Method and device for controlling the residual amount of a web

Abstract

The application provides a roll material residual amount control method and device, and relates to the field of roll material residual amount detection. The roll material residual amount control method comprises the following steps: recording a first rotation number in a winding process of raw materials by a first device; recording a second rotation number in a unwinding process of the wound roll material by a second device; comparing the difference between the first rotation number and the second rotation number in real time; and if the difference is less than or equal to a preset number of turns, controlling the second device to perform a roll replacement operation. The method can reasonably control the residual amount of the roll material in the roll replacement operation, reduce the waste of the residual amount of the roll material, and save production costs on the premise of ensuring automatic roll replacement without shutdown.

Description

Technical Field

[0001] This invention relates to the field of roll material allowance detection, and more specifically, to a method and apparatus for controlling roll material allowance. Background Technology

[0002] In current lithium battery manufacturing processes, the degree of automation in the electrode section is increasing, which also places higher demands on automatic roll changing. Because the electrode section is made of rolled material, the remaining amount of material on the roll is difficult to control. If the remaining amount is too much, it can easily lead to material waste and increase production costs. If the remaining amount is too little, it can cause equipment downtime during automatic roll changing operations, affecting production efficiency.

[0003] Therefore, controlling the excess material in the roll has become an urgent technical problem to be solved in the battery manufacturing process. Summary of the Invention

[0004] The present invention aims to provide a method and apparatus for controlling the roll material allowance, which can reasonably control the roll material allowance, avoid waste caused by excessive allowance and save production costs while ensuring automatic roll changing without stopping the machine.

[0005] The embodiments of the present invention can be implemented as follows:

[0006] In a first aspect, embodiments of the present invention provide a method for controlling the allowance of roll material, comprising:

[0007] Record the number of rotations of the first device during the winding process of the raw material;

[0008] Record the number of the second rotations during the unwinding process of the second device on the wound roll;

[0009] The difference between the first number of rotations and the second number of rotations is compared in real time.

[0010] If the difference is less than or equal to the preset number of turns, the second device is controlled to perform a roll change operation.

[0011] In an optional embodiment, the first device includes a reel with at least one marking on it;

[0012] The step of recording the first number of rotations during the winding process of the first device on the raw material includes:

[0013] If the identifier rotates once with the reel, a count is performed;

[0014] Count the number of times;

[0015] The first number of rotations during the winding process is generated based on the number of counts.

[0016] In an optional implementation, the step of recording the first number of rotations during the winding process of the first device on the raw material further includes:

[0017] Record the length and / or width of the raw material during the winding process.

[0018] In an optional implementation, before the step of recording the second number of rotations during the unwinding process of the second device on the wound roll, the following steps are included:

[0019] Receive the data signal of the first number of rotations.

[0020] In an optional implementation, the step of receiving the data signal of the first number of rotations includes:

[0021] A recognition code is generated based on the first number of rotations;

[0022] Read and save the information of the identification code.

[0023] In an optional implementation, the step of recording the second number of rotations during the unwinding process of the second device on the wound roll includes:

[0024] If the identifier rotates once during the unwinding process, a count is performed.

[0025] Count the number of times;

[0026] The second number of rotations during the unwinding process is generated based on the number of counts.

[0027] In an optional implementation, the step of recording the second number of rotations during the unwinding process of the second device on the wound roll further includes:

[0028] Record the length and / or width of the raw material during the unwinding process.

[0029] In an optional implementation, the step of controlling the second device to perform a roll change operation if the difference is less than or equal to a preset number of turns includes:

[0030] The difference between the winding length and the unwinding length of the raw material is compared in real time. If the difference is less than or equal to a preset parameter, the second device is controlled to perform a roll change operation.

[0031] In an optional implementation, the step of recording the first number of rotations during the winding process of the first device on the raw material further includes:

[0032] The first number of rotations during the second winding process on the rewinder is recorded.

[0033] Secondly, embodiments of the present invention provide a control device for the roll material allowance, applicable to the above-mentioned roll material allowance control method, including a first device, a second device, and a controller, wherein the first device and the second device are respectively connected to the controller;

[0034] The first device is used to wind up the raw material and record the first number of rotations during the winding process; the second device is used to unwind the wound material and record the second number of rotations during the unwinding process; the controller is used to compare the difference between the first number of rotations and the second number of rotations in real time. If the difference is less than or equal to a preset number of rotations, the controller controls the second device to perform a roll changing operation.

[0035] The present invention provides a method and apparatus for controlling the allowance of roll material, the beneficial effects of which include:

[0036] This method for controlling the roll material allowance records the first number of rotations during the winding process and the second number of rotations during the unwinding process. It compares the difference between the first and second rotations in real time. If the difference is less than or equal to a preset number of rotations, the second device is controlled to perform a roll change operation. This reduces wasted roll material allowance and avoids equipment damage and downtime caused by insufficient allowance, thus improving production efficiency and reducing production costs.

[0037] This roll material allowance control device can reasonably control the roll material allowance, avoiding waste caused by excessive allowance and saving production costs while ensuring that the automatic roll changing equipment does not stop. Attached Figure Description

[0038] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0039] Figure 1 A schematic flowchart illustrating the steps of a method for controlling the allowance of roll material according to an embodiment of the present invention;

[0040] Figure 2 This is a schematic diagram illustrating one method of setting markings on a roll according to an embodiment of the present invention;

[0041] Figure 3 This is a schematic diagram illustrating another method of setting the markings on the roll according to an embodiment of the present invention;

[0042] Figure 4This is a schematic block diagram of a roll material allowance control device provided in an embodiment of the present invention.

[0043] Icons: 100 - Roll; 110 - Identifier; 10 - First device; 20 - Second device; 30 - Controller. Detailed Implementation

[0044] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0045] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0046] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0047] In the description of this invention, it should be noted that if terms such as "upper," "lower," "inner," or "outer" are used to indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship in which the product of this invention is usually placed, they are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention.

[0048] Furthermore, the terms "first" and "second" are used only to distinguish descriptions and should not be interpreted as indicating or implying relative importance.

[0049] It should be noted that, where there is no conflict, the features in the embodiments of the present invention can be combined with each other.

[0050] In the manufacturing sector, coil-based materials are used in various production operations. With increasing automation, automatic coil-changing operations are becoming widespread. In the current lithium battery manufacturing industry, because the electrode sections are all made of coil-based materials, controlling the remaining amount of material is difficult. Excessive excess material can lead to waste and increased production costs. Insufficient excess material can cause equipment downtime during automatic coil-changing operations, potentially resulting in greater losses and severely impacting production efficiency.

[0051] Currently, in automated roll replacement, the remaining amount of roll material is mainly detected by ultrasonic thickness measurement or metering. If ultrasonic thickness measurement is used to determine whether the roll is used up and needs replacement, existing processes can only achieve a thickness measurement accuracy of ±0.5mm. To ensure smooth automated roll replacement, the remaining thickness of the roll material is generally at least 0.5mm, resulting in significant waste due to excess material and increased production costs. If metering is used to determine whether the roll is used up and needs replacement, this method generally has uncontrollable errors. Even slight deviations can lead to insufficient remaining material, resulting in greater scrap and potentially causing equipment downtime and reduced capacity utilization. This method is almost never used in lithium battery manufacturing.

[0052] In order to overcome the shortcomings of the prior art, the present invention provides a method and apparatus for controlling the roll material allowance, which can reasonably control the roll material allowance, avoid the waste of raw materials caused by excessive allowance, save production costs and improve production capacity while ensuring that the automatic roll changing equipment does not stop.

[0053] Please refer to Figures 1 to 4 This embodiment provides a method for controlling the roll material allowance, including:

[0054] S100: Record the first rotation number during the winding process of the first device 10 on the raw material;

[0055] S200: Record the second rotation number of the second device 20 during the unwinding process of the wound roll;

[0056] S300: Real-time comparison of the difference between the first number of rotations and the second number of rotations;

[0057] S400: If the difference is less than or equal to the preset number of turns, control the second device 20 to perform a roll change operation.

[0058] The first device 10 includes a roll 100 and a first detector. At least one mark 110 is provided on the roll 100. Optionally, the roll 100 has a cylindrical structure, used for winding raw materials, i.e., the raw materials are wound layer by layer around the outer surface of the roll 100. The mark 110 can be placed at any position on the roll 100, and the number of marks 110 can be one, two, three, four, or more. The mark 110 can be an identifiable pigment coating, and its shape and size can be flexibly set according to actual conditions, rotating with the roll 100 when it rotates. It is understood that the first detector and the mark 110 are spaced apart, and the first detector is fixedly installed, capable of identifying the mark 110 through sensing. Optionally, in this embodiment, a mark 110 is provided on the outer circumferential surface of the roll 100, such as... Figure 2As shown. Alternatively, two markings 110 are spaced apart on the end face of the roll 100, as shown. Figure 3 As shown. Of course, there are many other settings, which will not be specifically limited here.

[0059] Optionally, the first detector performs a count once for each revolution of the marker 110 as the drum 100 rotates. Since the first detector is fixed in place, there will be a preset position during the rotation of the marker 110, aligning the marker 110 with the first detector. When the first detector detects or senses the marker 110 at this position, it counts once. When the marker 110 rotates a second time to the same preset position, the first detector will detect the marker 110 a second time and perform a second count. This process repeats, and the number of revolutions of the drum 100 is the same as the number of revolutions of the marker 110, which is also the number of counts performed by the first detector. In this way, the first detector can obtain the first number of revolutions during the winding process by counting the number of revolutions and generate data information on the first number of revolutions.

[0060] It is easy to understand that the first detector can be a proximity switch, and the mark 110 can be a magnetic block attached to the roll 100. When the magnetic block rotates to a position close to the proximity switch, the proximity switch receives a high-level signal, that is, it senses the mark 110 and counts once. Alternatively, the first detector can be a laser sensor, and the mark 110 can be a coating that the laser sensor can detect. The coating is only set at a local position on the surface of the roll 100, including but not limited to being set on the outer peripheral surface or end face of the roll 100. It should be understood that only the place where the coating is set can be detected by the laser sensor, and other positions on the roll 100 cannot be detected by the laser sensor. In this way, every time the roll 100 rotates, the laser sensor detects the coating once and counts once, which can also achieve counting by the laser sensor. Of course, in other optional embodiments, there are many other methods to obtain the first rotation number during the winding process, and various other existing counters can be used, which will not be listed here.

[0061] It should be noted that, since the positions of the markings 110 on the roll 100 and the first detector may not perfectly correspond during roll installation, some measurement error is inevitable. Increasing the number of markings 110 can relatively reduce this measurement error and further improve the control accuracy of the roll allowance. Furthermore, while recording the first rotation number of the first device 10 during the winding process of the raw material, the length and / or width of the raw material during winding can also be recorded. In the allowance control calculation, the length during winding and the length during unwinding are compared, and the comparison result is used as a reference value to further improve the control accuracy of the roll allowance. Of course, this is not limited to this. In addition to recording the first rotation number, length, and width during winding, parameters such as material type, specifications, and thickness can also be selectively recorded. On the one hand, this can serve as a reference value for allowance judgment to improve the control accuracy of the roll allowance; on the other hand, it can accurately record the material type and model to prevent mis-unwinding of the roll during automatic roll changing.

[0062] Optionally, before recording the second rotation count during the unwinding process of the second device 20 on the wound roll, it is also necessary to receive the data signal of the first rotation count. The entity receiving the data signal of the first rotation count can be the second device 20 or a controller 30 connected to the second device 20. The controller 30 can be integrated into the second device 20 or set up separately; no specific limitation is made here. In this embodiment, the method for receiving the data signal of the first rotation count can be: the first device 10 generates an identification code based on the first rotation count, and the second device 20 or controller 30 reads and saves the information of the identification code. The identification code includes, but is not limited to, barcodes, QR codes, or other information reading codes. Optionally, the first detector acquires the first rotation count during the winding process and generates data information of the first rotation count. This data information is then used to generate a barcode or QR code, which can be sent to the second device 20 or controller 30 via data transmission so that the second device 20 or controller 30 can automatically read and save it. The barcode or QR code can also be printed out, scanned by a scanning device, converted into data information, and then sent or saved to the second device 20 or controller 30. It is easy to understand that the barcode or QR code can also include information such as the material's length, thickness, width, type, and specifications.

[0063] The second device 20 unwinds the wound material. The roll 100 and the material on it are mounted on the second device 20, and the material is unwound. The second number of rotations during unwinding is recorded. The counting principle for the second number of rotations during unwinding is similar to that for the first number of rotations during winding. The second device 20 is equipped with a second detector. If the marker 110 rotates once with the roll 100 during unwinding, the second detector performs a count. The second detector and the first detector can be the same type of sensor.

[0064] Optionally, the second detector counts the number of rotations and generates a second rotation count during the unwinding process based on the count. The second detector can transmit the second rotation count data signal to the controller 30. The controller 30 compares the difference between the first and second rotation counts in real time. If the difference is less than or equal to a preset number of rotations, the controller 30 controls the second device 20 to perform a roll change operation. It is easy to understand that the preset number of rotations can be flexibly set according to the actual type, model, specifications, thickness, etc. of the roll material, such as 5 to 100 rotations, or 10, 15, 20, 25, 30, 50, or 70 rotations, etc., without specific limitations. For example, if the first rotation count during the winding process is 500 rotations and the preset number of rotations is 10 rotations, then when the second device 20 performs a roll change operation, if the second detector detects a second rotation count of 490 rotations, the controller 30 controls the second device 20 to perform an automatic roll change operation.

[0065] Furthermore, during the unwinding process of the second device 20, the length and / or width of the raw material can also be recorded. By comparing the difference between the winding length and the unwinding length of the raw material in real time, if the difference is less than or equal to a preset parameter, the second device 20 is controlled to perform a roll change operation. This preset parameter can be flexibly set according to actual needs and is not specifically limited. This allows for further reference to the difference between the unwinding and winding lengths, based on the difference between the first and second rotation counts, thus improving the accuracy of the roll material allowance control. It should be noted that, in addition to recording the length and width of the roll material, information such as the thickness, type, and specifications of the roll material can also be selectively recorded; this is not specifically limited.

[0066] Optionally, the first number of rotations is recorded during the second winding process on the rewinder. In other optional embodiments, to adapt to the needs of the production process, the wound roll material needs to be rewound, and the recording of the first number of rotations, as well as information such as the length, width, and thickness of the raw material, can also be completed during the rewinding process, which is not specifically limited here.

[0067] Furthermore, it should be noted that in some optional embodiments, the second device 20 can also perform a winding operation after unwinding. The wound roll is then used for unwinding production on other devices. The winding process on the second device 20 is similar to the winding process on the first device 10, and will not be described in detail here. This winding and unwinding process can be applied to roll material processes such as coating, rolling, slitting, die-cutting, and gravure printing in lithium battery production. Of course, it can also be applied to other roll material manufacturing fields, which are not specifically limited here.

[0068] Please refer to Figure 4 This invention also provides a control device for the remaining amount of roll material, applicable to the aforementioned method for controlling the remaining amount of roll material. The control device includes a first device 10, a second device 20, and a controller 30, with the first device 10 and the second device 20 respectively connected to the controller 30. The first device 10 is used to wind up the raw material and record the first number of rotations during the winding process; the second device 20 is used to unwind the wound roll and record the second number of rotations during the unwinding process; the controller 30 is used to compare the difference between the first and second number of rotations in real time. If the difference is less than or equal to a preset number of rotations, the controller 30 controls the second device 20 to perform a roll changing operation.

[0069] It should be noted that the controller 30 here can be independently configured or integrated into the second device 20 or other devices; no specific limitation is made here. The controller 30 can use a general-purpose processor, including a Central Processing Unit (CPU), a Network Processor (NP), etc.; it can also be a Digital Signal Processor (DSP), an Application Specific Integrated Circuit (ASIC), a Field-Programmable Gate Array (FPGA), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc. Of course, the controller 30 can also be integrated as a PLC controller, a microcontroller, etc.; no specific limitation is made here. The second device 20 performs automatic roll changing operations, minimizing waste of roll material and reducing production costs while ensuring the equipment does not stop.

[0070] This invention provides a method and apparatus for controlling roll material allowance. The method involves first winding the raw material and recording the first number of rotations during the winding process. Then, the wound roll is unwound, and the second number of rotations during the unwound process is recorded. By comparing the difference between the second and first rotations in real time, an automatic roll change operation is performed when the difference is less than or equal to a preset number of rotations. This reduces waste of roll material allowance during automatic roll change operations while ensuring that the roll material allowance meets the automatic roll change requirements without stopping the equipment.

[0071] The calculation method for controlling the roll material remaining amount provided in this embodiment is used as the basis for whether to perform automatic roll changing. The counting accuracy can be reduced to within 10 turns. The following application scenario is used as an example for calculation and explanation:

[0072] The raw material is 6-micrometer thick copper foil. The outer diameter of the roll 100, which is also the inner diameter of the roll material, is D = 96.2 mm. When the remaining material on the roll 100 is 10 turns, the remaining length of the 10 turns of roll material is L1 = πD * 10 = 3.14 * 96.2 * 10 = 3020.68 mm = 3.02 m. The calculated result is about 3 meters, that is, the length of the remaining roll material is about 3 meters.

[0073] Using the above scenario as an example, the allowance is calculated according to the existing thickness measurement method, as a comparative example, as follows:

[0074] Based on the current highest thickness measurement accuracy of ±0.5mm, the required remaining length of the roll material is approximately L2 = (π*98.2*98.2 / 4 - π*96.2*96.2 / 4) / 0.006 / 1000, which is about 50 meters. This is only a rough calculation. Considering the roundness deviation of the roll 100mm, the assembly accuracy and stability of the equipment, etc., the actual remaining length will be much longer. Currently, the lithium battery industry typically wastes over 100 meters of roll material, sometimes even reaching two or three hundred meters, indicating significant waste.

[0075] As can be seen from this, taking the above-mentioned raw materials and application scenarios as examples, the existing technology calculates at the highest measurement accuracy and automatically changes rolls when the remaining margin is at least about 50 meters. However, the roll margin control method provided by the present invention automatically changes rolls when the remaining margin is about 3 meters. Each automatic roll change saves at least about 47 meters of roll material, which greatly reduces the waste of roll material margin and saves production costs.

[0076] In summary, the method and apparatus for controlling the roll material allowance provided by the embodiments of the present invention have the following beneficial effects:

[0077] The method and apparatus for controlling the roll material allowance provided in this invention can reasonably control the roll material allowance, avoid waste caused by excessive roll material allowance while ensuring automatic roll changing without stopping the machine, save production costs, and increase production capacity.

[0078] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A method for controlling the allowance of roll material, characterized in that, include: Record the number of rotations of the first device during the winding process of the raw material; Record the number of the second rotations during the unwinding process of the second device on the wound roll; The difference between the first number of rotations and the second number of rotations is compared in real time. If the difference is less than or equal to the preset number of turns, the second device is controlled to perform a roll change operation.

2. The method for controlling the roll material allowance according to claim 1, characterized in that, The first device includes a reel, and at least one mark is provided on the reel; The step of recording the first number of rotations during the winding process of the first device on the raw material includes: If the identifier rotates once with the reel, a count is performed; Count the number of times; The first number of rotations during the winding process is generated based on the number of counts.

3. The method for controlling the roll material allowance according to claim 2, characterized in that, The step of recording the first number of rotations during the winding process of the first device on the raw material further includes: Record the length and / or width of the raw material during the winding process.

4. The method for controlling the roll material allowance according to claim 2, characterized in that, Before the step of recording the second rotation number during the unwinding process of the second device on the wound roll, the following steps are included: Receive the data signal of the first number of rotations.

5. The method for controlling the roll material allowance according to claim 4, characterized in that, The step of receiving the data signal of the first number of rotations includes: A recognition code is generated based on the first number of rotations; Read and save the information of the identification code.

6. The method for controlling the roll material allowance according to claim 2, characterized in that, The step of recording the second number of rotations during the unwinding process of the second device on the wound roll includes: If the identifier rotates once during the unwinding process, a count is performed. Count the number of times; The second number of rotations during the unwinding process is generated based on the number of counts.

7. The method for controlling the roll material allowance according to claim 6, characterized in that, The step of recording the second number of rotations during the unwinding process of the second device on the wound roll also includes: Record the length and / or width of the raw material during the unwinding process.

8. The method for controlling the roll material allowance according to claim 1, characterized in that, The step of controlling the second device to perform a roll change operation if the difference is less than or equal to a preset number of turns includes: The difference between the winding length and the unwinding length of the raw material is compared in real time. If the difference is less than or equal to a preset parameter, the second device is controlled to perform a roll change operation.

9. The method for controlling the roll material allowance according to any one of claims 1 to 8, characterized in that, The step of recording the first number of rotations during the winding process of the first device on the raw material further includes: The first number of rotations during the second winding process on the rewinder is recorded.

10. A device for controlling the amount of roll material remaining, characterized in that, A method for controlling the roll material allowance applicable to any one of claims 1 to 9, comprising a first device, a second device, and a controller, wherein the first device and the second device are respectively connected to the controller; The first device is used to wind up the raw material and record the first number of rotations during the winding process; the second device is used to unwind the wound material and record the second number of rotations during the unwinding process; the controller is used to compare the difference between the first number of rotations and the second number of rotations in real time. If the difference is less than or equal to a preset number of rotations, the controller controls the second device to perform a roll changing operation.

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