Circular knife double-asynchronous collaborative die cutting process and equipment for multi-glue-layer blue film structure

Abstract

The invention relates to the technical field of machining, and discloses a circular knife double-asynchronous collaborative die cutting process and equipment for a multi-glue-layer blue film structure, and the process comprises the following steps: obtaining material parameters and pattern data, and carrying out pretreatment and real-time visual alignment on the multi-glue-layer blue film structure; and the central control module operates an algorithm according to the data, generates and drives the first circular cutter die cutting unit and the second circular cutter die cutting unit to perform asynchronous collaborative die cutting, and peels off waste materials. The system comprises a material conveying module, a visual alignment module, a first circular cutter die cutting unit, a second circular cutter die cutting unit, a central control module and a waste stripping module. By the adoption of the scheme, die cutting alignment precision and efficiency are improved, material loss and production cost are reduced, traditional die cutting errors and material deformation are avoided, cutting quality is optimized, and a technical basis is provided for lean production of electronic product parts.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of mechanical processing, and particularly relates to a circular knife double-asynchronous collaborative die-cutting process and equipment of a multi-glue-layer co-blue-film structure. BACKGROUND

[0002] In the field of modern electronic product manufacturing, especially consumer electronic products such as mobile phones and computers, the production efficiency, cost control and processing precision of internal precision parts are extremely high. Among them, the precision machining of flexible materials such as various glue layers and protective films is a key link that affects product performance and manufacturing cost. As an important process means to realize efficient and accurate forming of flexible materials, die-cutting technology has been widely used in the production line of the electronic industry.

[0003] Among them, for the precision die-cutting of complex flexible materials such as multi-glue-layer co-blue-film structure, the process complexity, precision requirement and efficiency bottleneck are particularly prominent. Traditional die-cutting process often adopts a layer-by-layer processing mode of single process, single layer material, or is limited to batch cutting of simple shapes. This mode faces challenges when processing multi-layer composite materials or structures integrating multiple glue layers and films, and is difficult to meet the growing demand for production efficiency and cost control.

[0004] The existing technology has the problems of low efficiency and high cost in the die-cutting process of the above-mentioned multi-glue-layer co-blue-film structure or similar multi-layer composite material. Specifically, the traditional circular knife die-cutting process usually cannot realize synchronous processing of multiple glue layers and precise cutting of complex shapes, and often needs to be carried out in steps, resulting in complicated process, low equipment utilization, and further increasing the connection time and labor cost between multiple processes. In addition, in the face of gap differences between different glue layers or special shape requirements, the existing die-cutting equipment often cannot effectively integrate asynchronous processing capacity, and needs to add additional stations, replace dies or combine with other types of equipment (such as flat knives), which not only greatly increases the equipment investment and die development cost, but also further reduces the flexibility and efficiency of the overall production line. More importantly, after continuous die-cutting, there is a lack of effective subsequent station integration processing mechanism, such as winding and transferring of isolation film, which forces the production process to be interrupted, increases the material handling and secondary processing links, leads to the extension of the production cycle, and intensifies the material loss. Therefore, how to develop a precision die-cutting process and equipment that can efficiently and collaboratively process multi-glue-layer structures, adapt to complex shape cutting, reduce process connection and reduce production cost has become a technical problem to be solved in the current industry. SUMMARY

[0005] In order to solve the problem that the cost of each part in the mobile phone and computer industry is strictly controlled, the optimization space of the production process is limited, and it is difficult to gain an advantage in market competition in the prior art, a round knife double-asynchronous collaborative die-cutting process and equipment of multi-glue layer co-blue film structure are provided.The present application aims to improve the die-cutting precision, efficiency and material utilization of multi-glue layer co-blue film structure through precise control and intelligent collaboration, thereby reducing production cost and enhancing market competitiveness.

[0006] The present application provides a round knife double-asynchronous collaborative die-cutting process of multi-glue layer co-blue film structure, comprising the following steps: Obtaining material parameters of multi-glue layer co-blue film structure and die-cutting pattern data; Pretreating the multi-glue layer co-blue film structure, the pretreatment includes surface cleaning, tension control and initial positioning; Using a high-resolution industrial vision system to collect image data of the surface of the multi-glue layer co-blue film structure in real time; Based on the image data, the fiducial marks on the multi-glue layer co-blue film structure are identified by image processing algorithm, and the real-time position and angle deviation of the multi-glue layer co-blue film structure relative to the preset die-cutting coordinate system are calculated; The real-time position and angle deviation data, the material parameters, and the die-cutting pattern data are input into the central control module; The central control module runs adaptive die-cutting path planning algorithm and dynamic cutting parameter optimization algorithm based on the input data, generates independent die-cutting path, cutting depth, cutting speed and round knife rotating speed of the first round knife die-cutting unit and the second round knife die-cutting unit; Driving the first round knife die-cutting unit and the second round knife die-cutting unit to perform asynchronous collaborative die-cutting on the multi-glue layer co-blue film structure according to the generated die-cutting path and cutting parameters; After die-cutting, the die-cutting waste is stripped from the multi-glue layer co-blue film structure by the waste matrix stripping mechanism; Collecting the finished products after die-cutting.

[0007] As a preferred embodiment of the present application, the obtaining of material parameters of multi-glue layer co-blue film structure and die-cutting pattern data specifically includes: Obtaining the physical property parameters of each glue layer and blue film layer in the multi-glue layer co-blue film structure, such as material type, thickness, hardness, viscosity, Young's modulus and friction coefficient; Obtaining vector geometry data of the die-cutting pattern, the vector geometry data including contour line, hole site, cutting area and half-cut area information.

[0008] As a preferred embodiment of the present application, the pretreatment specifically includes: The multi-adhesive layer co-blue film structure roll is unwound by an unwinding mechanism; Dust and particulate matter attached to the surface of the multi-adhesive layer co-blue film structure are removed by a cleaning unit; The constant tension of the multi-adhesive layer co-blue film structure during transportation is maintained by a closed-loop tension control system; The lateral position of the multi-adhesive layer co-blue film structure during transportation is adjusted by a deviation correction guide mechanism to ensure accurate movement along the preset path.

[0009] As a preferred embodiment of the present application, the high-resolution industrial vision system comprises at least one high-resolution industrial camera and a dedicated illumination module; the image processing algorithm specifically comprises: The image recognition technology based on template matching or feature point extraction is used to accurately identify at least two preset reference markers on the surface of the multi-adhesive layer co-blue film structure; The relative position offset and angular rotation between the reference markers and the preset die-cutting coordinate system are calculated by a sub-pixel level image processing algorithm, with a positioning accuracy of microns.

[0010] As a preferred embodiment of the present application, the adaptive die-cutting path planning algorithm and dynamic cutting parameter optimization algorithm specifically comprise: According to the geometric characteristics of the to-be-die-cut pattern and the material parameters, an independent die-cutting path for the first rotary die-cutting unit and the second rotary die-cutting unit is initially generated; According to the real-time position and angle deviation data, the independent die-cutting path is dynamically adjusted to compensate for the real-time deformation and position deviation of the multi-adhesive layer co-blue film structure; According to the physical properties of each layer of material in the multi-adhesive layer co-blue film structure, different cutting depths, cutting speeds, and rotary knife speeds are set for the first rotary die-cutting unit and the second rotary die-cutting unit, respectively, to achieve selective or penetrating die-cutting of different adhesive layers and blue film layers; The cutting depth setting specifically includes: for the first rotary die-cutting unit, the cutting depth is set to penetrate only part of the adhesive layer or the blue film layer; for the second rotary die-cutting unit, the cutting depth is set to penetrate all layers of the multi-adhesive layer co-blue film structure, or to penetrate different adhesive layers or blue film layers than the first rotary die-cutting unit.

[0011] The dynamic cutting parameter optimization algorithm adjusts the cutting depth, cutting speed, and rotary knife speed in real time by combining real-time feedback of die-cutting force data and vision detection data to maintain optimal die-cutting quality and efficiency.

[0012] As a preferred embodiment of the present application, the asynchronous cooperative die-cutting specifically comprises: The first rotary knife die-cutting unit and the second rotary knife die-cuting unit independently or in parallel perform die-cutting operations on the multi-ply common blue film structure according to the independently generated die-cutting paths and cutting parameters; The asynchronous cooperative die-cutting mode includes at least one of the following: The first rotary knife die-cutting unit performs half-cutting on the upper ply of the multi-ply common blue film structure, and the second rotary knife die-cuting unit performs full-cutting on the lower ply and the blue film layer of the multi-ply common blue film structure, and the die-cutting areas of the two units overlap or are adjacent; The first rotary knife die-cutting unit and the second rotary knife die-cuting unit simultaneously perform die-cutting on different die-cutting pattern areas on the multi-ply common blue film structure; The first rotary knife die-cutting unit and the second rotary knife die-cutting unit cooperatively complete the cutting of a single complex die-cutting pattern, for example, one unit is responsible for cutting straight lines, and the other unit is responsible for cutting curves, or one unit cuts the outer contour, and the other unit cuts the inner hole.

[0013] As a preferred embodiment of the present application, the waste matrix stripping mechanism specifically includes: A vacuum adsorption stripping unit selectively adsorbs and strips the die-cutting waste through a high-flow vacuum pump and a precision adsorption nozzle; An auxiliary stripping mechanism strips stubborn waste with the aid of an air knife or a mechanical scraper; A waste winding mechanism winds the stripped waste through an independently driven winding shaft.

[0014] The present application provides a rotary knife double-asynchronous cooperative die-cutting equipment for a multi-ply common blue film structure, which includes: A material conveying module for carrying and accurately conveying the multi-ply common blue film structure; A visual alignment module for real-time acquisition of image data of the multi-ply common blue film structure and calculation of real-time position and angle deviation thereof relative to a preset die-cutting coordinate system; A first rotary knife die-cutting unit for die-cutting the multi-ply common blue film structure; A second rotary knife die-cutting unit for die-cutting the multi-ply common blue film structure; A central control module electrically connected with the visual alignment module, the first rotary knife die-cutting unit and the second rotary knife die-cutting unit, respectively, for generating independent die-cutting paths, cutting depths, cutting speeds and rotary knife rotating speeds of the first rotary knife die-cutting unit and the second rotary knife die-cutting unit according to the real-time position and angle deviation data, material parameters and to-be-die-cut pattern data, and driving the first rotary knife die-cutting unit and the second rotary knife die-cutting unit to perform asynchronous cooperative die-cutting; A waste stripping module for stripping die-cutting waste.

[0015] As a preferred embodiment of the present application, the material conveying module comprises: An unwinding mechanism driven by a servo motor for unwinding the multi-layered co-blue film structure roll; A cleaning unit comprising a dust removal brush and an electrostatic elimination device for cleaning the surface of the multi-layered co-blue film structure; A tension control system comprising a tension sensor and a feedback control unit for maintaining constant tension during the conveying of the multi-layered co-blue film structure; A deviation correction guide mechanism comprising a photoelectric sensor and a linear actuator for adjusting the lateral position of the multi-layered co-blue film structure during conveying; A feeding mechanism comprising a precision servo roller and an encoder for accurately controlling the feeding length of the multi-layered co-blue film structure.

[0016] As a preferred embodiment of the present application, the visual alignment module comprises: At least one high-resolution industrial camera with a megapixel-level resolution for real-time image acquisition of the surface of the multi-layered co-blue film structure; A dedicated lighting module comprising a coaxial light source and a backlight source for providing uniform and stable lighting for the camera; An image processing unit comprising a high-performance image processor and a memory for running image processing algorithms to identify the reference marks and calculate position and angle deviations.

[0017] As a preferred embodiment of the present application, each of the first circular knife die-cutting unit and the second circular knife die-cutting unit comprises: A high-precision circular knife head made of high-hardness alloy steel material with a specific blade geometry for cutting the multi-layered co-blue film structure; A circular knife driving mechanism comprising a high-response servo motor and a precision reducer for accurately controlling the rotational speed of the circular knife head; A three-axis motion control mechanism comprising X-axis, Y-axis, and Z-axis high-precision linear actuators for accurately controlling the horizontal movement and cutting depth of the circular knife head, the linear actuators being linear motors or ball screws cooperating with high-precision linear guides; A cutting force sensor, which is a piezoelectric or strain gauge sensor, integrated into the circular knife head bracket for real-time measurement of the force generated during cutting and feedback of force data to the central control module; The circular knife head is provided with auxiliary heating or cooling devices for optimizing the cutting effect through temperature adjustment according to the adhesive properties of the adhesive layers in the multi-layered co-blue film structure.

[0018] As a preferred embodiment of the present application, the central control module comprises: a master control unit, which adopts an industrial programmable logic controller or a high-performance industrial computer, for executing system instructions and coordinating the work of each module; a motion control unit, which communicates with the three-axis motion control mechanisms of the first and second rotary die cutting units through a real-time Ethernet bus (e.g., EtherCAT) for high-speed communication, achieving multi-axis linkage and precise position control; a data acquisition unit for receiving real-time data from the visual alignment module, cutting force sensor, and tension control system; an algorithm processing unit for running the adaptive die cutting path planning algorithm and the dynamic cutting parameter optimization algorithm; a human-machine interface, including a touch display screen and input devices, for operators to monitor equipment status, set process parameters, and perform fault diagnosis.

[0019] As a preferred embodiment of the present application, the waste stripping module comprises: a vacuum suction mechanism with an array of suction nozzles and a high negative pressure vacuum pump for selectively suctioning and stripping the waste matrix after die cutting; an air knife auxiliary mechanism that further assists in separating the waste from the finished product through high-pressure air flow; a waste winding mechanism that uses an independent tension control system and a servo motor to neatly wind the stripped waste.

[0020] Compared with the prior art, the present application has the following advantages and positive effects: 1. The present application proposes a rotary die cutting process and equipment for multi-glue layer co-blue film structure with double asynchronous cooperation, effectively solving the problems of low precision, high material loss, low production efficiency, and difficult cost control in the prior art for such complex structure. By combining a high-resolution industrial vision system with sub-pixel level image processing algorithm, real-time compensation of position and angle deviation of multi-glue layer co-blue film structure is achieved at the micron level, improving the die cutting alignment accuracy.

[0021] 2、Central control module integrates adaptive die-cutting path planning algorithm and dynamic cutting parameter optimization algorithm, which can intelligently adjust the cutting depth, speed and rotation speed of the first circular knife die-cutting unit and the second circular knife die-cutting unit according to different material layer properties and real-time feedback data. This double-asynchronous cooperative working mode makes the two circular knife units not only can independently perform different tasks (for example, one half-cut, one full-cut), but also can cooperatively complete the die-cutting of complex patterns, thereby realizing the simultaneous or layered precise cutting of multi-layer materials, greatly reducing the multi-process connection, avoiding the accumulation of alignment errors and material deformation caused by multiple material handling in traditional die-cutting methods.

[0022] 3、The introduction of cutting force sensor and auxiliary heating and cooling device enables the system to real-time perceive the cutting state and optimize the cutting environment, effectively reducing the burr, stringing or delamination problems caused by the adhesive layer viscosity, and ensuring the die-cutting quality. This highly intelligent and precise collaborative die-cutting scheme greatly improves the production efficiency, reduces material loss, and ensures product quality stability, thereby reducing production cost, and providing a solid technical foundation for lean production of mobile phone, computer and other electronic product parts. BRIEF DESCRIPTION OF DRAWINGS

[0023] Figure 1 is the overall technical scheme architecture schematic diagram of the circular knife double-asynchronous collaborative die-cutting process and equipment of the multi-adhesive layer common blue film structure proposed by the present application; Figure 2 is the core principle framework schematic diagram of the double-asynchronous collaborative die-cutting in the present application; Figure 3 is the logic flow framework diagram of the circular knife double-asynchronous collaborative die-cutting process of the multi-adhesive layer common blue film structure proposed by the present application; Figure 4 is the multi-level interaction relationship and data flow schematic diagram of the visual alignment module, central control module and circular knife die-cutting unit in the present application; Figure 5 is the core principle framework schematic diagram of the adaptive die-cutting path planning algorithm and dynamic cutting parameter optimization algorithm in the present application; DETAILED DESCRIPTION Please refer to Figures 1-5The overall technical scheme architecture of the multi-glue layer co-blue film structure round knife double-asynchronous collaborative die-cutting equipment contains several functional modules that closely cooperate to achieve precise execution of the die-cutting process. The equipment mainly consists of a material supply unit, a visual alignment and detection unit, a central control and data processing unit, a double-asynchronous round knife die-cutting unit, a waste removal unit, and a finished product collection unit. The material supply unit is responsible for the precise delivery of the multi-glue layer co-blue film structure to be die-cut, ensuring the stable positioning of the material in the die-cutting area. The visual alignment and detection unit is equipped with a high-resolution industrial camera array and a light source system, which can capture real-time material surface texture, pre-set markers, and die-cutting contour information, and transmit image data to the central control and data processing unit. The central control and data processing unit is the intelligent core of the entire equipment, which integrates high-performance processors, memories, input / output interfaces, and pre-installed adaptive die-cutting path planning algorithms and dynamic cutting parameter optimization algorithms. The unit receives visual data, design pattern data, and operation instructions, performs complex calculations and decisions, and generates and issues die-cutting instructions to the double-asynchronous round knife die-cutting unit.

[0024] The double-asynchronous round knife die-cutting unit is the core execution mechanism of the equipment, which contains two independent round knife die-cutting components. Each round knife die-cutting component is composed of a high-precision servo motor driven round knife cutter, an independently adjustable die-cutting pressure mechanism, and an independent feeding drive mechanism. These two round knife die-cutting components can run independently while achieving high-precision time and space collaboration through the central control unit, i.e., double-asynchronous collaborative die-cutting. This asynchrony is reflected in the independent operation of the two round knives at different speeds, different die-cutting depths, and different cutting paths, thereby achieving differential precision cutting of different material layers or different areas in the multi-glue layer structure. The collaboration is reflected in the central control unit optimizing the working strategies of the two round knives according to the overall die-cutting task, for example, one round knife is responsible for half-cutting the upper glue layer, while the other round knife is responsible for full-cutting the lower glue layer or co-blue film, or both round knives cut the same layer of glue in different areas, thereby greatly improving production efficiency. The die-cutting pressure mechanism can accurately control the contact force between the round knife cutter and the material according to the instructions issued by the central control unit, to adapt to the die-cutting needs of different material thickness and hardness. The feeding drive mechanism ensures the continuous and stable movement of the material during the die-cutting process. The waste removal unit is responsible for effectively stripping and collecting the waste generated during die-cutting after the die-cutting is completed, to prevent it from interfering with the subsequent process or contaminating the finished product. The finished product collection unit classifies, stacks, or winds the qualified products after die-cutting, to facilitate subsequent packaging and transportation. The entire equipment realizes data interaction and instruction transmission between units through a high-speed communication network, ensuring the real-time, accuracy, and stability of the die-cutting process.

[0025] The method flow of the circular knife double-asynchronous collaborative die-cutting process of the multi-glue-layer co-blue film structure includes several key steps. The process aims to realize the dual improvement of die-cutting efficiency and quality through intelligent control and high-precision execution. The specific method includes: S101, obtaining material information to be die-cut and digital design pattern data.

[0026] This step is the basis of the entire die-cutting process, involving the comprehensive collection and analysis of physical material characteristics and digital product design specifications. First, the physical characteristic information of the material to be die-cut, i.e., the multi-glue-layer co-blue film structure, is crucial. This includes the overall thickness of the material, the thickness of each glue layer and blue film, the hardness, adhesion, elastic modulus, and thermal expansion coefficient of the material, etc. These data can be obtained through standard physical measurement tools such as thickness gauges, hardness testers, and material testing machines. The obtained data will be stored in the material database of the device and associated with a specific material batch or model to facilitate accurate matching of subsequent process parameters. Second, digital design pattern data is the blueprint for die-cutting. These data usually exist in computer-aided design file formats, such as Extensible Markup Language format or Digital Exchange format. Design pattern data defines the geometric shape, dimensional tolerance, chamfer requirement of die-cutting edge, and die-cutting depth requirement of different glue layers of the product to be cut in detail. In particular, for multi-glue-layer structures, the design pattern needs to clearly indicate which layers are full-cut, which layers are half-cut, and the geometric profile corresponding to different cutting depths. After importing into the central control and data processing unit, these design data will first be parsed and data checked to ensure their integrity and accuracy. Data checking includes topology structure checking of geometric figures, size legality verification, and compatibility assessment with preset die-cutting device working range. Any format error, size overrun, or topology defect will trigger an alarm and require manual intervention. The parsed design pattern data will be converted into an internal unified data structure, such as a geometric topology graph composed of nodes, line segments, and curves, with each geometric element's die-cutting attribute label, such as cutting type, layer information, and required die-cutting force and speed range. In addition, the production batch information, expected output, die-cutting speed preference, and quality control standards of the current die-cutting task need to be obtained. These information as task constraints will be input into the central control and data processing unit to provide comprehensive data support for subsequent die-cutting path planning and parameter optimization.

[0027] S102, performing multi-modal high-precision alignment and deviation correction based on visual sensing.

[0028] This step is the key link to ensure the die cutting accuracy and yield, the core of which is to accurately position the material through advanced vision system and compensate for possible deviations in real time. The vision positioning and detection unit first acquires images of the material to be processed entering the die cutting area through a high-resolution industrial camera array. These cameras usually use area array or line array complementary metal oxide semiconductor sensors, with high frame rate and high dynamic range characteristics to adapt to the reflectivity and motion speed of different material surfaces. During image acquisition, multi-angle ring light or backlight is used to ensure that the material surface features, pre-set positioning marks and potential defects can be clearly imaged. The raw image data collected is then transmitted to the central control and data processing unit for image preprocessing. Image preprocessing includes noise filtering, such as Gaussian filtering or median filtering, to eliminate random interference; contrast enhancement, such as histogram equalization or gamma correction, to highlight feature details; and image binarization or edge detection, such as Canny operator or Sobel operator, to extract the geometric information of the die cutting contour and positioning marks. Then, the system uses advanced image recognition algorithms, such as feature matching or template matching methods, to identify key positioning mark points on the material, such as product reference corner points or circular marks. By comparing the coordinates of the identified mark points with the theoretical mark point coordinates in the digital design pattern, the positional deviation of the material in the die cutting plane is calculated, including the offset along the horizontal axis, the offset along the vertical axis and the rotation angle deviation. In addition, for possible local deformation or warping of the material, the vision system can also use three-dimensional structured light scanning or binocular stereo vision technology to obtain the three-dimensional topographic data of the material surface, and then calculate more detailed deformation deviations. Based on these calculated positional deviations and deformation deviations, the central control and data processing unit will generate a series of correction instructions. These instructions will be transmitted through a high-precision motion control system to drive the material supply unit's feeding mechanism to make fine adjustments to achieve accurate positioning of the material in the die cutting area. For example, the actual position of the material can be aligned with the theoretical die cutting area by adjusting the starting position, feed speed and material posture in the horizontal direction. For small residual deviations that cannot be completely corrected by physical adjustment, such as slight stretching or compression of the material, the system will make adaptive compensation adjustments to the die cutting path to ensure that the die cutter always cuts along the precise trajectory specified by the design pattern. The accuracy requirement of this step is extremely high, usually reaching microns to meet the tolerance requirements of electronic product precision components. The entire positioning and correction process is completed in real time under the high-speed motion state of the material, ensuring the continuity and efficiency of the production line.

[0029] S103, generating and optimizing the double-asynchronous collaborative die cutting path based on the product structure and the state of the die cutting unit.

[0030] This step is one of the core innovations of the die-cutting process in this invention, aiming to fully utilize the advantages of the dual asynchronous circular die-cutting unit to achieve efficient and high-quality cutting of complex multi-layer adhesive materials. After completing the visual alignment and deviation correction in step S102, the central control and data processing unit has obtained accurate information on the current position of the material and the digital design drawing of the product to be die-cut. First, the system performs topology analysis on the design drawing to identify different die-cutting areas, different cutting level requirements, and logical dependencies between die-cutting paths. For example, the adhesive layer area requiring partial cutting and the base blue film area requiring full cutting will be identified separately. Next, the system acquires the real-time status information of the current dual asynchronous circular die-cutting unit, including the availability of the two circular die-cutting components, the current rotation speed limit, the maximum die-cutting depth, and whether there is tool wear or maintenance requirements. This status information will serve as constraints for path planning.

[0031] Based on this, the system employs an adaptive die-cutting path planning algorithm to generate and optimize the initial die-cutting path. This algorithm considers multiple optimization objectives, such as minimizing total die-cutting time, minimizing tool wear, maximizing material utilization, and avoiding interference or collisions during the die-cutting process. The core idea of ​​path planning is to decompose a complex overall die-cutting task into multiple sub-tasks and rationally allocate them to two independent circular die-cutting components. For example, for a structure containing two adhesive layers and a blue film, the first circular die can be responsible for partially cutting the upper adhesive layer, while the second circular die can fully cut the lower adhesive layer and the blue film. The path planning algorithm calculates the precise motion trajectory of each circular die, including its two-dimensional coordinate sequence in the material plane, as well as the corresponding rotation speed and die-cutting depth. For cutting complex shapes, the algorithm uses methods such as spline interpolation or Bézier curve fitting to generate smooth and continuous tool trajectories.

[0032] The die-cutting path optimization function can be represented as follows: ; in, Represents the set of die-cutting paths The total cost function, Show the first The length of the die-cutting path, Indicates the first The time cost of starting, stopping, or adjusting the speed of the secondary circular cutter. Indicates the first A potential penalty for circular knife collision or path intersection conflict. Path length weighting coefficient The time cost weighting coefficient, represents the conflict penalty weighting coefficient. This function aims to find an optimal combination of paths that minimizes the overall cost while satisfying all die-cutting requirements.

[0033] In the path generation process, considering the characteristics of double-asynchronous collaboration, the algorithm will divide the die-cutting area and schedule the tasks. A complex die-cutting area can be divided into several non-overlapping sub-areas, or partially overlapping areas, and then these sub-areas are assigned to different rotary knives for processing. The system will consider the working area of the two rotary knives, kinematic constraints, and the logical relationship of the die-cutting sequence. For example, in some cases, the processing of one rotary knife must be completed before the processing of the other rotary knife to avoid damage to the material structure. In other cases, the two rotary knives can die-cut in areas far enough apart to maximize parallel efficiency. If there is a die-cutting requirement for overlapping areas, the algorithm will accurately calculate the motion timing and spatial avoidance of the two rotary knives in the overlapping area to ensure interference-free collaborative work. The optimization algorithm usually uses genetic algorithms, particle swarm optimization, or rule-based heuristic search strategies to find the optimal solution in a vast path space. The final output of the die-cutting path set contains detailed motion instruction sequences for the two rotary knives, including coordinates, velocities, accelerations, and corresponding die-cutting depth and pressure settings at each time step. These instructions will be transmitted to the next step in the form of high-precision digital signals, which will dynamically adjust the die-cutting parameters and drive the die-cutting unit to work. This step converts complex manual experience into executable automated instructions through intelligent algorithms, significantly improving the intelligence level and production efficiency of the die-cutting solution.

[0034] S104, dynamically adjusting die-cutting parameters and driving rotary knife die-cutting units for collaborative die-cutting work.

[0035] This step is the core of the die-cutting process execution, which is based on the optimized die-cutting path generated in step S103 and combines real-time feedback information to finely adjust the die-cutting parameters to ensure the stability, efficiency, and quality of the die-cutting process. After receiving the motion instruction sequence of the two rotary knife die-cutting components issued by the central control and data processing unit, the independent servo drive system of each rotary knife die-cutting component starts to act according to the instructions. The dynamic adjustment of die-cutting parameters includes rotary knife speed, die-cutting depth, feeding speed, and die-cutting pressure. These parameters are not fixed values, but are continuously adjusted according to the local characteristics of the current die-cutting material, the complexity of the cutting geometry, and the real-time state of the rotary knife cutter. For example, when cutting a thin and brittle adhesive layer, the rotary knife speed may be appropriately reduced, the die-cutting depth is precisely controlled to half-cut requirements, and the die-cutting pressure is adjusted to avoid material tearing; when cutting a thicker or more flexible base film, the speed and die-cutting pressure may be increased accordingly, and the die-cutting depth is adjusted to full-cut.

[0036] The dynamic cutting parameter optimization algorithm continuously functions during the die cutting execution process. The algorithm receives real-time sensor data from within the die cutting unit, such as real-time vibration signals of the rotary knife, load current of the servo motor, feedback values of the material tension sensor, and local temperature of the die cutting area. These sensor data are used to assess whether the current die cutting state meets expectations, whether there are problems such as abnormal vibration, signs of tool dulling, material slipping, or local overheating. Based on these real-time data, the algorithm dynamically corrects the die cutting parameters through predictive control or adaptive control strategies. For example, if abnormal vibration of the knife is detected, the algorithm may slightly adjust the rotary knife speed or the material feeding speed within a safe range to suppress vibration and prolong the tool life. If the material tension fluctuates, the material feeding drive mechanism will fine-tune its speed to maintain stable feeding of the material.

[0037] Cutting depth The real-time adjustment strategy can be represented as: ; represents the cutting depth target value that needs to be applied in the next control cycle, represents the actual cutting depth value at the current time, is the proportional control gain, is the integral control gain, is the derivative control gain, represents the die cutting depth error, which is defined as the difference between the target die cutting depth and the actual die cutting depth feedback by the vision detection or laser ranging sensor. This formula embodies the classic proportional-integral-derivative controller idea, which achieves fast response, stable correction, and smooth transition to the cutting depth through the proportional, integral, and derivative terms of the error signal, to offset the effects of small fluctuations in material thickness or changes in mechanical clearance of the equipment.

[0038] For double-asynchronous collaborative die cutting, the parameter adjustment of the two rotary knife die cutting assemblies is independent but coordinated. This means that the speed, depth, and pressure of each rotary knife are independently optimized according to their respective die cutting tasks and local material conditions, but these optimization processes are subject to overall coordination by the central control unit to ensure that the movements of the two rotary knives do not interfere with each other and jointly achieve the die cutting target of the entire product. For example, when two rotary knives are simultaneously processing different areas, if the material in the area where one rotary knife is located suddenly hardens, the die cutting pressure of that rotary knife may be dynamically adjusted upward, while the parameters of the other rotary knife remain unchanged. This independent adjustment capability greatly enhances the adaptability to complex and variable die cutting scenarios. The entire dynamic adjustment and execution process is a high-speed, closed-loop control process that ensures that each die cutting action is performed with optimal parameters, thereby achieving high-precision, high-efficiency, and low-loss die cutting results.

[0039] S105, real-time monitoring of the die cutting process and quality detection and feedback optimization.

[0040] This step is an important guarantee for ensuring the final quality of the product and continuous improvement of the process. While the round knife die-cutting unit is performing the collaborative die-cutting operation, the die-cutting process is monitored in multiple dimensions and at a high frequency in real time. Quality detection and feedback optimization are mainly achieved through the following aspects. First, real-time monitoring of die-cutting physical parameters. This includes continuous measurement of the actual speed of the die-cutting knife, the die-cutting depth, the die-cutting force, and the feeding speed. High-precision encoders are used to feed back the actual speed of the round knife and the displacement of the feeding mechanism; force sensors are integrated into the die-cutting pressure mechanism to measure the force exerted by the die-cutting knife on the material; and laser ranging sensors or capacitive sensors are used for non-contact measurement of the remaining thickness of the material after die-cutting to verify whether the cutting depth meets the requirements of half-cutting or full-cutting. The real-time values of these physical parameters will be compared with the target values set in step S104, and any deviation beyond the preset tolerance range will trigger an alarm.

[0041] Second, online visual detection of die-cutting results. Immediately after or immediately following die-cutting, the vision alignment and detection unit again performs high-resolution image acquisition of the die-cut material. Through image processing and pattern recognition algorithms, the system can automatically detect the integrity of the die-cut edge, the presence or absence of burrs, whether the size meets the tolerance, and whether there are defects such as incomplete cutting or overcutting. For example, using methods based on edge gradient analysis or feature point recognition, the sharpness and smoothness of the die-cut edge are determined. For die-cutting of multi-layer structures, the system can also analyze the accuracy of each layer of die-cutting through tomographic imaging or image acquisition under different wavelength light sources, such as whether the half-cut layer is accurately cut to the target depth without damaging the underlying material.

[0042] When deviations or abnormalities in die-cutting quality are detected, the central control and data processing unit initiates a feedback optimization mechanism immediately. Feedback optimization is divided into two levels: immediate correction and long-term improvement. Immediate correction means adjusting parameters for the current or upcoming die-cutting operation. For example, if it is detected that the die-cutting depth is slightly insufficient, the system can immediately send instructions to the rotary die-cutting unit to fine-tune the die-cutting pressure or depth compensation value to ensure the die-cutting quality of subsequent products. This closed-loop control feedback mechanism enables the equipment to adaptively compensate for minor changes in materials or slight wear of the cutting tool. Long-term improvement involves analyzing historical die-cutting data and quality detection results. All die-cutting process data, parameter settings, environmental conditions, and corresponding product quality detection results are recorded and stored in a database. Through big data analysis and machine learning techniques, the system can identify potential patterns or associated factors that cause quality problems. For example, tool wear after a long period of operation and quality fluctuations of specific material batches may be identified as key factors affecting die-cutting quality. These analysis results will be used to optimize the die-cutting path planning algorithm in step S103 and the dynamic cutting parameter optimization algorithm in step S104, such as updating the tool wear model, adjusting the default values in the material parameter library, or optimizing the gain coefficient of parameter adjustment, so as to realize continuous self-improvement and performance improvement of the die-cutting process. This step not only guarantees the quality pass rate of the current production batch, but also provides a solid data foundation for the intelligent operation of the equipment and the iterative upgrade of future processes.

[0043] It should be noted that the relational terms, such as first and second, and the like, are used solely to distinguish one from another entity or action, without necessarily requiring or implying any actual relationship or order between or among such entities or actions. Moreover, the terms including comprising or any other variant thereof are intended to cover non-exclusive inclusions, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but can also include other elements not expressly listed or inherent to such process, method, article, or apparatus.

[0044] Although embodiments of the present application have been shown and described, it is to be understood that various modifications, substitutions, replacements and changes can be made to these embodiments without departing from the principles and spirit of the present application, and the scope of the present application is defined by the appended claims and their equivalents.

Claims

1. A circular blade dual asynchronous collaborative die-cutting process for a multi-layer co-coated film structure, characterized in that, include: Obtain the material parameters and die-cutting pattern data of the multi-layer co-blue film structure; The multi-layer co-blue film structure is pretreated, and the pretreatment includes surface cleaning, tension control and initial positioning. An industrial vision system is used to acquire image data of the surface of the multi-layer co-blue film structure in real time, and based on the image data, the real-time position and angle deviation of the multi-layer co-blue film structure relative to the preset die-cutting coordinate system is calculated. The real-time position and angle deviation data, the material parameters, and the pattern data to be die-cut are input to the central control module; based on the input data, the central control module runs an adaptive die-cutting path planning algorithm and a dynamic cutting parameter optimization algorithm to generate independent die-cutting paths, cutting depths, cutting speeds, and rotary knives for the first and second circular knives die-cutting units. The first and second circular die-cutting units are driven to asynchronously and collaboratively die-cut the multi-layer co-blue film structure according to the generated die-cutting path and cutting parameters. After die-cutting is completed, the die-cutting waste is peeled off from the multi-layer co-blue film structure by a waste stripping mechanism.

2. The circular blade dual asynchronous collaborative die-cutting process for the multi-layer co-coated film structure according to claim 1, characterized in that, Obtaining the material parameters and die-cutting pattern data of the multi-layer co-laminated film structure includes: Obtain the physical property parameters of each adhesive layer and blue film layer in the multi-layer adhesive co-blue film structure. The physical property parameters include material type, thickness, hardness, viscosity, Young's modulus and coefficient of friction. Obtain vector geometric data of the pattern to be die-cut, including outline, hole positions, cutting area and half-cut area information.

3. The circular blade dual asynchronous collaborative die-cutting process for the multi-layer co-coated film structure according to claim 1, characterized in that, Pretreatment of the multi-layer co-blue film structure includes: The multi-layer co-laminated film structure roll is unwound using an unwinding mechanism; The cleaning unit removes dust and particulate matter adhering to the surface of the multi-layer co-blue film structure; A closed-loop tension control system is used to maintain a constant tension in the multi-layer co-blue film structure during transport. The lateral position of the multi-layer co-blue film structure during the conveying process is adjusted by a correction and guiding mechanism.

4. The circular blade dual asynchronous collaborative die-cutting process for the multi-layer co-coated film structure according to claim 1, characterized in that, An industrial vision system is used to acquire image data of the surface of the multi-layer co-blue film structure in real time, and based on the image data, the real-time position and angular deviation of the multi-layer co-blue film structure relative to a preset die-cutting coordinate system are calculated, including: The industrial vision system includes a high-resolution industrial camera and a dedicated lighting module; Image recognition technology is used to identify preset reference marks on the surface of the multi-layer co-blue film structure; The relative position offset and angular rotation between the reference mark and the preset die-cutting coordinate system are calculated using a sub-pixel level image processing algorithm.

5. The circular blade dual asynchronous collaborative die-cutting process for the multi-layer co-coated film structure according to claim 1, characterized in that, Based on the input data, the central control module runs an adaptive die-cutting path planning algorithm and a dynamic cutting parameter optimization algorithm to generate independent die-cutting paths, cutting depths, cutting speeds, and rotary blade rotation speeds for the first and second circular blade die-cutting units, including: Based on the geometric features of the pattern to be die-cut and the material parameters, independent die-cutting paths for the first and second circular die-cutting units are initially generated. Based on the real-time position and angle deviation data, the independent die-cutting path is dynamically adjusted to compensate for the real-time deformation and position deviation of the multi-layer co-blue film structure; Based on the physical properties of each layer of the multi-layer co-laminated film structure, different cutting depths, cutting speeds, and rotary speeds are set for the first and second circular die-cutting units.

6. The circular blade dual asynchronous collaborative die-cutting process for the multi-layer co-coated film structure according to claim 5, characterized in that, Set different cutting depths, including: For the first circular die-cutting unit, its cutting depth is set to penetrate part of the adhesive layer or blue film layer of the multi-adhesive layer co-blue film structure; For the second circular die-cutting unit, its cutting depth is set to penetrate all layers of the multi-layer co-blue film structure, or to penetrate to an adhesive layer or blue film layer with a different cutting depth than the first circular die-cutting unit; The dynamic cutting parameter optimization algorithm adjusts the cutting depth, cutting speed, and rotary blade rotation speed in real time by combining real-time feedback die-cutting force data and visual inspection data.

7. The circular blade dual asynchronous collaborative die-cutting process for the multi-layer co-coated film structure according to claim 1, characterized in that, Asynchronous collaborative die-cutting of the multi-layer co-blue film structure includes: Under the coordination of the central control module, the first and second circular die-cutting units independently or in parallel perform die-cutting operations on the multi-layer co-blue film structure according to their respective generated independent die-cutting paths and cutting parameters. The asynchronous collaborative modifier method includes one or more of the following: The first circular die-cutting unit performs a half-cut die-cut on the upper adhesive layer of the multi-adhesive layer co-blue film structure, and the second circular die-cutting unit performs a full-cut die-cut on the lower adhesive layer and blue film layer of the multi-adhesive layer co-blue film structure. The die-cutting areas of the first circular die-cutting unit and the second circular die-cutting unit overlap or are adjacent. The first circular die-cutting unit and the second circular die-cutting unit simultaneously die-cut different die-cutting pattern areas on the multi-layer co-blue film structure; The first and second circular die-cutting units work together to cut a single complex die-cutting pattern, wherein the first circular die-cutting unit cuts the straight line portion and the second circular die-cutting unit cuts the curved portion.

8. The circular blade dual asynchronous collaborative die-cutting process for the multi-layer co-coated film structure according to claim 1, characterized in that, The waste stripping mechanism includes: The vacuum adsorption stripping unit is used to adsorb and strip die-cut waste material through a vacuum pump and adsorption nozzle; An auxiliary stripping mechanism is used to assist in stripping die-cutting waste using an air knife or mechanical scraper. The waste winding mechanism is used to wind up the stripped waste material via a winding shaft.

9. A circular blade dual asynchronous collaborative die-cutting device with a multi-layer co-coated film structure, characterized in that, include: The material conveying module is used to carry and convey the multi-layer co-blue film structure; The visual alignment module is used to acquire image data of the multi-layer co-blue film structure in real time and calculate the real-time position and angle deviation of the multi-layer co-blue film structure relative to the preset die-cutting coordinate system. The first circular die-cutting unit is used to die-cut the multi-layer co-blue film structure; The second circular die-cutting unit is used to die-cut the multi-layer co-blue film structure; The central control module is electrically connected to the vision alignment module, the first circular die-cutting unit, and the second circular die-cutting unit. It is used to generate independent die-cutting paths, cutting depths, cutting speeds, and circular die rotation speeds for the first and second circular die-cutting units based on the real-time position and angle deviation data, material parameters, and die-cutting pattern data. It also drives the first and second circular die-cutting units to perform asynchronous collaborative die-cutting. The waste stripping module is used to strip die-cut waste.

10. The circular blade dual asynchronous collaborative die-cutting device with a multi-layer co-coated film structure according to claim 9, characterized in that, The material conveying module includes: An unwinding mechanism is used to unwind the multi-layer co-laminated film structure roll material; The cleaning unit includes a dust removal brush and an electrostatic elimination device for cleaning the surface of the multi-layer co-blue film structure; The tension control system, including a tension sensor and a feedback control unit, is used to maintain constant tension during the transport of the multi-layer co-laminated film structure; The correction and guidance mechanism, including a photoelectric sensor and a linear actuator, is used to adjust the lateral position of the multi-layer co-blue film structure during the conveying process; The feeding mechanism, including a precision servo roller and an encoder, is used to control the feed length of the multi-layer co-blue film structure.

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