A compound control system and method for unifying a swath width reference and automatically aligning

Abstract

A composite control system and method for unifying the width reference and automatic alignment, comprising: a glue surface error detection mechanism for checking the glue surface length and centering of the glue spreader roll online; a fast clamping and automatic centering mechanism for driving the unwinding cone top clamping mechanism to quickly clamp and automatically center the unwinding drum core; an electric eye positioning mechanism for accurately positioning the width of the unwinding base material and providing a reference confirmation operation for the correction process; a winding fast clamping and automatic centering mechanism for driving the winding cone top clamping mechanism to quickly clamp and automatically center the winding drum core. The waste of film roll base material is greatly reduced, the production efficiency is improved, the labor intensity is reduced, and the operation skill requirement is also reduced.

Description

Technical Field

[0001] This invention relates to the field of solvent composites, and more specifically to a composite control system and method with a unified width reference and automatic alignment. Background Technology

[0002] Currently, the lamination process is implemented using a step-by-step adjustment method. The centering of the unwinding and rewinding of the roll and the paper core tube requires manual operation. The alignment photoelectric sensor needs to be adjusted experimentally by shifting it. After the glue roller is installed on the equipment, it cannot quickly detect the glue surface length and centering. During lamination, the width alignment error causes material waste. When starting the machine, each time from unwinding to coating, lamination to unwinding, a full path of film material needs to be introduced to adjust the width alignment of the first unwind and the second unwind (including multiple unwinds). It is even necessary to establish tension and run the machine for a considerable film travel distance to allow the width to be gradually aligned by the alignment mechanism. This not only wastes materials but also reduces production efficiency.

[0003] Based on the above, developing a composite control system and method with a unified width reference and automatic alignment is of profound significance for promoting the development of the industry. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a composite control system and method with a unified width reference and automatic alignment, which greatly reduces the waste of film roll substrate, improves production efficiency, reduces labor intensity, and also reduces the requirements for operating skills.

[0005] To solve the above-mentioned technical problems, the technical solution of the present invention is: a composite control system with a unified width reference and automatic alignment, wherein the solventless laminating machine includes a coating unit, one or more unwinding units, a winding unit, and a laminating unit; the coating unit includes a leveling roller; the unwinding unit includes an unwinding cone clamping mechanism for clamping the unwinding core; and the winding unit includes a winding cone clamping mechanism for clamping the winding core; the composite control system includes:

[0006] A glue surface error detection mechanism used for online inspection of the glue surface length and centering of the glue roller;

[0007] This is a quick-clamping and automatic centering mechanism for driving the unwinding cone clamping mechanism to quickly clamp and automatically center the unwinding core.

[0008] An electro-optic positioning mechanism for accurately positioning the width of the unwound substrate and providing a reference confirmation operation for the correction process;

[0009] This is a quick-clamping and automatic centering mechanism for driving the take-up cone clamping mechanism to quickly clamp and automatically center the take-up core.

[0010] The principle of this invention is as follows: the unified width reference is the center line of the equipment's inner section, each unwinding and quick clamping automatically centers, the positioning photoelectric eye accurately positions, the glue surface of the glue leveling roller is centered, the rewinding preparation is centered, and the width direction of the multi-layer composite film is aligned with the center line of the equipment's inner section as the reference. It is no longer necessary to gradually adjust the width alignment by feeding the film material along the full path from unwinding to rewinding when starting the machine. It achieves alignment upon clamping, greatly reduces the waste of film roll substrate, improves production efficiency, reduces labor intensity, and also reduces the skill requirements of operators.

[0011] As an improvement, the adhesive surface error detection mechanism is a double-jaw sliding ruler adhesive surface length error detection machine, which includes a scaled center width sliding ruler and two pointer sliding positioning jaws arranged parallel to the glue-spreading roller. The scaled center width sliding ruler takes the zero mark on the inner center line of the equipment as the absolute starting point of the width indication value, and the size scale is symmetrical and continuous from the middle 0 to the two sides of the maximum width value.

[0012] As an improvement, the adhesive surface error detection mechanism is a dual-laser ranging adhesive surface length error detection mechanism, which includes two laser ranging sensors respectively located at both ends of the distributing roller. The distance from the two end faces to the two sides of the frame is detected by the laser ranging sensors, and the adhesive surface length and whether the adhesive surface is centered are calculated by the PLC.

[0013] As an improvement, the unwinding quick clamping automatic centering mechanism includes a first slide rod arranged parallel to the unwinding cylinder core, a first unwinding wall plate slidably engaged with the first slide rod, a second unwinding wall plate slidably engaged with the first slide rod, a first unwinding cone head disposed on the first unwinding wall plate, a second unwinding cone head disposed on the second unwinding wall plate, a first servo drive correction mechanism for driving the first unwinding wall plate to move, a first quick clamping cylinder for driving the second unwinding wall plate to move, and a first laser rangefinder sensor for detecting the distance between the first unwinding wall plate and the second unwinding wall plate.

[0014] As an improvement, the photoelectric positioning mechanism includes a guide rod spanning the unwound substrate, an absolute positioning photoelectric probe mounted on the guide rod, a photoelectric positioning drive assembly for driving the absolute positioning photoelectric probe, and a width input touch screen for controlling the photoelectric positioning drive assembly. After the width of the unwound substrate is input, the absolute positioning photoelectric probe automatically moves to the position corresponding to the width under the drive of the photoelectric positioning drive assembly.

[0015] As an improvement, the photoelectric eye positioning mechanism includes a scale with a center mark width and a sliding photoelectric eye with a pointer that slides with it. The absolute positioning of the photoelectric eye is completed by manually moving the sliding photoelectric eye with the pointer so that its pointer is positioned on the scale corresponding to the width value and locking it.

[0016] As an improvement, the quick-clamping automatic centering mechanism for winding includes a second slide bar arranged parallel to the winding drum core, a first winding wall plate slidably engaged with the second slide bar, a second winding wall plate slidably engaged with the second slide bar, a first winding cone head disposed on the first winding wall plate, a second winding cone head disposed on the second winding wall plate, a second servo drive mechanism for driving the first winding wall plate to move, a second quick-clamping cylinder for driving the second winding wall plate to move, and a second laser rangefinder sensor for detecting the distance between the first winding wall plate and the second winding wall plate.

[0017] The control method of the composite control system of the present invention, which unifies the width reference and automatically aligns the data, includes the following steps:

[0018] (1) Before starting the machine, input the following on-site process parameters on the touch screen: the width of the roller surface of this batch of rubber rollers, the width of all substrates, the selection of edge correction or line correction, the distance of the tracking mark from the edge, the inner diameter of the core, and the length of the core.

[0019] (2) The glue surface error detection mechanism checks and confirms the glue surface length and centering of the glue roller online. When the error is within a certain range, the parameter is automatically calibrated and corrected. When the error is above a certain range, an alarm is triggered and manual intervention is required in the subsequent confirmation process.

[0020] (3) The quick unwinding clamping automatic centering mechanism quickly opens and closes to clamp the unwinding base material roll and immediately finds the absolute position based on the center line of the inner frame.

[0021] (4) Each unwound substrate is positioned by the photoelectric positioning mechanism and the servo correction mechanism compensates in time to eliminate the errors of uneven end faces of the unwound substrate and inconsistent exposed lengths at both ends of the core, so as to achieve precise alignment of the width of each unwound substrate during operation and finally achieve real-time alignment and composite of two or more layers.

[0022] (5) The quick-clamping and centering mechanism for winding quickly opens and closes to clamp the winding core and immediately finds the absolute position based on the center line of the inner frame.

[0023] The beneficial effects of this invention compared to the prior art are:

[0024] With a unified width reference as the center line of the equipment's inner frame, each unwinding and quick clamping unit automatically centers, positioning photoelectric sensors provide precise positioning, the adhesive surface of the leveling roller is centered, and the rewinding preparation is also centered. The width direction of two-layer and multi-layer composite films is aligned with the center line of the equipment's inner frame, eliminating the need to gradually adjust the width alignment by feeding in film material along the full path from unwinding to rewinding at startup. Alignment is achieved immediately upon clamping. This significantly reduces film roll substrate waste, improves production efficiency, reduces labor intensity, and also lowers the skill requirements for operators. Attached Figure Description

[0025] Figure 1A schematic diagram of a composite control system that unifies the width reference and automatically aligns the data.

[0026] Figure 2 This is a schematic diagram of the adhesive surface error detection mechanism.

[0027] Figure 3 This is a schematic diagram of the photoelectric eye positioning mechanism.

[0028] Figure 4 This is a schematic diagram of an automatic centering mechanism for quick unwinding and clamping.

[0029] Figure 5 This is a schematic diagram of an automatic centering mechanism for rapid winding and clamping. Detailed Implementation

[0030] The present invention will now be further described with reference to the accompanying drawings.

[0031] like Figure 1 As shown, the solventless laminating machine includes a coating unit, one or more unwinding units, a winding unit, and a laminating unit 6. The coating unit includes a leveling roller 5, the unwinding unit includes an unwinding cone clamping mechanism 36 for clamping the unwinding core, and the winding unit includes a winding cone clamping mechanism 46 for clamping the winding core. The first substrate 7 and the second substrate 8 unwound by the two unwinding units are laminated by the laminating unit 6 and then wound up in the winding unit. The laminating control system for the solventless laminating machine, which provides a unified width reference and automatic alignment, includes: a surface error detection mechanism 1 for online checking of the glue surface length and centering of the leveling roller 5; an unwinding quick clamping automatic centering mechanism 3 for driving the unwinding cone clamping mechanism 36 to quickly clamp and automatically center the unwinding core; a photoelectric positioning mechanism 2 for accurately positioning the width of the unwinding substrate and providing a reference confirmation operation for the correction process; and a winding quick clamping automatic centering mechanism 4 for driving the winding cone clamping mechanism 46 to quickly clamp and automatically center the winding core.

[0032] like Figure 2As shown, the adhesive surface error detection mechanism 1 has two modes: automatic and manual. The manual mode adhesive surface error detection mechanism is a double-jaw sliding ruler adhesive surface length error detection machine, which includes a scaled center width sliding ruler 12 and two pointer sliding positioning jaws 13 arranged parallel to the glue spreading roller 5. The scaled center width sliding ruler 12 takes the zero mark on the inner center line of the equipment as the absolute starting point of the width indication value. The size scale is symmetrical and continuous from the middle 0 to both sides of the maximum width value. The scale is 100 at the actual measurement 50, 200 at the actual measurement 100, and so on. The positioning jaws 13 are moved to lightly touch the two ends of the adhesive surface length to observe the corresponding sliding ruler scale value of the pointer, and determine whether the adhesive surface length of the glue roller is centered and whether the adhesive surface length of the glue spreading roller 5 corresponds to the width of the substrate. The automatic mode adhesive surface error detection mechanism is a dual-laser ranging adhesive surface length error detection mechanism, which includes two laser ranging sensors 11 respectively located at both ends of the glue-spreading roller 5. The laser ranging sensors 11 detect the distance from the two end faces to the two sides of the frame. The PLC calculates the adhesive surface length and whether the adhesive surface is centered, and displays it on the main control touch screen in real time. When the adhesive surface is not centered, an alarm signal is issued. L=F1-2C, where L is the actual adhesive surface length, F1 is the width of the first substrate, and C is the single-side allowance of the width of the first substrate. The actual adhesive surface length is smaller than the width of the substrate. This is to prevent glue from overflowing and sticking to the guide roller of the channel, and to compensate for the misalignment of the width. Before the introduction of a composite control system and method with a unified width benchmark and automatic alignment, the allowance C value was 6-10 mm. After the introduction of a composite control system and method with a unified width benchmark and automatic alignment, the C value becomes smaller, and can be 3 mm or even smaller. Taking a 600mm wide composite structure as an example, the waste is reduced by 5‰-11.6‰.

[0033] like Figure 4As shown, the unwinding quick clamping automatic centering mechanism 3 includes a first slide bar 35 arranged parallel to the unwinding cylinder core, a first unwinding wall plate 31 slidably engaged with the first slide bar 35, a second unwinding wall plate 32 slidably engaged with the first slide bar 35, a first unwinding cone head provided on the first unwinding wall plate 31, a second unwinding cone head provided on the second unwinding wall plate 32, a first servo drive correction mechanism 33 for driving the first unwinding wall plate 31 to move, a first quick clamping cylinder 34 for driving the second unwinding wall plate 32 to move, and a first laser rangefinder sensor 39 for detecting the distance between the first unwinding wall plate 31 and the second unwinding wall plate 32. The first servo-driven correction mechanism is mounted on the frame and connected to the movable wall plate on the winding cone clamping mechanism 36 via a ball screw and nut pair. A control button is provided above to adjust the left and right sides of this movable wall plate to adapt to the actual end face position of the core 37 of the material roll 38 transported by the material transport trolley. When the material roll 38 is clamped, the first quick clamping cylinder 34 drives the cone top clamping mechanism 36 to embed and complete the feeding action. The first laser range sensor 39 is mounted on one side of the movable wall plate. The data measured by the first laser range sensor 39 is fed back to the PLC system. After calculation, the PLC issues a command to drive the first servo-driven correction mechanism 33 to drive the wall plate to perform centering displacement compensation. K=(WN) / 2, where K is the servo drive target value, W is the inner size of the equipment, and N is the distance between the two movable plates after the first quick cylinder clamps, as measured by the first laser range sensor. This method eliminates the width centering error caused by the single-sided servo drive due to the inconsistent actual embedding and clamping length of the cone top caused by different inner diameters and materials of the same specification cores.

[0034] like Figure 3 As shown, the photoelectric positioning mechanism 2 has two modes: automatic and manual. The automatic mode of the photoelectric positioning mechanism 2 includes a guide rod spanning the unwound substrate, an absolute positioning photoelectric probe 24 mounted on the guide rod, a photoelectric positioning drive assembly 21 for driving the absolute positioning photoelectric probe 24, and a width input touchscreen 22 for controlling the photoelectric positioning drive assembly 21. The photoelectric positioning drive assembly 21 is mounted on the frame wall panel. The photoelectric probe is precisely displaced by a ball screw and nut pair driven by a servo motor under the guidance of a linear guide post. Inputting the substrate width on the touchscreen 22 controls the displacement of the absolute positioning photoelectric probe 24 to the corresponding scale position. The manual mode of the photoelectric positioning mechanism 2 includes a width slider 25 with a scale center mark and a sliding positioning photoelectric probe 23 with a pointer that slides in conjunction with it. During operation, manually moving the pointer-equipped sliding positioning photoelectric probe 23 until its pointer is positioned at the corresponding width value on the slider 25 and locking it completes the absolute positioning of the photoelectric probe.

[0035] like Figure 5As shown, the quick-clamping automatic centering mechanism 4 for winding includes a second slide bar 45 arranged parallel to the winding drum core 47, a first winding wall plate 41 slidably engaged with the second slide bar 45, a second winding wall plate 42 slidably engaged with the second slide bar 45, a first winding cone head provided on the first winding wall plate 41, a second winding cone head provided on the second winding wall plate 42, a second servo drive mechanism 43 for driving the first winding wall plate 41 to move, a second quick-clamping cylinder 44 for driving the second winding wall plate 42 to move, and a second laser rangefinder sensor 49 for detecting the distance between the first winding wall plate 41 and the second winding wall plate 42. The second laser rangefinder 49 is installed on one side of the movable wall panel. The second laser rangefinder 49 measures the distance between the two movable wall panels and feeds it back to the PLC system. After calculation, the PLC issues a command to the second servo drive mechanism to drive the wall panel to perform centering displacement compensation. K=(WN) / 2, where K is the servo drive target value, W is the inner size of the equipment, and N is the distance between the movable plates after the cylinder clamps as measured by the second laser rangefinder. This method eliminates the width centering error caused by the inconsistent actual length of the cone head being tightly embedded due to different inner diameters and materials of the same specification cylinder cores when using a single-sided servo drive.

[0036] The control method of the present invention includes the following steps:

[0037] (1) Before starting the machine, input the following on-site process parameters on the touch screen: the width of the roller surface of this batch of rubber rollers, the width of all substrates, the selection of edge correction or line correction, the distance of the tracking mark from the edge, the inner diameter of the core, and the length of the core.

[0038] (2) The glue surface error detection mechanism checks and confirms the glue surface length and centering of the glue roller 5 online. When the error is within a certain range, the parameter is automatically calibrated and corrected. When the error is above a certain range, an alarm is triggered and manual intervention is required in the subsequent confirmation process.

[0039] (3) The quick-clamping automatic centering mechanism 3 quickly opens and closes to clamp the unwound base material roll and immediately finds the absolute position based on the center line of the inner frame.

[0040] (4) Each unwound substrate is positioned by the photoelectric positioning mechanism 2, and the servo correction mechanism compensates in a timely manner to eliminate the errors of uneven end faces of the unwound substrate and inconsistent exposed lengths at both ends of the core, so as to achieve precise alignment of the width of each unwound substrate during operation and finally achieve real-time alignment and composite of two or more layers.

[0041] (5) The quick-clamping automatic centering mechanism 4 automatically finds the absolute position based on the center line of the inner frame after the quick-clamping of the winding core.

Claims

1. A composite control system with a unified width reference and automatic alignment, a solventless laminating machine comprising a coating unit, one or more unwinding units, a winding unit, and a laminating unit, wherein the coating unit includes a leveling roller, the unwinding unit includes an unwinding cone clamping mechanism for clamping the unwinding spool core, and the winding unit includes a winding cone clamping mechanism for clamping the winding spool core; characterized in that: The composite control system includes: A glue surface error detection mechanism used for online inspection of the glue surface length and centering of the glue roller; This is a quick-clamping and automatic centering mechanism for driving the unwinding cone clamping mechanism to quickly clamp and automatically center the unwinding core. An electro-optic positioning mechanism for accurately positioning the width of the unwound substrate and providing a reference confirmation operation for the correction process; This is a quick-clamping and automatic centering mechanism for driving the take-up cone clamping mechanism to quickly clamp and automatically center the take-up core. The adhesive surface error detection mechanism is divided into two modes: automatic and manual. The manual mode adhesive surface error detection mechanism is a double-jaw sliding ruler adhesive surface length error detection machine, which includes a scaled center width sliding ruler and two pointer sliding positioning jaws arranged parallel to the glue spreading roller. The scaled center width sliding ruler is marked with zero as the absolute starting point of the width indication value, and the size scale is symmetrical and continuous from the middle 0 to the two sides of the maximum width value. The automatic mode adhesive surface error detection mechanism is a dual laser ranging adhesive surface length error detection mechanism, which includes two laser ranging sensors respectively set at both ends of the glue spreading roller. The distance from the two end faces to the two sides of the frame is detected by the laser ranging sensors, and the PLC calculates the adhesive surface length and whether the adhesive surface is centered. The unwinding quick clamping automatic centering mechanism includes a first slide rod arranged parallel to the unwinding cylinder core, a first unwinding wall plate slidably engaged with the first slide rod, a second unwinding wall plate slidably engaged with the first slide rod, a first unwinding cone provided on the first unwinding wall plate, a second unwinding cone provided on the second unwinding wall plate, a first servo drive correction mechanism for driving the first unwinding wall plate to move, a first quick clamping cylinder for driving the second unwinding wall plate to move, and a first laser rangefinder for detecting the distance between the first unwinding wall plate and the second unwinding wall plate. The photoelectric positioning mechanism has two modes: automatic and manual. The automatic mode includes a guide rod spanning the unwound substrate, an absolute positioning photoelectric probe mounted on the guide rod, a photoelectric positioning drive assembly for driving the absolute positioning photoelectric probe, and a width input touchscreen for controlling the photoelectric positioning drive assembly. The photoelectric positioning drive assembly is mounted on the frame wall panel. The photoelectric probe is precisely displaced by a ball screw and nut pair driven by a servo motor under the guidance of a linear guide post. Inputting the substrate width on the touchscreen controls the absolute positioning photoelectric probe's displacement to the corresponding scale position. The manual mode includes a width slider with a scale center mark and a sliding positioning photoelectric probe with a pointer that slides with it. During operation, manually moving the pointer-equipped sliding positioning photoelectric probe until its pointer is positioned at the corresponding width value on the slider and locking it completes the absolute positioning of the photoelectric probe. The quick-clamping and automatic centering mechanism for winding includes a second slide bar parallel to the winding drum core, a first winding wall plate slidably engaged with the second slide bar, a second winding wall plate slidably engaged with the second slide bar, a first winding cone on the first winding wall plate, a second winding cone on the second winding wall plate, a second servo drive mechanism for driving the first winding wall plate to move, a second quick-clamping cylinder for driving the second winding wall plate to move, and a second laser rangefinder for detecting the distance between the first winding wall plate and the second winding wall plate. The standard width is the center line of the inner section of the equipment.

2. A control method for a composite control system with a unified width reference and automatic alignment as described in claim 1, characterized in that, Includes the following steps: (1) Before starting the machine, input the following on-site process parameters on the touch screen: the width of the roller surface of this batch of rubber rollers, the width of all substrates, the selection of edge correction or line correction, the distance of the tracking mark from the edge, the inner diameter of the core, and the length of the core. (2) The glue surface error detection mechanism checks and confirms the glue surface length and centering of the glue roller online. When the error is within a certain range, the parameter is automatically calibrated and corrected. When the error is above a certain range, an alarm is triggered and manual intervention is required in the subsequent confirmation process. (3) The quick unwinding clamping automatic centering mechanism quickly opens and closes to clamp the unwinding base material roll and immediately finds the absolute position based on the center line of the inner frame. (4) Each unwound substrate is positioned by the photoelectric positioning mechanism and the servo correction mechanism compensates in time to eliminate the errors of uneven end faces of the unwound substrate and inconsistent exposed lengths at both ends of the core, so as to achieve precise alignment of the width of each unwound substrate during operation and finally achieve real-time alignment and composite of two or more layers. (5) The quick-clamping and centering mechanism for winding quickly opens and closes to clamp the winding core and immediately finds the absolute position based on the center line of the inner frame.

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