Self-adaptive tension control system of dry-method electrode continuous rolling forming machine

Abstract

The invention relates to the technical field of rolling forming machine control, and discloses a self-adaptive tension control system of a dry-method electrode continuous rolling forming machine. The system is composed of a tension generation module, a state evaluation module, a dynamic compensation module, a strategy optimization module, a production management database and a rolling execution mechanism. The tension generation module collects original tension data in real time at a transmission node; the state evaluation module analyzes the operation state and generates a tension stability evaluation report; the dynamic compensation module calculates the material deformation compensation amount according to the report and generates a dynamic regulation and control instruction; the strategy optimization module optimizes a strategy and outputs a parameter packet in combination with the instruction and a historical record; the production management database stores material characteristics, equipment history and regulation and control cases; and the rolling execution mechanism is adjusted to operate according to the parameter packet. All the modules cooperate to achieve real-time monitoring, evaluation, compensation and optimization of tension, the traditional control problem is solved, and the product quality and efficiency are improved.

Description

Technical Field

[0001] The invention relates to the technical field of roller forming machine control, in particular to an adaptive tension control system of a dry electrode continuous roller forming machine. Background Art

[0002] In many industrial production processes, such as battery manufacturing, the dry electrode continuous roll-forming process is becoming a key development direction due to its advantages such as the lack of solvents, low energy consumption, and theoretically higher production efficiency. However, in actual dry electrode continuous roll-forming, tension control issues have become a key obstacle to the widespread application and efficient production of this process.

[0003] Traditional roller-pressing actuators lack effective tension monitoring at the transmission nodes during operation, making it difficult to obtain real-time raw tension data during the rolling process. This makes it impossible to promptly detect tension fluctuations that may occur at any time during the rolling process, and even more difficult to make corresponding adjustments based on these fluctuations. For example, in some conventional roller-pressing equipment, operators rely solely on regular inspections to observe the surface condition of the rolled material to roughly determine the tension. This method not only has significant lag, but the judgment results are also greatly affected by human factors, and cannot meet the needs of modern high-precision production.

[0004] Most current roller-pressing equipment lacks the ability to comprehensively and accurately analyze its operating status. When the original tension data cannot be accurately obtained in real time, it is naturally difficult to conduct an in-depth analysis of the current roller-pressing operating status, and it is therefore impossible to generate a reliable tension stability assessment report. During the production process, even if the tension of the rolled material has fluctuated significantly, the equipment is unable to identify it in time and continues to operate according to the original operating parameters. This seriously threatens the quality of the rolled material and significantly increases the defective rate. For example, in the roller-pressing production of a certain battery electrode sheet, due to the failure to detect the unstable tension in time, a large number of electrode sheets had problems such as uneven thickness and surface wrinkles, and had to be reworked or even scrapped, resulting in a huge waste of resources and economic losses.

[0005] When deformation occurs during rolling of the material, existing systems have difficulty calculating the exact amount of deformation compensation, let alone generating an effective set of dynamic tension control instructions to dynamically adjust the tension. When the material passes through the rolling equipment, it is very easy for the material to deform due to differences in the material's own properties and changes in external factors such as temperature and pressure during the rolling process. The lack of an effective dynamic compensation mechanism makes it impossible for the equipment to adjust the tension in a timely manner according to these deformations, resulting in serious problems such as breakage and delamination of the material during subsequent processing. For example, in the rolling production of some plastic films, the film often breaks due to the inability to effectively compensate for the deformation of the material during the rolling process, seriously affecting the continuity of production and product quality. Summary of the Invention

[0006] The object of the present invention is to provide an adaptive tension control system for a dry electrode continuous roll forming machine to solve the problems raised in the above background technology.

[0007] To achieve the above object, the present invention provides an adaptive tension control system for a dry electrode continuous roll forming machine, the system comprising:

[0008] The tension generation module is deployed on the transmission node of the rolling actuator to obtain the original tension data set during the rolling process in real time;

[0009] The state evaluation module receives the original tension data set from the tension generation module, analyzes the current roller operation state and generates a tension stability evaluation report;

[0010] The dynamic compensation module receives the tension stability assessment report from the state assessment module, calculates the deformation compensation amount of the rolled material and generates a dynamic tension control instruction set;

[0011] The strategy optimization module receives the dynamic tension control instruction set and historical control records from the dynamic compensation module, optimizes the tension control strategy and outputs the optimized tension control parameter package;

[0012] Production management database, which stores roll-pressed material property data sets, equipment operation history archives, and tension control case libraries;

[0013] The roller actuator receives the optimized tension control parameter package from the strategy optimization module and adjusts the operating parameters of the roller actuator.

[0014] Preferably, when the tension generation module obtains the original tension data set, the following specific operations are performed: real-time capture of the torque change waveform data of the driving shaft of the rolling actuator, synchronous collection of the speed difference sequence between the inlet and outlet of the rolled material, and integration and generation of the original tension data set by combining the surface friction coefficient detection data of the rolled material and the ambient temperature and humidity monitoring data; wherein the surface friction coefficient detection data of the material is periodically acquired by an online surface scanner, and the ambient temperature and humidity monitoring data is acquired in real time by a sensor array arranged inside the rolling cavity.

[0015] Preferably, the process of the state assessment module generating a tension stability assessment report includes: extracting the torque fluctuation characteristic value and the speed difference change gradient from the original tension data set, comparing the torque fluctuation characteristic value with the standard torque fluctuation threshold interval in the equipment operation history archive, and matching and verifying the speed difference change gradient with the upper limit of the material's allowable deformation rate; when the torque fluctuation characteristic value exceeds the standard torque fluctuation threshold interval or the speed difference change gradient exceeds the upper limit of the material's allowable deformation rate, activating the tension anomaly identifier and calculating the actual deviation; comprehensively considering the influence weights of the torque fluctuation characteristic value deviation, the speed difference change gradient deviation and the environmental temperature and humidity monitoring data on the material properties, to generate a tension stability assessment report containing multi-dimensional evaluation indicators.

[0016] Preferably, the operating procedure for the dynamic compensation module to generate a dynamic tension control instruction set is as follows: receive the tension stability assessment report sent by the state assessment module, and parse the tension anomaly identifier and multi-dimensional assessment indicators therein; call the material property data set in the production management database to match the elastic recovery coefficient and plastic deformation critical point parameters of the current rolled material; calculate the basic compensation amount according to the actual deviation amount and the material elastic recovery coefficient, and correct the compensation intensity coefficient in combination with the plastic deformation critical point parameters; generate a dynamic tension control instruction set including the compensation action position coordinates, compensation amount action timing and compensation intensity coefficient, and synchronously transmit the instruction set to the strategy optimization module and the production management database.

[0017] Preferably, the process of optimizing the tension control strategy by the strategy optimization module specifically includes: receiving the dynamic tension control instruction set sent by the dynamic compensation module, and extracting a historical similar scene data set from the tension control case library of the production management database; performing pattern matching on the compensation parameters in the current dynamic tension control instruction set and the control records in the historical similar scene data set, identifying the differences in the compensation strategy and marking the strategy optimization candidate area; recalculating the compensation timing arrangement combination based on the strategy optimization candidate area, and generating an optimized tension control parameter package; wherein the optimized tension control parameter package includes an optimized sequence of compensation action positions, a compensation amount intensity adjustment ratio, and a compensation duration correction value.

[0018] Preferably, the operation of the rolling actuator executing the optimized tension control parameter package includes: receiving the optimized tension control parameter package sent by the strategy optimization module, parsing the compensation action position optimization sequence therein; locating the specific execution unit of the rolling actuator according to the compensation action position optimization sequence, loading the compensation amount intensity adjustment ratio to the drive controller, and setting the compensation duration correction value as the execution time window; dynamically adjusting the rolling pressure output value according to the compensation amount intensity adjustment ratio within the specified execution time window, and at the same time monitoring the rolling material deformation feedback data in real time and feeding it back to the tension generation module.

[0019] Preferably, the system also includes a real-time speed monitoring module, which is configured to: continuously collect real-time linear speed change data during the transmission process of the rolled material, and calculate the speed fluctuation rate of adjacent sampling periods; cross-validate the speed fluctuation rate with the speed evaluation index in the tension stability evaluation report output by the state evaluation module; when the speed fluctuation rate exceeds the allowable range of the speed evaluation index, generate a motion stability parameter correction request and send it to the dynamic compensation module.

[0020] Preferably, the processing flow of the dynamic compensation module in response to the motion stability parameter correction request is: receiving the motion stability parameter correction request sent by the real-time speed monitoring module, extracting the actual sampling value of the current rolling material line speed; retrieving the equipment rated transmission speed reference value from the production management database, and calculating the speed offset between the actual sampling value and the rated reference value; determining the compensation intervention level according to the size of the speed offset, updating the compensation intensity coefficient in the dynamic tension control instruction set, and marking the updated compensation intensity coefficient as an emergency adjustment mark and transmitting it to the strategy optimization module.

[0021] Preferably, the operation of the strategy optimization module processing the emergency adjustment identifier includes: receiving the emergency adjustment identifier marked by the dynamic compensation module, interrupting the current strategy optimization process; immediately calling the emergency disposal plan data set in the equipment operation history archive in the production management database, matching the emergency control mode corresponding to the current speed offset, and generating an emergency tension control parameter package.

[0022] Preferably, the emergency tension control parameter package includes a maximum compensation intensity action interval and a minimum action duration.

[0023] Compared with the prior art, the present invention has the following beneficial effects:

[0024] The system's tension generation module is deployed at the transmission node of the rolling actuator. This ingenious layout enables real-time acquisition of raw tension data sets during the rolling process. Compared to traditional methods, this eliminates the reliance on periodic manual inspections or indirect detection methods with significant lags, and instead instantly captures subtle tension changes. This real-time, accurate data collection provides a solid foundation for subsequent tension analysis and control, ensuring that the entire control system responds based on the most accurate and up-to-date tension information.

[0025] After receiving the raw tension data set from the Tension Generation Module, the Status Assessment Module conducts an in-depth analysis of the current roll-pressing operation and generates a tension stability assessment report. Like an experienced diagnostician, it analyzes and analyzes a large amount of raw tension data to accurately determine whether tension is stable during the roll-pressing process, as well as the degree of instability and possible causes. This precise assessment of operating status allows operators and subsequent control modules to quickly understand the equipment's operating status, providing a clear basis for timely countermeasures and avoiding the production of large quantities of defective products due to ignorance of tension instability.

[0026] Based on the tension stability assessment report from the state assessment module, the dynamic compensation module calculates the deformation compensation for the rolled material and generates a set of dynamic tension control instructions. Material deformation is inevitable during the rolling process, and this module accurately calculates the corresponding compensation amount and generates targeted control instructions. Compared to traditional systems, it no longer "blindly" adjusts tension according to a fixed pattern, but instead provides dynamic and precise compensation based on the material's real-time deformation. This effectively avoids problems such as material breakage and delamination caused by a mismatch between tension and material deformation, significantly improving the quality and yield of rolled materials and reducing the waste of resources and economic losses caused by defective products.

[0027] The strategy optimization module receives the dynamic tension control instruction set and historical control records from the dynamic compensation module, optimizes the tension control strategy, and outputs an optimized tension control parameter package. As production continues, material characteristics and equipment operating conditions change across batches. This module leverages this real-time and historical data to continuously learn and optimize the control strategy. Like a constantly evolving "intelligent brain," it ensures that the tension control strategy remains constantly updated and optimized. This enables the equipment to better adapt to complex and changing production conditions, further improving the accuracy and stability of tension control and ensuring consistent and stable product quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 This is a timing diagram of the adaptive tension control system of the dry electrode continuous roll forming machine of the present invention;

[0029] Figure 2 Flowchart for collecting raw data of tension generation module;

[0030] Figure 3 Flowchart for generating tension stability assessment report for condition assessment module;

[0031] Figure 4 Flowchart for optimizing control strategies for strategy optimization module;

[0032] Figure 5Flowchart for the dynamic compensation module responding to a speed correction request. DETAILED DESCRIPTION

[0033] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0034] See also Figure 1 The present invention provides an adaptive tension control system for a dry electrode continuous roll forming machine, the system comprising:

[0035] The tension generation module, state assessment module, dynamic compensation module, strategy optimization module, production management database, and rolling actuator are included. The tension generation module is deployed on the transmission node of the rolling actuator and acquires the original tension data set during the rolling process in real time. The state assessment module receives the original tension data set, analyzes the current rolling operation status, and generates a tension stability assessment report. The dynamic compensation module receives the assessment report, calculates the deformation compensation amount of the rolling material, and generates a dynamic tension control instruction set. The strategy optimization module receives the control instruction set and historical control records, optimizes the tension control strategy, and outputs an optimized tension control parameter package. The production management database stores the rolling material characteristic data set, the equipment operation history archive, and the tension control case library. The rolling actuator receives the optimized tension control parameter package and adjusts the operating parameters to achieve adaptive tension control.

[0036] Example 1: See Figure 2 , the specific implementation process of the tension generation module. This module is deployed at the transmission node position of the rolling actuator, including the main drive shaft, the driven roller support point and the tension guide roller bearing seat. Data acquisition is completed through the collaboration of multiple types of sensors: a strain torque sensor is installed on the drive shaft flange to measure the shaft torsional deformation and convert it into a torque value. The sampling frequency is set to 1000 Hz, and the measurement range covers 0-5000 Nm. The laser speed measuring device is deployed below the front guide plate at the entrance of the rolled material and above the exit guide roller. The distance between the two measuring points is fixed as the reference distance value, and the linear velocity signal is collected non-contactly based on the Doppler frequency shift principle. The speed difference sequence is obtained by real-time calculation of the inlet and outlet velocities of 100 consecutive sampling points, with a calculation cycle of 10 milliseconds.

[0037] The material surface friction coefficient is measured using an online scanning device. This device is installed at the entrance of the roller pressing chamber, with the scanning probe at a 45-degree angle to the material conveying plane and a scanning frequency of 10 scans per second. Each scan covers a 15-centimeter width of the material surface. A blue laser light source penetrates the surface dust, and the dynamic friction coefficient is calculated by analyzing the reflected light intensity. The test data includes three sub-items: static friction coefficient, dynamic friction coefficient, and surface roughness gradient.

[0038] The environmental parameter monitoring system consists of a distributed sensor array. Six sets of integrated temperature and humidity sensors are placed within the roller press chamber, located in the roller press gap, on the sidewalls of the material transfer channel, and at the exhaust port. Each sensor set is spaced 150 mm apart, monitoring temperatures from 50°C to 150°C and humidity from 10% to 90% relative humidity. Data acquisition uses a 4-20 mA current signal, collecting five samples per second.

[0039] The raw data set integration process includes three steps: time synchronization, format conversion, and quality verification. The central processing unit is equipped with a precision clock generator, and all sensor data is timestamped with millisecond accuracy. Torque waveform data is stored in floating decimal format, with 1,000 samples per second. The speed difference sequence generates a set of double-precision floating-point numbers every 10 milliseconds. Friction coefficient data is formed into a vector containing three parameters every second. Temperature and humidity data is generated as a six-dimensional array every 200 milliseconds. Before the data is transmitted via industrial Ethernet to the processing core, it must pass a validity verification process: verifying that the temperature value is within the predetermined range; confirming that the torque waveform has zero-value anomalies; and checking whether the speed difference exceeds the physical limits of the device.

[0040] The data processing unit structures and encapsulates the raw data set. Each complete data unit consists of a timestamp segment, a device identification segment, and an actual data segment. The timestamp segment records the year, month, day, hour, minute, second, and millisecond information; the device identification segment contains the sensor serial number and location code; and the actual data segment integrates all parameter values ​​collected at that time. The integrated data set is stored in a predefined data structure, with each record containing a torque waveform array, a speed difference sequence, a friction coefficient vector, and a temperature and humidity matrix.

[0041] The data transmission protocol utilizes industry-standard communication specifications. The processing core receives raw data via a dual-channel redundancy mechanism, automatically switching to the backup channel if the transmission delay on the primary channel exceeds 3 milliseconds. A data compression algorithm removes duplicate timestamps, retaining only complete records of parameter changes. Each complete data set is transmitted to the input buffer of the condition assessment module within 20 milliseconds of generation and simultaneously written to the raw data archive area of ​​the production management database. The cycle jitter of the entire acquisition, integration, and transmission process is controlled within ±2 milliseconds, meeting the real-time requirements of the roll-forming process.

[0042] Example 2: See Figure 3 The implementation of the state assessment module and dynamic compensation module is described. The state assessment module receives the raw tension dataset from the tension generation module via a dedicated data interface. This dataset includes a timestamp-aligned torque waveform array, a velocity difference sequence, a material surface friction coefficient vector, and an ambient temperature and humidity matrix. This module is deployed on an industrial-grade computing platform and processes the input data using a real-time operating system. The feature extraction unit first analyzes the torque waveform data and calculates the torque fluctuation characteristic value using a sliding window method with a 100-millisecond window width. The mean absolute deviation and spectral peak within each window are calculated as characteristic parameters. The velocity difference gradient is calculated using a differential algorithm, calculating the rate of change based on a continuous 100-millisecond velocity difference sequence. The comparison phase utilizes the equipment operation history archive in the production management database, where standard torque fluctuation threshold ranges are predefined and stored based on material type and equipment model, and are dynamically updated. The upper limit of the material's allowable deformation rate is extracted from a subset of material properties in the database and automatically matched based on the material code of the current rolling material. A detection mechanism monitors parameter limits. When the torque fluctuation characteristic value exceeds the threshold range or the velocity difference gradient exceeds the deformation rate upper limit, the anomaly detector is activated and the tension anomaly indicator is set to a high state. At the same time, the deviation calculation subunit calculates the actual deviation, such as the torque deviation is the difference between the characteristic value and the median of the interval, and the speed gradient deviation is the proportional difference between the current gradient value and the upper limit value. The environmental impact factor processing unit integrates the temperature and humidity monitoring data, and assigns weight factors through a preset relationship matrix. The matrix is ​​stored in the database, and each weight factor corresponds to the degree of influence of the temperature and humidity values ​​on the viscoelastic properties of the material. Finally, the report generator combines all calculation results, including torque deviation, speed gradient deviation, environmental impact weight and anomaly identifier to form a tension stability assessment report containing a 12-dimensional indicator vector. The report format uses a structured data frame, and each indicator is stored as a double-precision floating point number, and a timestamp and device status code are added, and transmitted to the input queue of the dynamic compensation module via the communication bus.

[0043] The dynamic compensation module, configured as an independent control processor, immediately initiates the parsing process upon receiving the tension stability assessment report from the state assessment module. The report parser decomposes the input data structure, identifies the tension anomaly identifier status, and extracts multi-dimensional evaluation indicator values. The material parameter retrieval engine queries the production management database based on the unique identifier of the current rolled material to accurately obtain the elastic recovery coefficient and plastic deformation threshold parameters. These parameters are derived from the material property dataset in the database. The elastic recovery coefficient is stored as a dimensionless value, and the plastic deformation threshold parameters include the stress yield point and strain limit. The compensation calculation logic is based on the actual deviation. The basic compensation solution uses a numerical algorithm to analyze the response characteristics of the elastic recovery coefficient to deviation. For example, the initial compensation value is the torque deviation multiplied by the inverse of the elastic recovery coefficient. A compensation strength correction mechanism further adjusts the compensation strength coefficient based on the plastic deformation threshold parameters, applying a nonlinear function to limit the compensation value to a range that avoids permanent material deformation. The instruction generator integrates the calculation results to generate a dynamic tension control instruction set. The instruction set contains three-dimensional spatial coordinate data, corresponding to the positions of compensation points on the rolling actuator. The compensation action sequence is defined as a microsecond time series, representing the triggering and stopping points of the compensation action. The compensation intensity coefficient is standardized as a floating-point number in the range of 0-1. The instruction set is encapsulated in JSON format and comes with a unique transaction ID and timestamp tag. The transmission unit synchronously distributes the instruction set to the strategy optimization module and the input interface of the strategy optimization module, and writes it to the tension control case library in the production management database. The entire process takes less than 50 milliseconds, and data integrity is guaranteed by a checksum mechanism. High-speed data bus communication is used between system modules to ensure seamless connection from state evaluation to dynamic compensation, meeting the real-time response requirements of the rolling process. This implementation method covers the entire processing flow and does not rely on external hypothetical effect verification. Instead, it achieves precise control through preset algorithms and database interaction.

[0044] Example 3: See Figure 4The strategy optimization module and the roller-pressing actuator implement the following implementation scheme. The strategy optimization module receives the dynamic tension control instruction set from the dynamic compensation module via a high-speed data channel. This instruction set contains structured data such as compensation action position coordinates, compensation action timing, and compensation intensity coefficients. Simultaneously, the module activates the database access interface to retrieve a historical dataset of similar scenarios from the tension control case library in the production management database. The data matching engine sets a similarity threshold of 85%. The retrieval algorithm is based on distance calculations in a multidimensional feature space. Features include material type codes, ambient temperature and humidity vectors, original tension fluctuation amplitude patterns, and compensation intensity temporal distributions. The pattern recognition unit applies a dynamic time warping algorithm to compare the current dynamic tension control instruction set with control records in the retrieved historical dataset of similar scenarios. This algorithm processes parameter sequences with different time scales and finds the optimal alignment mapping by accumulating minimum distance paths. The difference analysis module identifies compensation parameter deviations, including position coordinate offsets, temporal phase differences, and intensity ratio differences. Strategy optimization candidate regions are defined based on cluster analysis results. Specifically, regions in the high-dimensional parameter space that deviate from the historical optimization strategy threshold are marked. The optimization calculation is implemented using a genetic algorithm, with a population size of 100 chromosomes, each of which encodes a candidate compensation timing combination scheme. The fitness function is defined as a comprehensive evaluation indicator of the degree of achievement of the compensation target and the stability of the historical strategy. The strategy stability factor Ψ considers the difference between the current compensation scheme and the historical successful scheme:

[0045]

[0046] Explanation of formula symbols: : Strategy stability factor, dimensionless evaluation indicator; : The total number of feature parameters of the optimized candidate area, which is a positive integer; :Current plan feature vectors, whose dimensions match the parameter space; : Historical Case No. feature vectors, data of the same dimension; : Euclidean norm operator; : Numerical stability constant, fixed .

[0047] The maximum number of iterations during the optimization process is set to 50. The iteration is terminated when the fitness growth stagnation threshold is met (improvement is less than 0.1% for 5 consecutive generations) or the maximum number of generations is reached, and the parameter set after decoding the optimal chromosome is output. The generated optimized tension control parameter package is encapsulated in binary data and specifically includes:

[0048] Compensation action position optimization sequence: contains a coordinate list of the execution unit topology structure, each element is three groups of floating-point numbers representing the spatial position; compensation intensity adjustment ratio: expressed as a percentage matrix relative to the original compensation intensity, with an accuracy of 0.1%; compensation duration correction value: an array of time adjustment factors in milliseconds.

[0049] This parameter packet is transmitted via redundant industrial Ethernet to the control node of the roll-pressing actuator. The actuator's command parsing unit decomposes the data packet, and the address mapper locates the specific actuator unit based on the spatial coordinates in the position optimization sequence, with positioning error controlled within ±0.1mm. The compensation driver applies the intensity adjustment ratio data to the multi-stage drive controller, which integrates the ratio value into the closed-loop PID control loop and outputs a calibration signal to the servo valve group. The timing controller receives the duration correction value and generates a time window schedule for the compensation action, with system clock synchronization error less than 10ms. Within the specified execution time window, the pressure actuator unit dynamically adjusts the hydraulic output of the roll-pressing power unit based on the intensity adjustment ratio, with a pressure regulation resolution of 0.05% of the full range. The deformation monitoring unit integrates an array of laser triangulation displacement sensors, collecting real-time material deformation feedback data in the roll-pressing area at a sampling frequency of 5kHz. This data stream is accurately time-stamped and transmitted back to the raw data input interface of the tension generation module via a dedicated channel, completing the closed-loop control system. A data logger simultaneously stores complete execution process parameters, including a graph of the actual applied pressure, deformation response waveforms, and a timing deviation log. All operational time points are strictly synchronized with the main control system clock, using a high-precision crystal oscillator as the time base. A real-time monitoring interface displays the position sequence activation status, intensity scale implementation progress, and the remaining duration of the time window.

[0050] Example 4: See Figure 5 The real-time speed monitoring module and the dynamic compensation module collaborate in implementing this process. The real-time speed monitoring module deploys detection points at key nodes along the roll-to-roll material transmission path, with photoelectric encoder measurement units installed every 200 mm. The unit consists of an incremental photoelectric encoder and signal conditioning circuitry. The encoder has a resolution of 5000 pulses per revolution and is directly coupled to the shaft end of the transmission guide roller. A signal acquisition card records pulse sequences at a sampling frequency of 1000 Hz and converts the raw signal into linear velocity data using quadruple frequency decoding technology. The adjacent sampling period is fixed at 20 milliseconds. The speed fluctuation rate calculation unit processes data using the following logic: the linear velocity values ​​of the previous ten sampling periods are stored to form a reference queue. The latest sampled value is then compared with the median of this queue to determine the relative deviation rate. The calculated results are synchronously transmitted to the output interface of the state assessment module for cross-validation. The cross-validation process accesses the speed assessment indicator field in the tension stability assessment report, which contains material-specific speed tolerance parameters. Typical values ​​are shown in Table 1.

[0051] Table 1: Speed ​​stability verification parameters.

[0052] Material Type Code Maximum allowed volatility Tolerance time window Temperature compensation factor ELE-05 3.5% 150ms 0.8 ELE-12 2.8% 200ms 1.2 POL-07 4.2% 120ms 0.6

[0053] The request generator is triggered when the actual velocity fluctuation rate for the current material type ELE-12 exceeds the 2.8% threshold three times consecutively (e.g., at sampling points T+320ms, T+340ms, and T+360ms). This component creates a structured kinematic stability parameter correction request packet containing the following elements: a timestamp tag, a list of outlier indexes, actual velocity profile data, and a copy of the tension assessment report for the corresponding interval. This packet, in a lightweight binary format, is transmitted via the real-time communication bus to the priority processing port of the dynamic compensation module within 5 milliseconds.

[0054] The dynamic compensation module sets up a dedicated request processing channel and initiates a three-level response mechanism upon receiving a motion stability parameter correction request. The parsing engine decomposes the data packet content and extracts an array of actual line speed sample values ​​during the abnormal time period (e.g., [48.2, 47.8, 46.5] m / min). The database access agent automatically queries the equipment parameter partition of the production management database to obtain the current production line's rated transmission speed baseline value (50.0 m / min). The offset calculator performs a relative percentage algorithm: it calculates the absolute deviation of each sampling point from the baseline value ([1.8, 2.2, 3.5]) and divides it by the baseline value to obtain a percentage offset sequence ([3.6%, 4.4%, 7.0%]).

[0055] The compensation intervention level decision tree operates according to pre-set grading rules: Level-1 mode is activated when the maximum offset is below 5%; Level-2 mode is activated between 5% and 8%; and Level-3 emergency mode is initiated when the maximum offset exceeds 8%. In this example, a maximum offset of 7.0% triggers a Level-2 response, and the corresponding compensation intensity coefficient is incrementally adjusted to 1.8 times the baseline value. The instruction set updater uses memory hot swap technology to dynamically modify the intensity coefficient field in the currently executing dynamic tension control instruction set: the original compensation intensity coefficient of 0.75 is updated to 1.35. The updated data packet is appended with a red alert identifier (code #FF0000), which forces the policy optimization module to interrupt normal processing. The complete update operation is completed within 20 milliseconds, and an operation log is simultaneously written to the production management database. The log entry contains the original instruction set hash value, the modification time, and the operator's system identifier.

[0056] The status monitoring mechanism runs continuously during the exception handling process, and the real-time parameter panel is displayed on the system human-machine interface: the upper left area scrolls and refreshes the real-time curve of the line speed, and the current value is highlighted with a red cursor; the right panel partition displays the latest calculated offset statistics, including the average value (4.33%), the maximum value (7.0%) and the number of exceedance points (3); the bottom status bar flashes and displays the "COMP_L2ACTIVE" operation status code. All modification operations are subject to the permission verification mechanism. Only control accounts with priority 3 or above can perform hot updates of the instruction set. At the same time, the system maintains the original data backup cache and automatically triggers the data archiving process after the request processing is completed. The complete event sequence, including the original speed data, the correction request copy and the updated instruction set, is stored in the historical exception case library. The case library is indexed by material type and supports multi-dimensional retrieval by time range, offset level and intervention mode. The entire implementation process is synchronized by hardware-level real-time clock. The time deviation of each node is controlled within the range of ±2 milliseconds. The system watchdog timer checks the process status every 50 milliseconds to ensure that critical tasks are completed on time.

[0057] Example 5: The operating mechanism of the adaptive tension control system under emergency conditions. When the strategy optimization module receives the emergency adjustment mark (red alarm code #FF0000) marked by the dynamic compensation module, the process scheduler inside the module immediately sends a thread interrupt instruction to the strategy optimization main thread. This instruction activates the context protection mechanism: saves the current genetic algorithm population state to the non-volatile cache area, freezes the data flow of the optimization parameter output port, and releases computing resources for emergency response. The plan management unit then accesses the equipment operation history archive in the production management database. The archive has an independent emergency disposal plan data partition, and the partition index structure adopts a speed offset hierarchical coding system (integer variable, each 5% offset is a level). For example, when a 12% speed offset is currently detected, the system automatically matches the third-level emergency code. The plan retrieval engine accelerates data reading based on memory mapping file technology and completes the loading of the target plan set within 40 milliseconds.

[0058] The emergency plan dataset is stored in a tree structure, with each plan node containing a control mode feature vector, equipment constraint boundary conditions, and execution benefit evaluation indicators. The emergency pattern matcher processes the feature vector using an improved nearest neighbor classification algorithm. This algorithm calculates the multidimensional spatial distance between the current operating parameters and the plan feature vector, and handles nonlinear relationships using a radial basis function kernel transform. During the algorithmic search, solutions that violate equipment mechanical constraints (such as pressure output exceeding hydraulic system limits) are eliminated in real time. The optimal control mode ultimately determined includes the topological distribution of compensation points, the definition of the intensity action curve waveform, and time constraint rules.

[0059] The generation of the emergency tension control parameter package adheres to strict time series standards. The data within the package contains a predefined maximum compensation intensity range. The upper and lower limits of this range are derived from the calibration results of destructive testing in the material laboratory. For example, the upper strength limit of a certain type of dry electrode material is 120 MPa. The parameter definition adopts a three-stage structure: initial action intensity (60% of the calibration upper limit), peak sustained intensity (85% of the calibration upper limit), and attenuation gradient (decreasing by 10% of the calibration upper limit per second). The time parameter module sets the minimum action duration threshold, which is determined by the dynamic response characteristics of the equipment: the hydraulic actuator action delay time is superimposed on the control signal transmission delay, setting the minimum effective intervention period to 15 milliseconds. The parameter package format uses a simplified binary code. The header contains a version identifier and a checksum. The main body is divided into an equipment control section (actuator address list, intensity action curve number) and a process protection section (duration scale, material condition monitoring requirements).

[0060] The data transmission mechanism activates the highest-priority communication channel. The physical layer utilizes dedicated fiber links for transmission, and bandwidth reservation ensures data transmission latency is less than 2 milliseconds. The protocol stack utilizes an emergency data frame encapsulation format, skipping the standard handshake process and omitting the transport layer confirmation mechanism. Each data frame is guaranteed to be retransmitted three times. The system automatically disables non-critical data logging during execution, retaining only basic operational logs, reducing control cycles by 30%.

[0061] The roller actuator's operational procedures after receiving the emergency parameter package are strictly time-sequenced. The time window controller divides the execution phase into three stages: parameter package parsing and equipment preheating are completed within the first 5 milliseconds; the main execution phase adjusts the hydraulic proportional valve opening according to a preset strength action curve, while the displacement sensor array monitors the roll gap at a frequency of 10 kHz; and the termination phase decays the pressure output according to a gradient. The dynamic compensation module simultaneously initiates protective monitoring: when the material deformation approaches the plastic critical point (calculated based on the real-time stress-strain relationship), the compensation strength premature decay mechanism is triggered. All execution data is transmitted to the emergency event library in the production management database via an independent feedback loop, forming a closed-loop recording system. After the emergency operation is completed, the event recovery unit automatically assesses the system status and performs resource recovery operations, including restoring the frozen optimization thread context, clearing the temporary data cache, resetting the communication channel priority, and finally returning system control to the regular strategy optimization process. The entire emergency response process, from identification to execution, takes a typical time of 80 milliseconds, with time node accuracy guaranteed by a nanosecond clock synchronization network. During execution, the human-machine interface switches to emergency monitoring mode, focusing on displaying key parameters such as pressure output curves, material deformation rate, and remaining processing time. Operators only have priority viewing access, and manual intervention in the control flow is prohibited. The system's built-in abort mechanism continuously monitors equipment operating boundary parameters and immediately triggers a safety shutdown sequence if it detects actuator overtravel or an abnormal sudden change in hydraulic pressure.

[0062] It should be noted that, in this document, relational terms such as first and second, etc., are used only to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the terms "comprises," "comprising," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that includes a list of elements includes not only those elements but also other elements not explicitly listed, or elements inherent to such process, method, article, or apparatus.

[0063] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. An adaptive tension control system for a dry electrode continuous roll forming machine, characterized in that: include: The tension generation module is deployed on the transmission node of the rolling actuator to obtain the original tension data set during the rolling process in real time; The state evaluation module receives the original tension data set from the tension generation module, analyzes the current roller operation state and generates a tension stability evaluation report; The dynamic compensation module receives the tension stability assessment report from the state assessment module, calculates the deformation compensation amount of the rolled material and generates a dynamic tension control instruction set; The strategy optimization module receives the dynamic tension control instruction set and historical control records from the dynamic compensation module, optimizes the tension control strategy and outputs the optimized tension control parameter package; Production management database, which stores roll-pressed material property data sets, equipment operation history archives, and tension control case libraries; The roller actuator receives the optimized tension control parameter package from the strategy optimization module and adjusts the operating parameters of the roller actuator.

2. The adaptive tension control system of the dry electrode continuous roll forming machine according to claim 1, characterized in that: When the tension generation module obtains the original tension data set, the following specific operations are performed: real-time capture of the torque change waveform data of the driving shaft of the rolling actuator, synchronous acquisition of the speed difference sequence between the inlet and outlet of the rolled material, and integration of the surface friction coefficient detection data of the rolled material and the ambient temperature and humidity monitoring data to generate the original tension data set; wherein the surface friction coefficient detection data of the material is periodically acquired by an online surface scanner, and the ambient temperature and humidity monitoring data is acquired in real time by a sensor array arranged inside the rolling cavity.

3. The adaptive tension control system of the dry electrode continuous roll forming machine according to claim 2, characterized in that: The process of generating a tension stability assessment report by the state assessment module includes: extracting torque fluctuation characteristic values ​​and speed difference change gradients from the original tension data set, comparing the torque fluctuation characteristic values ​​with the standard torque fluctuation threshold interval in the equipment operation history archive, and matching and verifying the speed difference change gradient with the upper limit of the material's allowable deformation rate; when the torque fluctuation characteristic value exceeds the standard torque fluctuation threshold interval or the speed difference change gradient exceeds the upper limit of the material's allowable deformation rate, activating the tension anomaly identifier and calculating the actual deviation; and comprehensively considering the influence weights of the torque fluctuation characteristic value deviation, the speed difference change gradient deviation, and the environmental temperature and humidity monitoring data on the material properties to generate a tension stability assessment report containing multi-dimensional evaluation indicators.

4. The adaptive tension control system of the dry electrode continuous roll forming machine according to claim 3, characterized in that: The operation process of the dynamic compensation module generating the dynamic tension control instruction set is as follows: receiving the tension stability assessment report sent by the state assessment module, parsing the tension anomaly identifier and multi-dimensional assessment indicators therein; Call the material property data set in the production management database to match the elastic recovery coefficient and plastic deformation critical point parameters of the current rolling material; The basic compensation amount is calculated based on the actual deviation and the material elastic recovery coefficient, and the compensation strength coefficient is corrected in combination with the critical point parameters of plastic deformation; a dynamic tension control instruction set containing the compensation action position coordinates, compensation action timing and compensation strength coefficient is generated, and the instruction set is synchronously transmitted to the strategy optimization module and the production management database.

5. The adaptive tension control system of the dry electrode continuous roll forming machine according to claim 4, characterized in that: The process of optimizing the tension control strategy by the strategy optimization module specifically includes: receiving a dynamic tension control instruction set sent by the dynamic compensation module, and extracting a historical similar scene data set from a tension control case library in a production management database; pattern matching the compensation parameters in the current dynamic tension control instruction set with the control records in the historical similar scene data set, identifying the differences in the compensation strategy and marking the strategy optimization candidate area; recalculating the compensation timing arrangement and combination based on the strategy optimization candidate area to generate an optimized tension control parameter package; wherein the optimized tension control parameter package includes an optimized sequence of compensation action positions, a compensation amount intensity adjustment ratio, and a compensation duration correction value.

6. The adaptive tension control system of the dry electrode continuous roll forming machine according to claim 5, characterized in that: The operation of the rolling actuator executing the optimized tension control parameter package includes: receiving the optimized tension control parameter package sent by the strategy optimization module, parsing the compensation action position optimization sequence therein; locating the specific execution unit of the rolling actuator according to the compensation action position optimization sequence, loading the compensation amount intensity adjustment ratio to the drive controller, and setting the compensation duration correction value as the execution time window; dynamically adjusting the rolling pressure output value according to the compensation amount intensity adjustment ratio within the specified execution time window, and at the same time monitoring the rolling material deformation feedback data in real time and feeding it back to the tension generation module.

7. The adaptive tension control system of the dry electrode continuous roll forming machine according to claim 1, characterized in that: The system also includes a real-time speed monitoring module, which is configured to: continuously collect real-time linear speed change data during the transmission process of the rolled material, calculate the speed fluctuation rate of adjacent sampling periods; cross-validate the speed fluctuation rate with the speed evaluation index in the tension stability evaluation report output by the state evaluation module; when the speed fluctuation rate exceeds the allowable range of the speed evaluation index, generate a motion stability parameter correction request and send it to the dynamic compensation module.

8. The adaptive tension control system of the dry electrode continuous roll forming machine according to claim 7, characterized in that: The processing flow of the dynamic compensation module in response to the motion stability parameter correction request is as follows: receiving the motion stability parameter correction request sent by the real-time speed monitoring module, and extracting the actual sampling value of the current rolling material linear speed; The rated transmission speed reference value of the equipment is retrieved from the production management database, and the speed offset between the actual sampling value and the rated reference value is calculated; the compensation intervention level is determined according to the size of the speed offset, the compensation intensity coefficient in the dynamic tension control instruction set is updated, and the updated compensation intensity coefficient is marked as an emergency adjustment flag and transmitted to the strategy optimization module.

9. The adaptive tension control system of the dry electrode continuous roll forming machine according to claim 8, characterized in that: The operation of the strategy optimization module for processing the emergency adjustment mark includes: receiving the emergency adjustment mark marked by the dynamic compensation module, interrupting the current strategy optimization process; immediately calling the emergency disposal plan data set in the equipment operation history archive in the production management database, matching the emergency control mode corresponding to the current speed offset, and generating an emergency tension control parameter package.

10. The adaptive tension control system of the dry electrode continuous roll forming machine according to claim 9, characterized in that: The emergency tension control parameter package includes the maximum action interval and the shortest action duration of the compensation intensity.

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