Tension control methods and devices

Abstract

This application relates to a tension control method and apparatus. The method includes: acquiring a first tension of a substrate within a preset range of a take-up and unwinding mechanism; when the first tension exceeds a target first interval, iteratively adjusting the angular velocity of the take-up and unwinding mechanism until the first tension is within the target first interval, obtaining an initial angular velocity; controlling the take-up and unwinding mechanism to rotate according to the initial angular velocity, periodically acquiring a second tension of the substrate within a preset range of the take-up and unwinding mechanism; when the second tension exceeds a target second interval, iteratively adjusting the angular velocity of the take-up and unwinding mechanism until the second tension is within the target second interval; wherein the target second interval is smaller than the target first interval. Embodiments of this disclosure do not rely on sensor data, achieving precise self-adjustment within the system.

Description

Technical Field

[0001] This application relates to the field of automation technology, and in particular to a tension control method and apparatus. Background Technology

[0002] In vacuum winding processes, such as magnetron sputtering coating, target material excited by glow discharge is sputtered onto the surface of a film attached to a mirror roller for smoothing. This necessitates a high-load drive in the electrical control system to achieve film smoothing in a vacuum environment. Existing tension control methods require real-time acquisition of the roll diameter via sensors. However, in a vacuum environment, sensors and other measuring equipment are difficult to install and operate normally. Furthermore, the limited accuracy of sensors can introduce errors that exacerbate tension fluctuations in the film. Therefore, developing a feasible, self-stabilizing, real-time tension and roll diameter calculation scheme that is independent of external input for film tension control in vacuum processes has become a pressing technical challenge. Summary of the Invention

[0003] Therefore, it is necessary to provide a tension control method and device to address the aforementioned technical problems.

[0004] Firstly, this application provides a tension control method. The method includes:

[0005] A tension control method is applied to a winding apparatus, the winding apparatus comprising: an unwinding mechanism, an intermediate roller, and a winding mechanism, wherein the substrate released by the unwinding mechanism passes through the intermediate roller and is wound up by the winding mechanism, the method comprising:

[0006] A first tension of the substrate is obtained within a preset range of the winding and unwinding mechanism; wherein the winding and unwinding mechanism includes the unwinding mechanism or the winding mechanism;

[0007] If the first tension exceeds the target first interval, the angular velocity of the winding and unwinding mechanism is iteratively adjusted until the first tension is within the target first interval to obtain the initial angular velocity;

[0008] The winding and unwinding mechanism is controlled to rotate at the initial angular velocity, and the second tension of the substrate within a preset range from the winding and unwinding mechanism is periodically acquired.

[0009] If the second tension exceeds the target second range, the angular velocity of the winding and unwinding mechanism is iteratively adjusted until the second tension is within the target second range; wherein the target second range is smaller than the target first range.

[0010] In one possible implementation, obtaining the first tension of the substrate within a preset range from the unwinding / rewinding mechanism includes:

[0011] Control the winding and unwinding mechanism to rotate at a preset angular velocity to obtain the first tension of the substrate within a preset range from the winding and unwinding mechanism;

[0012] The step of iteratively adjusting the angular velocity of the winding and unwinding mechanism when the first tension exceeds the target first interval, until the first tension is within the target first interval, to obtain an initial angular velocity, includes:

[0013] If the first tension exceeds the first range, adjust the angular velocity of the take-up and unwinding mechanism, and control the take-up and unwinding mechanism to rotate at the adjusted angular velocity until the first tension is within the first range.

[0014] The first interval is narrowed several times until the target first interval is reached. Each time the interval is narrowed, the angular velocity of the winding and unwinding mechanism is adjusted until the first tension is within the target first interval.

[0015] In one possible implementation, before periodically acquiring the second tension of the substrate within a preset range from the winding / unwinding mechanism, the method further includes:

[0016] According to a preset cycle, the second tension of the substrate within a preset range from the winding and unwinding mechanism is periodically acquired to obtain the first data;

[0017] The preset cycle is adjusted a certain number of times, and according to the cycle after each adjustment, the second tension of the substrate within a preset range from the winding and unwinding mechanism is periodically acquired to obtain multiple second data; wherein, each second data corresponds to the cycle after each adjustment.

[0018] The sampling period is determined to be the period corresponding to the data with the smallest standard deviation among the first data and multiple second data;

[0019] According to the sampling period, the second tension of the substrate within a preset range from the winding and unwinding mechanism is periodically acquired.

[0020] In one possible implementation, the periodic acquisition of the second tension of the substrate within a preset range from the unwinding / rewinding mechanism includes:

[0021] Periodically acquire multiple second tensions of the substrate within a preset range from the winding and unwinding mechanism;

[0022] According to the preset data cleaning rules, multiple second tensions are filtered to obtain multiple filtered second tensions;

[0023] The second tension of the substrate within a preset range from the winding and unwinding mechanism is determined to be the average value of the second tension after screening.

[0024] In one possible implementation, before acquiring the first tension of the substrate within a preset range from the take-up and unwinding mechanism, the method further includes:

[0025] The tension of a preset substrate segment of the winding device is obtained; wherein, the preset substrate segment includes the substrate between the unwinding mechanism and the intermediate roller, and the substrate between the intermediate roller and the winding mechanism;

[0026] When the tension exceeds the preset range corresponding to the preset substrate segment, the winding and unwinding mechanism is determined to be the winding and unwinding mechanism corresponding to the preset substrate segment.

[0027] In one possible implementation, iteratively adjusting the angular velocity of the take-up and unwinding mechanism includes:

[0028] The proportional coefficient between the angular velocity of the winding and unwinding mechanism and the angular velocity of the system spindle is iteratively adjusted; wherein the proportional coefficient is the spindle radius / current spindle radius, and the spindle radius is a preset value.

[0029] Secondly, this application also provides a tension control device. The device includes:

[0030] This is applied to a winding apparatus, which includes an unwinding mechanism, an intermediate roller, and a winding mechanism. The substrate released by the unwinding mechanism passes through the intermediate roller and is then wound up by the winding mechanism. The tension control device includes:

[0031] The acquisition module is used to acquire the first tension of the substrate within a preset range of the winding and unwinding mechanism; wherein the winding and unwinding mechanism includes the unwinding mechanism or the winding mechanism;

[0032] The first adjustment module is used to iteratively adjust the angular velocity of the winding and unwinding mechanism when the first tension exceeds the target first interval, until the first tension is within the target first interval, and obtain the initial angular velocity;

[0033] The acquisition module is also used to control the winding and unwinding mechanism to rotate according to the initial angular velocity, and periodically acquire the second tension of the substrate within a preset range from the winding and unwinding mechanism;

[0034] The second adjustment module is used to iteratively adjust the angular velocity of the winding and unwinding mechanism when the second tension exceeds the target second range, until the second tension is within the target second range; wherein the target second range is smaller than the target first range.

[0035] In one possible implementation, the acquisition module includes:

[0036] The first acquisition submodule is used to control the winding and unwinding mechanism to rotate at a preset angular velocity and acquire the first tension of the substrate within a preset range from the winding and unwinding mechanism;

[0037] The first adjustment module includes:

[0038] The second adjustment submodule is used to adjust the angular velocity of the take-up and unwinding mechanism when the first tension exceeds the first range, and to control the take-up and unwinding mechanism to rotate according to the adjusted angular velocity until the first tension is within the first range.

[0039] The third adjustment submodule is used to reduce the first interval several times until the target first interval is reached. Each time the interval is reduced, the angular velocity of the winding and unwinding mechanism is adjusted until the first tension is within the target first interval.

[0040] In one possible implementation, the device further includes:

[0041] The acquisition module is also used to periodically acquire the second tension of the substrate within a preset range from the winding and unwinding mechanism according to a preset period, and obtain the first data;

[0042] The third adjustment module is used to adjust the preset cycle a certain number of times, and periodically acquire the second tension of the substrate within a preset range from the winding and unwinding mechanism according to the cycle after each adjustment, to obtain multiple second data; wherein, each second data corresponds to the cycle after each adjustment;

[0043] The first determining module is used to determine the sampling period as the period corresponding to the data with the smallest standard deviation among the first data and multiple second data.

[0044] In one possible implementation, the second acquisition module includes:

[0045] The second acquisition submodule is used to periodically acquire multiple second tensions of the substrate within a preset range from the winding and unwinding mechanism;

[0046] The filtering submodule is used to filter the data of multiple second tensions according to preset data cleaning rules, so as to obtain multiple filtered second tensions;

[0047] The determination submodule is used to determine the second tension of the substrate within a preset range from the winding and unwinding mechanism as the average value of the second tension after screening.

[0048] In one possible implementation, the device further includes:

[0049] The acquisition module is further configured to acquire the tension of a preset substrate segment of the winding device; wherein, the preset substrate segment includes the substrate between the unwinding mechanism and the intermediate roller, the substrate between the two intermediate rollers, and the substrate between the intermediate roller and the winding mechanism;

[0050] The first determining module is used to determine, when the tension exceeds a preset range corresponding to the preset substrate segment, that the winding / unwinding mechanism is the winding / unwinding mechanism corresponding to the preset substrate segment.

[0051] In one possible implementation, the first adjustment module includes:

[0052] The fourth adjustment submodule is used to iteratively adjust the proportional coefficient of the angular velocity of the winding and unwinding mechanism; wherein the proportional coefficient is the main shaft radius / current shaft radius, and the main shaft radius is a preset value.

[0053] The aforementioned tension control method and apparatus, in the initial stage of the winding device, sets a target first interval with a large variation range. By detecting the first tension, the angular velocity of the take-up and unwinding mechanism is iteratively adjusted to stabilize the tension fluctuation amplitude. In the balancing stage of the winding device, a target second interval with a smaller variation range is set. By periodically detecting the second tension, the angular velocity of the take-up and unwinding mechanism is iteratively adjusted to stabilize the tension fluctuation amplitude within a smaller range, achieving more precise tension control. Compared to the traditional scheme of adding a sensor to the take-up and unwinding mechanism to control tension based on the change in the take-up diameter, the embodiments of this disclosure do not rely on sensor data, achieving precise self-adjustment within the system. Furthermore, since the change in the radius of the take-up and unwinding mechanism is negligible compared to the radius of the take-up and unwinding mechanism in a short time during the balancing stage, the aforementioned periodic tension adjustment is more reasonable and efficient. Attached Figure Description

[0054] Figure 1 This is a diagram illustrating the application environment of the tension control method in one embodiment;

[0055] Figure 2 This is a schematic diagram of the first process of a tension control method in one embodiment;

[0056] Figure 3 This is a schematic diagram of the second process of the tension control method in another embodiment;

[0057] Figure 4 This is a diagram showing the relationship between the spindle and the roller in one embodiment of the tension control method;

[0058] Figure 5 A diagram showing the relationship between the spindle and roller in existing tension control methods;

[0059] Figure 6This is a schematic diagram of the third process of the tension control method in another embodiment;

[0060] Figure 7 This is a structural block diagram of a tension control device in one embodiment. Detailed Implementation

[0061] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0062] It should be noted that the terms "first," "second," etc., used in the specification, claims, and accompanying drawings of this disclosure are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of this disclosure described herein can be implemented in orders other than those illustrated or described herein. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with this disclosure. Rather, they are merely examples of apparatuses and methods consistent with some aspects of this disclosure as detailed in the appended claims.

[0063] It should also be noted that the user information (including but not limited to user device information, user personal information, etc.) and data (including but not limited to data used for display, data used for analysis, etc.) involved in this disclosure are all information and data authorized by the user or fully authorized by all parties. The acquisition, storage, use, and processing of data in the technical solution of this application all comply with the relevant provisions of national laws and regulations.

[0064] The tension control method provided in this application embodiment can be applied to, for example, Figure 1 The winding device is shown in the application environment. The unwinding mechanism includes an unwinding roller 105, and the winding mechanism includes a winding roller 107. Multiple intermediate rollers are arranged between the unwinding roller 105 and the winding roller 107, sequentially including, according to the substrate conveying direction, a conventional guide roller, a flattening roller 113, a conventional guide roller, a tension measuring roller, a first cooling coating roller 101, a conventional guide roller 117, a conventional guide roller, a flattening roller, a tension measuring roller 115, a second cooling coating roller 103, a tension measuring roller, a tension interrupting roller 111, a tension measuring roller, a conventional guide roller, a flattening roller, and a conventional guide roller 109. It should be noted that in this embodiment, the number and type of intermediate rollers can be increased or decreased according to actual scenario requirements. Those skilled in the art, inspired by the essence of this application, may make other modifications, but as long as their functions and effects are the same as or similar to those of this application, they should be covered within the scope of protection of this application.

[0065] In one embodiment, such as Figure 2 As shown, a tension control method is provided, which is applied to... Figure 1 Taking a winding device as an example, the winding device includes: an unwinding mechanism, an intermediate roller, and a winding mechanism. The substrate released by the unwinding mechanism passes through the intermediate roller and is then wound up by the winding mechanism.

[0066] Step S201: Obtain the first tension of the substrate within a preset range of the winding and unwinding mechanism; wherein the winding and unwinding mechanism includes the unwinding mechanism or the winding mechanism.

[0067] Specifically, the unwinding and take-up mechanism includes an unwinding mechanism or a take-up mechanism, wherein the unwinding mechanism includes at least an unwinding roller, and the take-up mechanism includes at least a take-up roller. The preset range may include a preset length range, or it may include the substrate range between the preset roller and the unwinding and take-up mechanism. Figure 1 Taking the unwinding roller 105 as an example, the preset roller may include: a first cooling coating roller 101. Obtaining the first tension of the substrate within a preset range from the unwinding mechanism by using a tension measuring roller may include obtaining the first tension between the unwinding roller 105 and the first cooling coating roller 101. For another example, taking... Figure 1 Taking the take-up roller 107 as an example, the preset roller may include a tension-breaking roller 111. Obtaining the first tension of the substrate within a preset range of the take-up and unwinding mechanism through a tension measuring roller located between the tension-breaking roller 111 and the take-up roller 107 may include: a first tension between the take-up roller 107 and the tension-breaking roller 111. In an exemplary embodiment, the take-up and unwinding mechanism may include: a vacuum winding coating take-up and unwinding mechanism. Figure 4 As shown, the winding tension control system independently controls the unwinding shaft, the first cooling coating roller shaft A, the second cooling coating roller shaft B, the partition roller shaft, and the take-up shaft. The first cooling coating roller shaft A, the second cooling coating roller shaft B, and the partition roller shaft are intermediate shafts. In this embodiment, the winding tension control system mainly controls the unwinding motor and the take-up motor separately through a servo controller, and obtains feedback control of real-time tension fluctuations to achieve tension balance during unwinding and take-up.

[0068] In this embodiment, the first tension of the substrate within a preset range of the intermediate roller can also be obtained to adjust the tension of the intermediate roller, for example, the first cooling coating roller 101 and the second cooling coating roller 103. Since the roller diameter remains constant (film thickness is negligible) during substrate transfer, in practical applications, only a slight adjustment of the tension ratio is needed for the intermediate roller, without needing to consider the impact of radius changes.

[0069] Step S203: When the first tension exceeds the target first interval, iteratively adjust the angular velocity of the winding and unwinding mechanism until the first tension is within the target first interval to obtain the initial angular velocity.

[0070] Specifically, the target first interval may include a preset tension range, such as a range between 80N and 160N. Its size can be set according to the specific application scenario; for example, a relatively large variation range can be set. Generally, during the initial operation of the winding device, the tension fluctuation range is large. If the first tension exceeds the target first interval, it indicates that the tension fluctuation amplitude of the corresponding take-up and unwinding mechanism is inappropriate, and tension adjustment is required. The angular velocity of the take-up and unwinding mechanism is iteratively adjusted until the first tension is within the target first interval. In an exemplary embodiment, at the unwinding end, if the detected tension is relatively large (e.g., greater than the maximum value of the target first interval or greater than a preset value), it indicates that the substrate is relatively tight, and the value of the unwinding mechanism's angular velocity can be increased; conversely, if the detected tension is relatively small (e.g., less than the minimum value of the target first interval or a preset value), it indicates that the substrate is relatively loose, and the value of the take-up and unwinding mechanism's angular velocity can be decreased. This process can be repeated multiple times until the first tension is within the target first interval. At this point, it indicates that the first tension has stabilized. Furthermore, the winding end operates in the opposite mode to the unwinding end. At the winding end, if the detected tension is relatively high (e.g., greater than the maximum value of the first target interval or greater than the preset value), it indicates that the substrate is relatively tight, and the angular velocity of the winding mechanism can be reduced. If the detected tension is relatively low (e.g., less than the minimum value of the first target interval or the preset value), it indicates that the substrate is relatively loose, and the angular velocity of the winding mechanism can be increased. Further explanation is not provided here.

[0071] Step S205: Control the winding and unwinding mechanism to rotate according to the initial angular velocity, and periodically acquire the second tension of the substrate within a preset range from the winding and unwinding mechanism.

[0072] Specifically, in the aforementioned steps, the tension near the take-up and unwinding mechanism tends to stabilize. However, since the roller diameter changes as the substrate decreases or increases during the operation of the take-up and unwinding mechanism, the tension in its vicinity will also change. In this embodiment, a second tension of the substrate within a preset range from the take-up and unwinding mechanism is periodically acquired. This periodicity may include acquiring the second tension at preset time intervals. The preset time interval can be set according to the specific application scenario or adjusted in real time during the operation of the winding device.

[0073] In this embodiment, the change in the roll diameter of the winding and unwinding mechanism is relatively small in a short time compared to the entire roll diameter (at a speed of 12m / min and a film thickness of 3 micrometers, the roll diameter changes by approximately 10 micrometers every 10 minutes, which is almost constant in a short time compared to the unwinding roll diameter of 200mm). Therefore, it is not necessary to adjust it every moment, but rather to periodically obtain the second tension of the substrate within a preset range from the winding and unwinding mechanism.

[0074] Step S207: When the second tension exceeds the target second interval, iteratively adjust the angular velocity of the winding and unwinding mechanism until the second tension is within the target second interval; wherein the target second interval is smaller than the target first interval.

[0075] Specifically, when the second tension exceeds the target second range, the angular velocity of the take-up and unwinding mechanism is adjusted. The target second range may include a preset tension range, such as a range between (-5N) and (+5N). Its size can be set according to specific application scenarios; for example, a range with relatively small changes can be set to improve the stability of tension adjustment. The target second range is smaller than the target first range. In an exemplary embodiment, at the unwinding end, if the detected tension is relatively large (e.g., greater than the maximum value of the target first range or greater than a preset value), it indicates that the substrate is relatively tight, and the value of the angular velocity of the take-up and unwinding mechanism can be increased; conversely, if the detected tension is relatively small (e.g., less than the minimum value of the target first range or a preset value), it indicates that the substrate is relatively loose, and the value of the angular velocity of the take-up and unwinding mechanism can be decreased until the second tension is within the target second range.

[0076] In the aforementioned tension control method, during the initial stage of the winding device, a target first interval with a large variation range is set. By detecting the first tension, the angular velocity of the take-up and unwinding mechanism is iteratively adjusted to stabilize the tension fluctuation amplitude. During the balancing stage of the winding device, a target second interval with a smaller variation range is set. By periodically detecting the second tension, the angular velocity of the take-up and unwinding mechanism is adjusted to stabilize the tension fluctuation amplitude within a smaller range, achieving more precise tension control. Compared to the traditional scheme of adding a sensor for the roll diameter change to the take-up and unwinding mechanism and controlling the tension based on the roll diameter change value, this embodiment does not rely on data from the roll diameter test sensor, achieving self-adjustment within the system. Furthermore, since the change in the radius of the take-up and unwinding mechanism is negligible compared to the radius of the take-up and unwinding mechanism in a short time during the balancing stage, the aforementioned periodic tension adjustment is more reasonable and efficient.

[0077] In one possible implementation, obtaining the first tension of the substrate within a preset range from the unwinding / rewinding mechanism includes:

[0078] Control the winding and unwinding mechanism to rotate at a preset angular velocity to obtain the first tension of the substrate within a preset range from the winding and unwinding mechanism;

[0079] The step of iteratively adjusting the angular velocity of the winding and unwinding mechanism when the first tension exceeds the target first interval, until the first tension is within the target first interval, to obtain an initial angular velocity, includes:

[0080] When the first tension exceeds the first range, the angular velocity of the winding and unwinding mechanism is iteratively adjusted, and the winding and unwinding mechanism is controlled to rotate according to the adjusted angular velocity until the first tension is within the first range.

[0081] The first interval is narrowed several times until the target first interval is reached. Each time the interval is narrowed, the angular velocity of the winding and unwinding mechanism is adjusted until the first tension is within the target first interval.

[0082] Specifically, the preset angular velocity can include a velocity lower than a preset value. During the initial operation phase of the winding device, a lower angular velocity can be used for rotation. In this embodiment, the first interval can include an interval larger than the target first interval. During the initial operation phase, the tension is prone to extremely large or small values, so a larger first interval can be set, such as 50N-150N. In an exemplary embodiment, the tension of the winding mechanism is kept within the first interval by adjusting the angular velocity of the winding and unwinding mechanism. In an exemplary embodiment, the range of the first interval can be gradually reduced. For example, the first interval can be reduced to the second interval the first time; the first interval can be reduced to the third interval the second time; ... the Nth interval can be reduced to the target first interval the Nth time. After each reduction of the interval, the angular velocity of the winding and unwinding mechanism can be adjusted until the first tension falls within the target first interval.

[0083] In the above embodiments, by gradually narrowing the tension range, the amount of change in the angular velocity adjustment amplitude is reduced, thereby reducing tension instability caused by large changes in angular velocity.

[0084] In one possible implementation, before periodically acquiring the second tension of the substrate within a preset range from the winding / unwinding mechanism, the method further includes:

[0085] According to a preset cycle, the second tension of the substrate within a preset range from the winding and unwinding mechanism is periodically acquired to obtain the first data;

[0086] The preset cycle is adjusted a certain number of times, and according to the cycle after each adjustment, the second tension of the substrate within a preset range from the winding and unwinding mechanism is periodically acquired to obtain multiple second data; wherein, each second data corresponds to the cycle after each adjustment.

[0087] The sampling period is determined to be the period corresponding to the data with the smallest standard deviation among the first data and multiple second data;

[0088] According to the sampling period, the second tension of the substrate within a preset range from the winding and unwinding mechanism is periodically acquired.

[0089] Specifically, a second tension is obtained during a sampling period. Within this sampling period, second tension data is sampled at a preset period. Multiple tension values ​​are obtained within the sampling period. The maximum and minimum values ​​are removed, and the remaining tension values ​​are averaged or directly averaged to obtain a relatively accurate second tension. For example, the sampling period is 1 second, and the preset period is 2 ms. In this embodiment, adjusting the preset period a certain number of times may include increasing or decreasing a preset time amount based on the preset period to obtain an adjusted period; or it may include increasing or decreasing the preset time amount on the adjusted period. According to each adjusted period, the second tension of the substrate within a preset range from the winding and unwinding mechanism is periodically acquired to obtain multiple second data points. Each second data point corresponds to each adjusted period, for example: period a corresponds to second data point 1; period b corresponds to second data point 2; period c corresponds to second data point 3, and so on.

[0090] In this embodiment, the standard deviation of the first data and the standard deviations of multiple second data are obtained respectively. The period corresponding to the data with the smallest standard deviation is determined, and this period is used as the sampling period. According to the sampling period, the second tension of the substrate within a preset range from the winding and unwinding mechanism is periodically obtained.

[0091] In the above embodiment, by adaptively adjusting the sampling period, the period corresponding to the data with the smallest standard deviation is determined as the optimal sampling period, and the second tension is sampled using this sampling period. This allows the system to sample the tension with a better sampling period, resulting in a more realistic tension. To a certain extent, outliers or unstable values ​​with large fluctuations are filtered out, thereby achieving more stable adjustment.

[0092] In one possible implementation, periodically acquiring the second tension of the substrate between the intermediate roller closest to the take-up / unwinding mechanism and the take-up / unwinding mechanism includes:

[0093] Periodically acquire multiple second tensions of the substrate between the intermediate roller closest to the winding and unwinding mechanism and the winding and unwinding mechanism;

[0094] According to preset data cleaning rules, multiple second tensions are filtered to obtain filtered second tensions;

[0095] The second tension of the substrate within a preset range from the winding and unwinding mechanism is determined to be the average value of the second tension after screening.

[0096] Specifically, the multiple second tensions are obtained by measuring data at the same position at different times using a tension test roller. In this embodiment of the disclosure, the multiple second tensions are acquired periodically, which may include acquiring multiple second tensions at preset intervals. For example, the preset interval may include 1 ms (second). In an exemplary embodiment, 1 s can be further divided into multiple ms (milliseconds), such as 2 ms, 10 ms, 15 ms, etc., with each scanning cycle corresponding to one second tension.

[0097] In this embodiment of the disclosure, the data cleaning rules may include rules for deleting outliers from the data, such as deleting maximum values, minimum values, and values ​​outside a preset range. Multiple second tensions are filtered according to the data cleaning rules to obtain multiple filtered second tensions. The average value of the multiple filtered second tensions is taken as the second tension sampled in the preset period.

[0098] In the above embodiments, by periodically acquiring multiple second tensions of the substrate within a preset range from the winding and unwinding mechanism, and by filtering and averaging the data of these multiple second tensions, the effectiveness of obtaining the second tensions can be improved, and the impact of outliers on tension control can be reduced.

[0099] In one possible implementation, refer to Figure 3 As shown, before obtaining the first tension of the substrate within a preset range from the winding and unwinding mechanism, the method further includes:

[0100] Step S301: Obtain the tension of the preset substrate segment of the winding device; wherein, the preset substrate segment includes the substrate between the unwinding mechanism and the intermediate roller, and the substrate between the intermediate roller and the winding mechanism; here, the intermediate roller can be a first cooling coating roller or a second cooling coating roller, which obtains the tension of the preset substrate segment of the winding device through a tension measuring roller.

[0101] Step S303: When the tension exceeds the preset range corresponding to the preset substrate segment, determine that the winding and unwinding mechanism is the winding and unwinding mechanism corresponding to the preset substrate segment.

[0102] Specifically, the tension of any substrate segment in the winding device can be monitored. The preset substrate segment includes the substrate between the unwinding mechanism and the intermediate roller, and the substrate between the intermediate roller and the winding mechanism. In this embodiment, different preset tension ranges can be set for different substrate segments. If the tension exceeds the preset range corresponding to the preset substrate segment, it indicates that the tension of the preset substrate segment is abnormal, and the rollers adjacent to the substrate segment need to be adjusted.

[0103] In an exemplary embodiment, the rollers located between the unwinding mechanism and the winding mechanism can both serve as intermediate rollers. The preset substrate segment includes the substrate between the unwinding mechanism and the intermediate roller, where the intermediate roller can be a first coating cooling roller; while the preset substrate segment includes the substrate between the intermediate roller and the winding mechanism, where the intermediate roller can be a tension-breaking roller, without further limitation.

[0104] In an exemplary embodiment, if an abnormal tension occurs in the substrate segment corresponding to the winding and unwinding mechanism, the tension of the winding and unwinding mechanism is adjusted.

[0105] In the above embodiments, by monitoring any substrate segment of the winding device, if an abnormality occurs, the corresponding roller can be adjusted, thus achieving precise adjustment.

[0106] In one possible implementation, iteratively adjusting the angular velocity of the take-up and unwinding mechanism includes: iteratively adjusting a proportional coefficient of the angular velocity of the take-up and unwinding mechanism; wherein the proportional coefficient is the angular velocity of the take-up and unwinding mechanism / the angular velocity of the spindle, wherein the spindle is a virtual axis assumed for ease of calculation, and the spindle radius is a preset value. In this embodiment, the spindle can be the roller shaft of the first cooling coating roller or the second coating cooling coating roller.

[0107] Specifically, in this embodiment, the angular velocity of the roller can be adjusted by regulating the ratio of the roller's angular velocity. In an exemplary embodiment, the tension control system inherently requires consistent winding and unwinding linear velocities. Therefore, during the stable phase of the coating process, the linear velocity is constant, and the angular velocity is inversely proportional to the shaft radius (linear velocity = angular velocity × shaft radius). Thus, this proportionality coefficient is expressed as the angular velocity of the winding / unwinding mechanism / the angular velocity of the main shaft, mathematically equal to the main shaft radius / the current shaft radius. The current shaft radius is the shaft radius of the winding / unwinding mechanism, which changes during the coating process. The roller shaft of the first or second cooling coating roller corresponding to the main shaft, however, has a default coating roller (i.e., main shaft) radius that remains constant throughout the coating process and does not change with coating time; mathematically, they are equivalent. In practical applications, the real-time roll diameter can be calculated, from which a control quantity (corresponding to the angular velocity control of the shaft) is given, and the roll diameter ratio is used as the input quantity. Therefore, during the entire coating process, changes in the radius of the current shaft (the radius of the take-up and untake-off rollers) will cause corresponding changes in the tension of the substrate. Consequently, it is necessary to adjust the proportional coefficient of the angular velocity of the take-up and untake-off mechanism, i.e., adjust the angular velocity of the current roller, to achieve precise adjustment of the substrate tension. (Reference) Figure 4 As shown in the embodiments of this disclosure, the relationship between the main shaft and each roller shaft is direct, meaning that the adjustment of the angular velocity of any one roller shaft does not depend on the other roller shafts. (Reference) Figure 5As shown, in the prior art, the setting of the proportional coefficient of angular velocity often depends on adjacent rollers, such as unwinding roller / cold roller A. In this case, adjusting the angular velocity of cold roller A will also affect the angular velocity of unwinding roller. If there is an error, it will cause the error to accumulate.

[0108] In the above embodiments, the real-time error of the cascaded servo in the first part of the system is synchronously amplified in motion control and becomes the reference target for the subsequent servo to follow. This can easily cause the control characteristics of the subsequent servo to deteriorate. By adopting a mathematical relationship linkage of system stability and servo synchronization within the group, the impact of transient error amplification in servo cascade topology design can be effectively reduced.

[0109] Figure 6 This is a schematic diagram of the third process of the tension control method in another embodiment. In this embodiment, the mathematical model of the abstract axis angular velocity proportional coefficient is C = principal axis radius / current axis radius, C = C(offset) + C(PIDRatio), where C(offset) is the proportional coefficient R_principal axis / r_current axis, and C(PIDRatio) is the adjustment coefficient, i.e., C = R_principal axis / r_current axis + Delta × PID. The proportional coefficient is the current axis angular velocity / principal axis angular velocity, which is mathematically equal to the principal axis radius / current axis radius (the principal axis radius is a preset constant value). During the iteration process, C(offset) is the R_principal axis / r_current axis proportional coefficient of the previous iteration cycle, and C(PIDRatio) is the real-time adjustment coefficient formed based on tension fluctuations in the current cycle. (Reference) Figure 6As shown, when the winding device starts running, if the system tension amplitude is detected to be appropriate, that is, the tension of each preset substrate segment does not exceed the preset range, the real-time characteristics of the system are analyzed. If the tension of a single unwinding segment is abnormal, the tension of the unwinding mechanism is adjusted. The unwinding tension segment fluctuation amplitude is checked for appropriateness. If it is not appropriate, low-speed tension building can be used, with an initial C(offset) of 0, relying solely on PID control. This continues until the tension fluctuation trend stabilizes and oscillates without diverging. That is, the first tension in the above embodiment is within the target first interval. The initial iteration C(offset) = C is obtained using the initial variation of the formula C = C(offset) + C(PIDRatio), C = + C(PIDRatio). When the unwinding tension segment amplitude is appropriate, tension is collected in real time for data processing. When the data adjustment cycle meets the preset data volume or interval duration, the adjustment conditions for the sampling cycle can be set, such as the preset data volume or interval duration. When the adjustment conditions are not met, C(offset) = C is iteratively obtained according to the formula C = C(offset) + C(PIDRatio). When the adjustment conditions are met, the real-time tension acquisition sample size, sampling period, and filtering are adjusted. The tension data of each sampling period are optimized and iterated, and the standard deviation of the tension data is analyzed to obtain the optimal sampling period. Subsequently, the second tension is acquired and adjusted according to the optimal sampling period. In this embodiment, due to the change in roll diameter, tension fluctuations cause changes in C(PIDRatio), which are reflected in C. Through mathematical relationships, we have C(offset) approximately equal to C. By selecting a suitable time interval and iterating to obtain a suitable C(offset), we can control C(PID) within a small range. This is reflected in the system as the tension adjusting itself within the allowable range of the index. Specifically, the short-time filtered value of the real-time tension is obtained. Based on the system's stability constraint C = C(offset) + C(PIDRatio), the tension fluctuation compensation is reflected in C(PIDRatio), and C(offset) is approximately equal to C. After a certain period of iterative correction of C(offset), the tension iteration of the system is completed. Returning to the initial stage, the above process begins with the balancing phase. Before entering this phase, we also adopt C=C(offset)+C(PIDRatio). Since there is no initial roll diameter concept, we initially obtain an approximate C(offset) through complete PID adjustment of the system (this operation has limitations; the tension fluctuation amplitude is large, and the vibration is large, but in the low-speed tension build-up phase, a relatively suitable initial convergence C can be obtained). Combined with steady-state angular velocity iteration, the overall tension control model of the system is then completed. In addition, regarding the iteration cycle of the above iteration method, the iteration cycle of C(offset) is on the order of minutes, for example, it can be an iteration every 100-300 seconds, while the iteration cycle of C(PIDRatio) is real-time, that is, fine-tuning every second.

[0110] The iterative change of angular velocity corresponding to the iterative process of the above-mentioned abstract axis angular velocity proportional coefficient is as follows:

[0111] ω1=ω0+Δω

[0112] Where ω1 is the real-time angular velocity of unwinding and winding, ω0 is the initial angular velocity, and Δω is the adjustment angular velocity. Taking the unwinding roller as an example, when the winding device starts running, the initial C (offset) is 0, relying solely on PID control, i.e., the ω0 of the unwinding roller is zero. The tension of the substrate is obtained through a tension measuring roller located between the unwinding roller 105 and the first cooling coating roller 101. This tension is greater than or less than a reference tension, where the reference tension corresponds to the tension value of each substrate under the ideal coating state. At this time, for the unwinding roller, if the tension is greater than the reference tension, the angular velocity of the unwinding roller needs to be increased to make the linear velocity of the substrate on the unwinding roller 105 and the first cooling coating roller 101 the same, thereby reducing the tension of the substrate. If the tension is less than the reference tension, the angular velocity of the unwinding roller needs to be decreased to increase the tension of the substrate. In this state, relying solely on PID regulation, after obtaining the substrate tension, the data is processed and the control system provides Δω to adjust the angular velocity of the unwinding roller. At this time, ω1=0+Δω. After adjustment, ω1 is assigned to ω0, which is equivalent to obtaining the initial iteration C(offset)=C by relying on the initial variation of the formula C=C(offset)+C(PIDRatio) C=+C(PIDRatio).

[0113] Because of the lag during the adjustment process, after the angular velocity is adjusted, the tension of the substrate is obtained again through the tension measuring roller. At this time, the tension is close to the reference tension. After data processing, i.e., C=C(offset)+C(PIDRatio), the tension fluctuation compensation is reflected in C(PIDRatio), the proportional coefficient is supplemented by the change, and then the corresponding Δω is given for adjustment. At this time, ω1'=ω0+Δω. After adjustment, ω1' is assigned to ω0 again, which is equivalent to iteratively adjusting the proportional coefficient of the angular velocity of the unwinding mechanism again.

[0114] Repeat the above steps, iteratively adjusting the angular velocity (i.e., iteratively adjusting the proportional coefficient of the angular velocity of the unwinding mechanism) until the tension measuring roller obtains that the tension of the substrate is within the target first range, thus completing the initial stage of angular velocity adjustment.

[0115] In addition, the tension measuring roller obtains that the tension of the substrate is within the first interval. After multiple iterations, the proportional coefficient of the angular velocity of the unwinding mechanism is adjusted to adjust the angular velocity until the tension measuring roller obtains that the tension of the substrate is within the target second interval. The iterative adjustment of the proportional coefficient of the angular velocity of the unwinding mechanism in the stable stage is completed, wherein the target second interval is smaller than the target first interval.

[0116] It should be understood that although the steps in the flowcharts of the embodiments described above are shown sequentially according to the arrows, these steps are not necessarily executed in the order indicated by the arrows. Unless explicitly stated herein, there is no strict order restriction on the execution of these steps, and they can be executed in other orders. Moreover, at least some steps in the flowcharts of the embodiments described above may include multiple steps or multiple stages. These steps or stages are not necessarily completed at the same time, but can be executed at different times. The execution order of these steps or stages is not necessarily sequential, but can be performed alternately or in turn with other steps or at least some of the steps or stages of other steps.

[0117] Based on the same inventive concept, this application also provides a tension control device for implementing the tension control method described above. The solution provided by this device is similar to the solution described in the above method; therefore, the specific limitations in one or more tension control device embodiments provided below can be found in the limitations of the tension control method described above, and will not be repeated here.

[0118] In one embodiment, such as Figure 7 As shown, a tension control device is provided for use in a winding apparatus. The winding apparatus includes an unwinding mechanism, an intermediate roller, and a winding mechanism. The substrate released by the unwinding mechanism passes through the intermediate roller and is then wound up by the winding mechanism. The tension control device includes:

[0119] The acquisition module 701 is used to acquire the first tension of the substrate within a preset range of the winding and unwinding mechanism; wherein the winding and unwinding mechanism includes the unwinding mechanism or the winding mechanism.

[0120] The first adjustment module 703 is used to iteratively adjust the angular velocity of the winding and unwinding mechanism when the first tension exceeds the target first interval, until the first tension is within the target first interval, and obtain the initial angular velocity.

[0121] The acquisition module 701 is also used to control the winding and unwinding mechanism to rotate according to the initial angular velocity, and periodically acquire the second tension of the substrate within a preset range from the winding and unwinding mechanism;

[0122] The second adjustment module 707 is used to iteratively adjust the angular velocity of the winding and unwinding mechanism when the second tension exceeds the target second range, until the second tension is within the target second range; wherein the target second range is smaller than the target first range.

[0123] In one possible implementation, the acquisition module includes:

[0124] The acquisition submodule is used to control the winding and unwinding mechanism to rotate at a preset angular velocity and acquire the first tension of the substrate within a preset range from the winding and unwinding mechanism;

[0125] The first adjustment module includes:

[0126] The second adjustment submodule is used to adjust the angular velocity of the take-up and unwinding mechanism when the first tension exceeds the first range, and to control the take-up and unwinding mechanism to rotate according to the adjusted angular velocity until the first tension is within the first range.

[0127] The third adjustment submodule is used to reduce the first interval several times until the target first interval is reached. Each time the interval is reduced, the angular velocity of the winding and unwinding mechanism is adjusted until the first tension is within the target first interval.

[0128] In one possible implementation, the device further includes:

[0129] The acquisition module is also used to periodically acquire the second tension of the substrate within a preset range from the winding and unwinding mechanism according to a preset period, and obtain the first data;

[0130] The third adjustment module is used to adjust the preset cycle a certain number of times, and periodically acquire the second tension of the substrate within a preset range from the winding and unwinding mechanism according to the cycle after each adjustment, to obtain multiple second data; wherein, each second data corresponds to the cycle after each adjustment;

[0131] The first determining module is used to determine the sampling period as the period corresponding to the data with the smallest standard deviation among the first data and multiple second data.

[0132] In one possible implementation, the second acquisition module includes:

[0133] The second acquisition submodule is used to periodically acquire multiple second tensions of the substrate within a preset range from the winding and unwinding mechanism;

[0134] The filtering submodule is used to filter the data of multiple second tensions according to preset data cleaning rules, so as to obtain multiple filtered second tensions;

[0135] The determination submodule is used to determine the second tension of the substrate within a preset range from the winding and unwinding mechanism as the average value of the second tension after screening.

[0136] In one possible implementation, the device further includes:

[0137] The acquisition module is further configured to acquire the tension of a preset substrate segment of the winding device; wherein the preset substrate segment includes the substrate between the unwinding mechanism and the intermediate roller, and the substrate between the intermediate roller and the winding mechanism;

[0138] The first determining module is used to determine, when the tension exceeds a preset range corresponding to the preset substrate segment, that the winding / unwinding mechanism is the winding / unwinding mechanism corresponding to the preset substrate segment.

[0139] In one possible implementation, the first adjustment module includes:

[0140] The fourth adjustment submodule is used to iteratively adjust the proportional coefficient of the angular velocity of the winding and unwinding mechanism; wherein the proportional coefficient is the main shaft radius / current shaft radius, and the main shaft radius is a preset value.

[0141] Each module in the aforementioned tension control device can be implemented entirely or partially through software, hardware, or a combination thereof. These modules can be embedded in or independent of the processor in a computer device, or stored in the memory of a computer device as software, so that the processor can call and execute the operations corresponding to each module.

[0142] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0143] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of this patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this application should be determined by the appended claims.

Claims

1. A tension control method characterized by, The method is applied to a winding device, the winding device comprising a pay-off mechanism, an intermediate roller and a winding mechanism, wherein a base material released by the pay-off mechanism is wound by the winding mechanism after passing through the intermediate roller, and the method comprises: obtaining a first tension of the base material within a preset range of the winding and unwinding mechanism; wherein the winding and unwinding mechanism comprises the pay-off mechanism or the winding mechanism; in a case where the first tension exceeds a target first interval, iteratively adjusting an angular velocity of the winding and unwinding mechanism until the first tension is within the target first interval, to obtain an initial angular velocity; controlling the winding and unwinding mechanism to rotate at the initial angular velocity, and periodically obtaining a second tension of the base material within a preset range of the winding and unwinding mechanism; in a case where the second tension exceeds a target second interval, iteratively adjusting the angular velocity of the winding and unwinding mechanism until the second tension is within the target second interval; wherein the target second interval is smaller than the target first interval.

2. The method of claim 1, wherein, The method comprises: controlling the winding and unwinding mechanism to rotate at a preset angular velocity, and obtaining a first tension of the base material within a preset range of the winding and unwinding mechanism; in a case where the first tension exceeds a target first interval, iteratively adjusting an angular velocity of the winding and unwinding mechanism until the first tension is within the target first interval, to obtain an initial angular velocity; in a case where the first tension exceeds a first interval, iteratively adjusting the angular velocity of the winding and unwinding mechanism, and controlling the winding and unwinding mechanism to rotate at the adjusted angular velocity until the first tension is within the first interval; narrowing the first interval several times until reaching a target first interval, and adjusting the angular velocity of the winding and unwinding mechanism each time the interval is narrowed until the first tension is within the target first interval.

3. The method of claim 1, wherein, Before the periodically obtaining a second tension of the base material within a preset range of the winding and unwinding mechanism, the method further comprises: periodically obtaining a second tension of the base material within a preset range of the winding and unwinding mechanism according to a preset period, to obtain first data; adjusting the preset period several times, and periodically obtaining a second tension of the base material within a preset range of the winding and unwinding mechanism according to each adjusted period, to obtain multiple second data; wherein each second data corresponds to each adjusted period; determining a sampling period as a period corresponding to a data with a minimum standard deviation among the first data and the multiple second data; periodically obtaining a second tension of the base material within a preset range of the winding and unwinding mechanism according to the sampling period.

4. The method of claim 3, wherein, The periodically obtaining a second tension of the base material within a preset range of the winding and unwinding mechanism comprises: periodically obtaining multiple second tensions of the base material within a preset range of the winding and unwinding mechanism; performing data screening on the multiple second tensions according to a preset data cleaning rule, to obtain multiple screened second tensions; determining a second tension of the base material within a preset range of the winding and unwinding mechanism as an average value of the screened second tensions.

5. The method of claim 1, wherein, Before the first tension of the base material within the preset range of the winding and unwinding mechanism is acquired, further comprising: acquiring the tension of the preset base material section of the winding device; wherein the preset base material section comprises the base material between the unwinding mechanism and the intermediate roller, and the base material between the intermediate roller and the winding mechanism; in the case that the tension exceeds the preset range corresponding to the preset base material section, determining that the winding and unwinding mechanism is the winding and unwinding mechanism corresponding to the preset base material section.

6. The method of claim 1, wherein, iteratively adjusting the angular velocity of the winding and unwinding mechanism, comprising: iteratively adjusting the angular velocity of the winding and unwinding mechanism and the angular velocity proportional coefficient of the system main shaft; wherein the proportional coefficient is the main shaft radius / current shaft radius, and the main shaft radius is a preset value.

7. A tension control device characterized by comprising: applied to a winding device, the winding device comprising: an unwinding mechanism, an intermediate roller and a winding mechanism, wherein the base material released by the unwinding mechanism passes through the intermediate roller and is wound by the winding mechanism, and the tension control device comprises: an acquisition module for acquiring the first tension of the base material within the preset range of the winding and unwinding mechanism; wherein the winding and unwinding mechanism comprises the unwinding mechanism or the winding mechanism; a first adjustment module for iteratively adjusting the angular velocity of the winding and unwinding mechanism in the case that the first tension exceeds the target first interval until the first tension is within the target first interval to obtain an initial angular velocity; the acquisition module is further configured to control the winding and unwinding mechanism to rotate at the initial angular velocity and periodically acquire the second tension of the base material within the preset range of the winding and unwinding mechanism; a second adjustment module for iteratively adjusting the angular velocity of the winding and unwinding mechanism in the case that the second tension exceeds the target second interval until the second tension is within the target second interval; wherein the target second interval is smaller than the target first interval.

8. The apparatus of claim 7, wherein, the acquisition module comprises: a first acquisition submodule for controlling the winding and unwinding mechanism to rotate at a preset angular velocity and acquiring the first tension of the base material within the preset range of the winding and unwinding mechanism; the first adjustment module comprises: a second adjustment submodule for adjusting the angular velocity of the winding and unwinding mechanism in the case that the first tension exceeds the first interval, controlling the winding and unwinding mechanism to rotate at the adjusted angular velocity until the first tension is within the first interval; a third adjustment submodule for narrowing the first interval several times until reaching the target first interval, and adjusting the angular velocity of the winding and unwinding mechanism each time until the first tension is within the target first interval.

9. The apparatus of claim 7, wherein, further comprising: the acquisition module is further configured to periodically acquire the second tension of the base material within the preset range of the winding and unwinding mechanism according to a preset period to obtain first data; a third adjustment module for adjusting the preset period several times and periodically acquiring the second tension of the base material within the preset range of the winding and unwinding mechanism according to the period adjusted each time to obtain multiple second data; wherein each second data corresponds to the period adjusted each time. The first determining module is configured to determine a sampling period as a period corresponding to data with a minimum standard deviation among the first data and the plurality of second data.

10. The apparatus of claim 7, wherein, The acquisition module further includes: The second acquisition sub-module is configured to periodically acquire a plurality of second tensions of the base material within a preset range from the winding and unwinding mechanism. The screening sub-module is configured to perform data screening on the plurality of second tensions according to a preset data cleaning rule to obtain screened second tensions. The determining sub-module is configured to determine the second tension of the base material within the preset range from the winding and unwinding mechanism as an average value of the screened second tensions.

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