control signal output end of the second remote thermometer 13 is respectively connected with the control end of the third steam valve 10 and the control end of the first exhaust valve 8; the third steam valve 10 is installed on the second steam pipeline, one end of the second steam pipeline is communicated with the defoamer adding pipeline between the second remote thermometer 13 and the sterile defoamer inlet, and the other end of the second steam pipeline is used for introducing the clean steam; one end of the exhaust pipeline is communicated with one end of the second self-control valve 5, which is far away from the first self-control valve 4, and the first exhaust valve 8 is arranged on the exhaust pipeline.
In the present embodiment, the second remote thermometer 13 forms a third interlocking circuit with the third steam valve 10 and the first exhaust valve 8. In the sterilization process, the third steam valve 10 and the first exhaust valve 8 are sequentially and automatically opened, the second remote thermometer 13 is used as a sterilization temperature indication, and when the monitoring temperature of the second remote thermometer 13 reaches the sterilization temperature required by the process, automatic timing is started; when the timing reaches the time required by the process, the first exhaust valve 8 and the third steam valve 10 are automatically closed in sequence, and the timing is finished, so that the defoaming agent adding pipeline on one side of the second automatic control valve 5, which is far away from the fermentation tank, is sterilized, and the sterile function is realized. If the detected temperature of the second remote thermometer 13 is lower than the process required sterilization temperature in the sterilization process, the timing is automatically stopped, and the timing is restarted until the detected temperature of the second remote thermometer 13 reaches the process required sterilization temperature again after the fault is removed, so as to ensure the sterilization effect of the defoaming agent adding pipeline on the side of the second self-control valve 5 away from the fermentation tank.
In one embodiment of the present invention, as shown in fig. 3, the defoaming system further includes a second steam valve 7, a fourth steam valve 11 and a second exhaust valve 9, wherein the second steam valve 7 is installed on the first steam pipeline, the fourth steam valve 11 is installed on the second steam pipeline, the second exhaust valve 9 is installed on the exhaust pipeline, and a control signal output end of the first remote thermometer 12 is connected with a control end of the second steam valve 7; the control signal output end of the second remote thermometer 13 is respectively connected with the control end of the fourth steam valve 11 and the control end of the second exhaust valve 9.
In this embodiment, a redundant second steam valve 7, a redundant fourth steam valve 11 and a redundant second exhaust valve 9 are correspondingly added on the first steam pipeline, the second steam pipeline and the exhaust pipeline respectively, and the double valves act together to ensure the complete sealing of the defoamer adding pipeline and ensure the sterile feeding environment. When sterilization is carried out, the valve at one side of the clean steam inlet is firstly opened, which is equivalent to the prior sterilization of the exposed pipeline; when sterilization is completed, the valve on one side is closed after clean steam is introduced, so that continuous output of the clean steam is ensured, invasion of miscellaneous bacteria is prevented when the valve is closed, and sterilization effect is ensured. In addition, when sterilization is carried out, the exhaust valve close to the defoaming agent adding pipeline is opened firstly, and when sterilization is finished, the exhaust valve far away from the defoaming agent adding pipeline is closed firstly, so that the exhaust port can be continuously sterilized by the steam discharged subsequently. It should be noted that, the defoamer adding pipeline, the steam pipeline, the exhaust pipeline, all the above control valves and the like may be configured in a single group or in multiple groups according to actual situations.
Although the present invention is disclosed above, the present invention is not limited thereto. Various changes and modifications may be made by one skilled in the art without departing from the spirit and scope of the invention, and the scope of the invention should be assessed accordingly to that of the appended claims.
Claims (10)
1. A method of detecting foam comprising:
Acquiring a liquid level real-time image in a fermentation tank and a tank wall image of the fermentation tank;
calibrating the height of the fermentation tank in the tank wall image to obtain a limit height value and a height scale mark of the fermentation tank;
inputting the liquid level real-time image into an identification model, and identifying a pure liquid level area and a foam surface area;
Determining a pure liquid level height value and a foam surface height value according to the height scale marks, the number of pure liquid level areas and the number of foam surface areas;
determining the foam amount according to the pure liquid level height value, the foam surface height value and the limit height value;
and generating a control signal according to the foam quantity and a preset foam threshold, wherein the control signal is used for controlling the on-off of a defoaming agent adding pipeline and the adding parameters of the defoaming agent.
2. The foam detection method of claim 1, wherein said determining a pure level height value and a foam level height value based on the height tick mark, the number of pure level regions, and the number of foam level regions comprises:
when the number of the pure liquid level areas is equal to 1 and the number of the foam surface areas is 0, positioning the positions of the height scale marks corresponding to the pure liquid level areas to obtain the pure liquid level height value, and enabling the foam surface height value to be equal to the pure liquid level height value.
3. The foam detection method of claim 1, wherein said determining a pure level height value and a foam level height value based on the height tick mark, the number of pure level regions, and the number of foam level regions comprises:
Analyzing whether there is the pure liquid surface area in contact with the tank wall of the fermenter among the plurality of pure liquid surface areas when the number of the pure liquid surface areas is greater than or equal to 1 and the number of the foam surface areas is greater than or equal to 1;
When the pure liquid surface areas contacted with the tank wall of the fermentation tank exist in the pure liquid surface areas, positioning the positions of the height scale marks corresponding to the pure liquid surface areas contacted with the tank wall of the fermentation tank to obtain the pure liquid surface height value;
When there is no pure liquid surface area in contact with the tank wall of the fermentation tank in a plurality of pure liquid surface areas, optionally one pure liquid surface area, and determining the pure liquid surface height value according to the installation position of the image acquisition device and the selected position of the pure liquid surface area;
and obtaining the foam surface height value according to the position of the height scale mark corresponding to the foam surface area.
4. A foam detection method according to claim 2 or 3, wherein said determining a pure liquid level value and a foam level value from said height tick mark, said number of pure liquid level regions and said number of foam level regions comprises:
When the number of the pure liquid level areas is 0 and the number of the foam surface areas is equal to 1, obtaining the foam surface height value according to the positions of the height scale marks corresponding to the foam surface areas;
and taking the last pure liquid level value determined before the current time point as the pure liquid level value of the current time point.
5. The foam detection method of claim 1, wherein said determining the amount of foam based on said pure liquid level value, said foam level value, and said limit height value comprises:
determining a difference value between the foam surface height value and the pure liquid surface height value, and marking the difference value as a first difference value;
Determining the difference between the limit height value and the pure liquid level height value, and recording the difference as a second difference;
and dividing the first difference value by the second difference value to obtain the foam quantity.
6. A visual identifier comprising a memory, a processor and a computer program stored on the memory and executable on the processor, which when executed by the processor, implements the foam detection method of any one of claims 1-5.
7. A defoaming system, characterized by comprising a visual identifier, an atomizer (2), a first self-control valve (4) and a defoaming agent adding pipeline according to claim 6, wherein the visual identifier is used for determining the foam amount of the surface of fermentation liquid in a fermentation tank (1) and outputting a control signal; the first self-control valve (4) is arranged on the defoamer adding pipeline; the atomizer (2) is used for being arranged in the fermentation tank (1), the atomizer (2) is connected with one end of the defoaming agent adding pipeline, and the other end of the defoaming agent adding pipeline is used for being introduced with a sterile defoaming agent.
8. The defoaming system of claim 7 further comprising a second self-control valve (5), a first remote thermometer (12), a first steam valve (6) and a first steam line; the second self-control valve (5) is arranged on the defoaming agent adding pipeline, and the second self-control valve (5) is connected with one end, far away from the fermentation tank (1), of the first self-control valve (4); the first remote thermometer (12) is arranged on the defoamer adding pipeline between the first automatic control valve (4) and the fermentation tank (1) and is used for measuring the temperature in the defoamer adding pipeline, and the control signal output end of the first remote thermometer (12) is respectively connected with the control end of the first steam valve (6) and the control end of the first automatic control valve (4); one end of the first steam pipeline is communicated with the defoaming agent adding pipeline between the first automatic control valve (4) and the second automatic control valve (5), the other end of the first steam pipeline is used for introducing clean steam, and the first steam valve (6) is arranged on the first steam pipeline.
9. The defoaming system according to claim 8, further comprising a second remote thermometer (13), a third steam valve (10), a second steam line, an exhaust line and a first exhaust valve (8); the second remote thermometer (13) is arranged on the defoamer adding pipeline between the second self-control valve (5) and the sterile defoamer inlet and is used for measuring the temperature in the defoamer adding pipeline, and the control signal output end of the second remote thermometer (13) is respectively connected with the control end of the third steam valve (10) and the control end of the first exhaust valve (8); the third steam valve (10) is arranged on the second steam pipeline, one end of the second steam pipeline is communicated with the defoaming agent adding pipeline between the second remote thermometer (13) and the sterile defoaming agent inlet, and the other end of the second steam pipeline is used for introducing the clean steam; one end of the exhaust pipeline is communicated with one end, far away from the first self-control valve (4), of the second self-control valve (5), and the first exhaust valve (8) is arranged on the exhaust pipeline.
10. The defoaming system according to any one of claims 7 to 9, further comprising a second steam valve (7), a fourth steam valve (11) and a second exhaust valve (9), said second steam valve (7) being mounted on said first steam line, said fourth steam valve (11) being mounted on said second steam line, said second exhaust valve (9) being mounted on said exhaust line, a control signal output of said first remote thermometer (12) being connected to a control end of said second steam valve (7); the control signal output end of the second remote thermometer (13) is respectively connected with the control end of the fourth steam valve (11) and the control end of the second exhaust valve (9).
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| CN119339536A (en) * | 2024-12-19 | 2025-01-21 | 宁波宇晟星和智能科技有限公司 | Pot distillation abnormality warning method, system and intelligent terminal |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN119339536A (en) * | 2024-12-19 | 2025-01-21 | 宁波宇晟星和智能科技有限公司 | Pot distillation abnormality warning method, system and intelligent terminal |
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