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超高压食品处理容器关键技术及在线视觉监测技术的研究
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摘要
食品超高压处理技术以其独特的优势已成为备受关注的非热食品加工方法之一。食品经超高压处理后,不仅能够实现货架期的延长、食品体系的物理性质与功能性质的改变等,而且能够最大限度的保持其色香味及营养成分。因此,食品超高压处理技术是食品工业中最具潜力及产业化前景的一项高新技术。
     食品超高压处理的核心装置是超高压容器。目前,超高压容器的密封装置及辅助设备仍有待于进一步深入研究与开发以满足实际食品处理中的应用。另外,容器在高压环境下工作,其安全性至关重要,因此开展超高压容器的在线非接触监测技术的探索与研究十分必要。
     本文针对目前食品超高压处理过程中原料包装材料(容器)存在的不足,应用TRIZ创新理论对超高压处理食品包装形式的进化过程进行了分析,从而得出刚性盛装内容器将替代软包装的发展趋势。通过“物-场分析”方法,确定了刚性盛装内容器的主体结构形式,提出了实现刚性盛装内容器与超高压容器同步操作的“物-场模型”,解决了各组成机构间的矛盾冲突,为刚性盛装内容器的创新设计提供了原始思路。采用虚拟样机技术完成了刚性盛装内容器物理样机的研制,并进行了内容器的密封性能试验。通过不同压力下的密封试验,证明了该内容器具有较好的密封性能,且实现了与超高压容器密封盖的同步操作,操作方便,仅需一人即可完成。该内容器能够有效完成与软包装相同的功能。
     本文采用ANSYS软件建立了超高压容器密封结构的整体非线性有限元模型,并建立了将超高压容器密封盖,双层缩套式筒体,端盖法兰,密封元件通过非线性接触单元作为整体进行研究的非线性数值模拟方法,并通过该方法完成不同工况、不同夹角三角环、不同径比三角环及不同径向间隙的超高压容器密封结构的变形规律的研究,得到三角环及各个关键部件的受力特征及变形情况,为确定密封元件的最佳尺寸的设计提供参考和理论依据。
     本文采用数字图像相关方法实现食品超高压处理容器的在线监测,因此首先针对数字图像相关亚像素位移测量算法——迭代梯度算法对初值较敏感这一不足,提出了基于粒子群算法的迭代梯度算法。通过模拟散斑实验验证了该算法对初值具有一定的鲁棒性。同时,通过模拟平移及复杂变形实验,将该算法与已有亚像素算法(曲面拟合算法、梯度算法、N-R算法及迭代梯度算法)进行了比较研究,结果证明该算法没有降低原算法的性能,仍具有较高的位移测量精度。
     以本文提出的数字图像相关亚像素算法为基础,建立了食品超高压处理容器的在线监测系统。应用该系统对食品超高压处理容器的筒体、端盖法兰及密封盖的轴向位移做了初步测量,并将测量结果与有限元法的计算结果进行了对比。测量结果表明,该测量系统能够实现超高压容器的在线变形等的监测,且具有较高的测量精度,同时也证明了本文的算法具有较高的精度与可靠性。最后,对该系统的测量误差及采取的改进措施进行了详细的分析,为基于数字图像相关方法的超高压容器的在线监测技术的深入研究与开发奠定了基础。
Ultra high pressure (UHP) food processing technology is receiving a great deal ofattention due to its unique advantages over non-thermal treatments methods. Foodstuffsare pressurised at hundreds MPa levels to produce a high nutritional and sensorial qualityproduct, with more desirable texture and longer shelf life, by enzyme deactivation andreduction of microorganisms. Therefore, the ultra high pressure food processingtechnology has bocome one of unique technologies with the most potential andindustrialization prospect.
     Ultra high pressure vessel (UHPV) is the core equipment of UHP food processingtechnology. At present, seal structure of UHPV and auxillary equipment should be furtherresearched and exploited to meet their application in food processing. In addition, itssafety performance is very crucial when the UHPV works under ultra high pressurecondition. So it is very necessary to explore and study an online non-contact monitoringtechnology for UHPV.
     According to disadvantages of food packaging materials or container employed inultra high pressure processing, the history of evolution of food packaging form wasanalyzed by TRIZ (a theory of inventive problem solving). The development trend offood packaging form in ultra high pressure processing was that rigid container willreplace flexible packaging. The main structure of rigid container was determined bymaterial-field analysis in TRIZ. Material-field models of synchronous movementbetween rigid container and UHPV were proposed, and then solutions of innovativeprinciples were obtained in order to solve different contradictions and conflicts in rigidcontainer. Consequently, an initial design idea was offered by these for innovative designof rigid container. Prototype of rigid container was researched and manufactured byvirtual prototype technology. Then seal performance tests were performed under differentpressure conditions. There were many advantages of the rigid container, such as perfectsealing, synchronous movement with top cover of UHPV,easy operation by one person.The rigid container has the same function as flexible food package.
     Numerical simulation model of sealing structure of UHPV was established by ANSYS12.0sofeware. Top cover of UHPV, two-layer shrink-fit cylinder, end closureflange, sealing element were intergrated by nonlinearity contact element. Deformationrules of delta-ring and other key components were obtained by nonlinearity numericalsimulation method under different inner pressure conditions, differen angels ofdelta-ring,different dimeter ratio of delta-ring and different ridial clearances between topcover and cylinder. They were useful theoretical basis and reference to determineoptimum parameters of the delta-ring.
     Digital image correlation method was used to online monitor UHPV employed infood processing. A new iterative gradient algorithm based on particle swarm optimizationalgorithm was proposed to overcome a shortage of iterative gradient algorithm. Theshortage was that iterative gradient algorithm was insensitive to initial value. Robustnessof the proposed algorithm was verified by simulation experiments. The proposedalgorithm, coarse-fine algorithm, gradient algorithm, N-R algorithm, and iterativegradient algorithm were compared by simulation translation and complex deformanceexperiments in this dissertation. The results revealed that the proposed algorithm hadhigher computational accuracy of sub-pixel displacement.
     The online monitor system applied in UHPV was establised based on the proposedalgorithm, a new iterative gradient algorithm based on particle swarm optimizationalgorithm. The axial displacements of cylinder, end closure flange and top cover ofUHPV were measured initially by this system. Compared tests results with finite elementmethod, this system can online monitor deformances of UHPV and had higher precisionand reliability. At last, Measurement error of the system and the improvement meanswere analyzed in detail. Consequently, it can offer basis for further study anddevelopment of online monitor techonology in UHPV.
引文
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