汾酒用曲块制作机理及其关键技术研究
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摘要
机械制曲的生产方式有着生产效率高、产品一致性好、劳动强度低等方面的优点,但是也存在提浆效果差等方面的缺点。甚至造成某些国内知名白酒曲块制作方式的“人工踩制方式”与“机械制曲方式”的反复倒换、举棋不定的现象。
首先对定型化生产以来确定了的汾酒用大曲生产的前六个环节进行深入的分析和研究,并同时对其中模盒的清洗环节、料斗下料速度控制环节进行了深入实验研究、数值模拟仿真优化。对料斗下料速度进入可控范围的条件进行研究并提出了几个关键的控制参数；对模盒清洗环节中喷雾清洗喷嘴的喷嘴形式、安装角度、安装高度、供水压力等参数进行实验研究并运用MATLAB中的ANFIS工具对实验数据进行规律提炼并指导关键参数的优选工作。
本文以公认的合格的大曲曲块的密度参数分布作为切入点,设计了对大曲的密度进行了分层、分区、分点的方式进行的密度测定的物理实验。得出了以大曲密度可以综合体现大曲的提浆效果与密实程度两个重要因素的参数——分点密度差,以及该参数在合格曲块中的分布规律。
为了得到曲块的在不同压缩速度、不同含水率、弹性后效、不同重复压缩次数等因素影响下的曲块的密实程度以及曲块的提浆效果的变化程度,本文组织了大量的压缩致密实验,对压缩过程的规律进行归纳和总结,并得出了一组在现行条件下的制曲工艺参数。
为了摸清曲块密度分布规律的影响因素、改善机械制曲的提浆效果,本文又从曲块压制过程中的压力分布、潮湿颗粒模型、侧压力分布实验、侧压摩擦系数等方面着手,结合宏观物理实验现象,开展了压制成型的机理分析和提浆机理的分析。主要从造成曲块密度分布特性的原因进行了细观层面上进行分析,对曲块的压制成型的机理和细观层面上的提浆机理结合物理实验的现象进行了分析。
本文设计了三种实验压曲的锤头,结合目前针对颗粒状物料有独到优势的PFC系列模拟仿真软件,对三种锤头的压缩的过程进行了仿真,指出了一种可以保证压缩效果但是又改善提浆效果的空间曲面压曲锤头。三种压曲锤头分别是：平板压曲锤头、仿生压曲锤头、空间曲面压曲锤头。通过整板压曲锤头压缩对仿真的数值模型进行了标定和验证。仿真后证明,这种压曲锤头的交变压力作用影响范围最广泛、最均匀,提浆效果也最为明显。
最后,结合本文中提出的三项关键技术和特定的外围约束条件下,在山西某清香型酒厂的车间进行了现场的工业试制试验。选定的空间曲面压曲锤头并结合本文提出的一组压缩工艺参数,在实验室内进行了密度分布测试和分点测试,结果表明与人工踩制的曲块在密度分布上和提浆效果上相类似。
试验结果表明,课题组研制开发的机械制曲设备在装备了带有空间曲面的压缩锤头、扇形喷嘴的清洗设施、恒速稳定供料的料斗后,做出的曲块优于现行的平板锤头压制的效果,且与人工踩制的曲块的参数分布情况更加贴近。
Mode of production in Mechanical starter-making have saveral advantages such as higher efficacy, better consistency of products, lower intensity of labour, etc. But there are also drawbacks of poor effect in purifying syrup etc., which cause the phenomenon, the choice of starter-making way between artificial and mechanical cannot determine.
In this paper, firstly, analysis and research the key technology in the first six links of starter making. At the same time, did a deeply experimental study and numerical simulation optimization on box cleaning process and hopper speed control methods. As the results, some key arguments were listed for hopper, installation angle, installation height, water supply pressure parameters for nozzles of cleaning were chosen, guided by the ANFIS tools in MATLAB.
In this paper, the accepted starter qualified of the density of the distribution parameters as a starting point, and designed the density of starter stratification, zoneing density by the physics experiment. The key paramete integrated the density of starter purifying syrup effect and the degree of compaction, two important factors, density difference between center and border, and distribution law of the parameters in qualified starter were obtained.
In order to get variations of purifying syrup effect and the compaction degree of starter in different compression speed, different moisture content, elastic lag, different repeat times of compression etc,. This paper organized a lot of compression density experiments, summarized the compression process of the law. As conclusiones, a group of starter-making procession parameters was aquired, in the current conditions.
Research effortes were done to understanded the density distribution rule and improve purifying syrup result of starter, on pressure distribution, damp particle model, side pressure distribution experiment, side pressure coefficient of friction, etc. Combined with the macro physical experiment phenomenon, the mechanism of compression molding and purifying syrup was studied, at the microscopic level.
In this paper, three kinds of experimental hammer designed, and were simulated by using PFC2D. One kind of perfect hummer with space curve surface was proposed, that result to compression and purifying syrup perfectively. The three kinds of experimental hammer were list as follows, flat hammer, bionic hammer, space surface hammer. The compression numerical model was corrected by simulating the compression process for flat hammer. By using the simulation tool, the last hummer was perfect to purifying syrup because its alternating role was very widespread.
After test density distribution, the results of purifying syrup and the rule of density distribution were similar to the artificial way of starter making. Finally, integrateing three key technologies and particular peripheral constraints, in the factory of Fen-chiew Company, pilot production was done. The special hummer and the technological parameter were used simultaneously.
The pilot production results showed that the densification effects of mechanical system equipment with the special hummer, the special fan cleaning nozzle and the special hopper of developed by research group, was similar to the artificial way and was superior to the current technological parameter.
首先对定型化生产以来确定了的汾酒用大曲生产的前六个环节进行深入的分析和研究,并同时对其中模盒的清洗环节、料斗下料速度控制环节进行了深入实验研究、数值模拟仿真优化。对料斗下料速度进入可控范围的条件进行研究并提出了几个关键的控制参数；对模盒清洗环节中喷雾清洗喷嘴的喷嘴形式、安装角度、安装高度、供水压力等参数进行实验研究并运用MATLAB中的ANFIS工具对实验数据进行规律提炼并指导关键参数的优选工作。
本文以公认的合格的大曲曲块的密度参数分布作为切入点,设计了对大曲的密度进行了分层、分区、分点的方式进行的密度测定的物理实验。得出了以大曲密度可以综合体现大曲的提浆效果与密实程度两个重要因素的参数——分点密度差,以及该参数在合格曲块中的分布规律。
为了得到曲块的在不同压缩速度、不同含水率、弹性后效、不同重复压缩次数等因素影响下的曲块的密实程度以及曲块的提浆效果的变化程度,本文组织了大量的压缩致密实验,对压缩过程的规律进行归纳和总结,并得出了一组在现行条件下的制曲工艺参数。
为了摸清曲块密度分布规律的影响因素、改善机械制曲的提浆效果,本文又从曲块压制过程中的压力分布、潮湿颗粒模型、侧压力分布实验、侧压摩擦系数等方面着手,结合宏观物理实验现象,开展了压制成型的机理分析和提浆机理的分析。主要从造成曲块密度分布特性的原因进行了细观层面上进行分析,对曲块的压制成型的机理和细观层面上的提浆机理结合物理实验的现象进行了分析。
本文设计了三种实验压曲的锤头,结合目前针对颗粒状物料有独到优势的PFC系列模拟仿真软件,对三种锤头的压缩的过程进行了仿真,指出了一种可以保证压缩效果但是又改善提浆效果的空间曲面压曲锤头。三种压曲锤头分别是：平板压曲锤头、仿生压曲锤头、空间曲面压曲锤头。通过整板压曲锤头压缩对仿真的数值模型进行了标定和验证。仿真后证明,这种压曲锤头的交变压力作用影响范围最广泛、最均匀,提浆效果也最为明显。
最后,结合本文中提出的三项关键技术和特定的外围约束条件下,在山西某清香型酒厂的车间进行了现场的工业试制试验。选定的空间曲面压曲锤头并结合本文提出的一组压缩工艺参数,在实验室内进行了密度分布测试和分点测试,结果表明与人工踩制的曲块在密度分布上和提浆效果上相类似。
试验结果表明,课题组研制开发的机械制曲设备在装备了带有空间曲面的压缩锤头、扇形喷嘴的清洗设施、恒速稳定供料的料斗后,做出的曲块优于现行的平板锤头压制的效果,且与人工踩制的曲块的参数分布情况更加贴近。
Mode of production in Mechanical starter-making have saveral advantages such as higher efficacy, better consistency of products, lower intensity of labour, etc. But there are also drawbacks of poor effect in purifying syrup etc., which cause the phenomenon, the choice of starter-making way between artificial and mechanical cannot determine.
In this paper, firstly, analysis and research the key technology in the first six links of starter making. At the same time, did a deeply experimental study and numerical simulation optimization on box cleaning process and hopper speed control methods. As the results, some key arguments were listed for hopper, installation angle, installation height, water supply pressure parameters for nozzles of cleaning were chosen, guided by the ANFIS tools in MATLAB.
In this paper, the accepted starter qualified of the density of the distribution parameters as a starting point, and designed the density of starter stratification, zoneing density by the physics experiment. The key paramete integrated the density of starter purifying syrup effect and the degree of compaction, two important factors, density difference between center and border, and distribution law of the parameters in qualified starter were obtained.
In order to get variations of purifying syrup effect and the compaction degree of starter in different compression speed, different moisture content, elastic lag, different repeat times of compression etc,. This paper organized a lot of compression density experiments, summarized the compression process of the law. As conclusiones, a group of starter-making procession parameters was aquired, in the current conditions.
Research effortes were done to understanded the density distribution rule and improve purifying syrup result of starter, on pressure distribution, damp particle model, side pressure distribution experiment, side pressure coefficient of friction, etc. Combined with the macro physical experiment phenomenon, the mechanism of compression molding and purifying syrup was studied, at the microscopic level.
In this paper, three kinds of experimental hammer designed, and were simulated by using PFC2D. One kind of perfect hummer with space curve surface was proposed, that result to compression and purifying syrup perfectively. The three kinds of experimental hammer were list as follows, flat hammer, bionic hammer, space surface hammer. The compression numerical model was corrected by simulating the compression process for flat hammer. By using the simulation tool, the last hummer was perfect to purifying syrup because its alternating role was very widespread.
After test density distribution, the results of purifying syrup and the rule of density distribution were similar to the artificial way of starter making. Finally, integrateing three key technologies and particular peripheral constraints, in the factory of Fen-chiew Company, pilot production was done. The special hummer and the technological parameter were used simultaneously.
The pilot production results showed that the densification effects of mechanical system equipment with the special hummer, the special fan cleaning nozzle and the special hopper of developed by research group, was similar to the artificial way and was superior to the current technological parameter.
引文
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