Control device and control method for gap distance between linear compression roller and surface of material film

Abstract

The invention discloses a device for controlling the surface clearance distance between a linear compression roller and a material film, which comprises the linear compression roller and the material film which are in clearance fit, the material film is arranged on a winding drum, a nut is fixedly connected to the linear compression roller, the nut is in threaded connection with a ball screw, one end of the ball screw is connected with a servo motor, and the servo motor is connected with an absolute value encoder. The servo motor and the absolute value encoder are in signal connection with a driver, the driver is in signal connection with a control system, and the control system is in signal connection with a human-computer interface. The transmission combination of the servo motor and the ball screw is adopted, the absolute value encoder is arranged for accurate position feedback, high-precision control over the position of the linear pressing roller can be achieved, and therefore the gap distance between the linear pressing roller and the surface of a material film can be adjusted more accurately. The invention further discloses a control method for the gap distance between the linear compression roller and the material film surface, the position of the linear compression roller is judged by detecting the pulse number of the absolute value encoder, and control over the gap distance between the linear compression roller and the material film surface is achieved.

Description

Technical Field

[0001] The invention belongs to the field of coating machinery and control technology, and specifically relates to a control device for the gap distance between a linear pressure roller and a material film surface, and also relates to a control method for the gap distance between a linear pressure roller and a material film surface. Background Art

[0002] In the process of refinement of today's industrial production, as a key equipment in many industries, the performance of the coating machine directly affects the quality and production efficiency of the product. With the rapid development of science and technology and the increasing market demand for high-quality products, the control accuracy of the coating machine has become one of the core concerns. Higher control accuracy means that during the coating process, the paint can be more accurately and evenly applied to the material film, thereby ensuring that the coating thickness of the material film is consistent and the surface quality is excellent, greatly reducing the waste caused by uneven coating.

[0003] The original method of using sawtooth positioning strips and proximity switches to control the gap distance between the winding linear rollers was relatively rough. The distance between the proximity switch and the sawtooth was easily affected by many factors, such as equipment vibration, wear of mechanical parts, and installation and commissioning accuracy. These factors led to uncertainty in the distance adjustment between the two. This uncertainty made it impossible to calculate the gap accurately, which seriously affected the stability of the winding tension. Summary of the invention

[0004] The first purpose of the present invention is to provide a control device for the gap distance between a linear pressure roller and a material film surface, which solves the technical problem in the prior art that the gap calculation is inaccurate due to the uncertainty of the distance adjustment between the proximity switch and the saw teeth during the operation of the linear pressure roller.

[0005] The second object of the present invention is to provide a method for controlling the gap distance between the linear pressure roller and the surface of the material film.

[0006] The first technical solution adopted by the present invention is a control device for the gap distance between a linear pressure roller and the surface of a material film, comprising a linear pressure roller and a material film with clearance fit, the material film being mounted on a reel, a nut being fixedly connected to the linear pressure roller, a ball screw being threadedly connected to the nut, a servo motor being connected to one end of the ball screw, the servo motor being connected to an absolute encoder, the servo motor and absolute encoder signals being connected to a driver, the driver signals being connected to a control system, and the control system signals being connected to a human-machine interface.

[0007] The first technical solution of the present invention is also characterized in that: The transmission ratio of the servo motor to the ball screw is 1:1.

[0008] The control system adopts PLC controller.

[0009] The second technical solution adopted by the present invention is a method for controlling the gap distance between the linear pressure roller and the surface of the material film, which adopts the above-mentioned control device for the gap distance between the linear pressure roller and the surface of the material film, and is specifically implemented according to the following steps: S1: Detect the minimum diameter r, maximum diameter R of the film on the roll, and the gap distance X between the film and the linear roller, and confirm the maximum distance L of the linear roller when the film is at the minimum diameter r; S2: Zero the absolute encoder, servo motor and linear roller; S3: The driver controls the servo motor to rotate one circle, confirming the pulse number k of the absolute encoder when the servo motor rotates one circle and the moving distance d of the linear pressure roller; S4: Calculate the position A of the linear pressure roller when the gap distance between the linear pressure roller and the material film is X, and calculate the pulse number a of the absolute encoder of the linear pressure roller from point O to point A. The control system controls the servo motor to rotate according to the pulse number a to drive the linear pressure roller to move to the set gap distance X between the linear pressure roller and the material film.

[0010] The second technical solution of the present invention is also characterized in that: The absolute value encoder is zeroed in S2 as follows: a zeroing instruction is sent to the absolute value encoder through the control system, and the absolute value encoder records and stores the current position information as zero-position data, and at the same time, the position counting device or register inside the absolute value encoder is cleared.

[0011] The linear roller zeroing in S2 is specifically as follows: the linear roller is moved to the end point of the ball screw away from one end of the material film, which is marked as point O, and the distance between point O and the maximum diameter R of the material film is L.

[0012] In S4, the position A of the linear roller is calculated when the gap between the linear roller and the film is X, as shown in the following formula: OA=LX-(Rr) / 2 Wherein, OA represents the distance from point O to point A of the linear roller, L represents the maximum distance of the linear roller when the material film is of the minimum diameter, X represents the gap distance between the material film and the linear roller, R represents the maximum diameter of the material film, and r represents the minimum diameter of the material film.

[0013] The pulse number a of the absolute encoder of the linear roller from point O to point A is calculated in S4 as follows:

[0014] In the formula, a represents the number of pulses, OA represents the distance from point O to point A of the linear roller, d represents the moving distance of the linear roller when the servo motor rotates one circle, and k represents the number of pulses of the absolute encoder when the servo motor rotates one circle.

[0015] Compared with the prior art, the present invention has the following beneficial effects: The present invention adopts a transmission combination of a servo motor and a ball screw, and is equipped with an absolute encoder for precise position feedback, which can achieve high-precision control of the position of the linear roller, thereby more accurately adjusting the gap distance with the surface of the film. Compared with the problems of large mechanical structure errors and inaccurate position control that may exist in traditional technologies, the present invention can significantly improve the control accuracy during the film processing process, effectively avoid problems such as uneven film thickness and poor printing and coating quality caused by inaccurate gap distance, improve the yield rate and quality stability of the product, and is particularly suitable for high-end manufacturing fields with strict precision requirements, such as electronics and optical film production. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 It is a schematic structural diagram of a device for controlling the gap distance between a linear pressure roller and a material film surface of the present invention; Figure 2 It is a schematic diagram of the moving distance of the linear pressing roller in the method for controlling the gap distance between the linear pressing roller and the surface of the material film of the present invention; Figure 3 yes Figure 2 A simplified schematic diagram of the .

[0017] In the figure, 1. servo motor, 2. absolute encoder, 3. linear pressure roller, 4. ball screw, 5. reel, 6. drive, 7. control system, 8. human-machine interface, 9. material film, 11. nut. DETAILED DESCRIPTION

[0018] The following will be combined with the drawings in the embodiments of the present application to clearly and completely describe the technical solutions in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, not all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of this application.

[0019] Example 1 like Figure 1 As shown, the control device for the gap distance between the linear pressure roller and the surface of the material film disclosed in this embodiment includes a linear pressure roller 3 and a material film 9 with clearance fit, the material film 9 is installed on the reel 5, a nut 11 is fixedly connected to the linear pressure roller 3, the nut 11 is threadedly connected to the ball screw 4, one end of the ball screw 4 is connected to a servo motor 1, the servo motor 1 is connected to an absolute encoder 2, the signals of the servo motor 1 and the absolute encoder 2 are connected to a driver 6, the signals of the driver 6 are connected to a control system 7, and the signals of the control system 7 are connected to a human-machine interface 8.

[0020] In this embodiment, the linear pressure roller 3 directly cooperates with the material film 9 to apply pressure to the material film 9 on the reel 5, thereby achieving the processing requirements of the material film; the ball screw 4 and the nut 11 fixed to the linear pressure roller 3 form a threaded transmission structure. When the ball screw 4 rotates, due to the effect of the thread, the nut 11 will drive the linear pressure roller 3 to move linearly along the axial direction of the ball screw 4, and can accurately convert the rotational movement of the servo motor 1 into the linear displacement of the linear pressure roller 3, thereby achieving precise control of the position of the linear pressure roller 3 to meet the fine adjustment requirements of the gap distance on the surface of the material film in different process processes; the servo motor 1 serves as a power source to provide driving force for the rotation of the ball screw 4. The servo motor 1 has high-precision position control, speed control and torque control capabilities, and can accurately rotate a certain angle or speed according to the instructions of the control system 7, and then drive the linear pressure roller 3 through the ball screw 4 to achieve precise position adjustment, ensuring that the gap distance between the material film 9 and the linear pressure roller 3 is always maintained within the set range to adapt to different materials, thicknesses and processes. The absolute encoder 2 monitors the rotation position and angle information of the shaft of the servo motor 1 in real time, and converts it into a digital signal to feed back to the driver; the driver 6 receives the control signal from the control system 7, and according to the position information fed back by the absolute encoder 2, accurately drives and controls the servo motor 1, and can convert the command signal of the control system 7 into a driving signal such as current and voltage suitable for the servo motor 1, and monitor and adjust the running state of the servo motor 1 at the same time; the control system 7 is the core control unit of the whole device. In this embodiment, the control system 7 adopts a PLC controller, which is responsible for receiving the process parameter settings and operation instructions from the human-machine interface 8, and then generates corresponding control signals according to these information and sends them to the driver 6 to control the operation of the servo motor 1 and the position adjustment of the linear pressure roller 3. The human-machine interface 8 serves as an interactive window between the operator and the control system 7, providing an intuitive and convenient operation platform. The operator can input various process parameters through the human-machine interface 8, such as the thickness of the material film, the required gap distance between the pressure roller and the material film surface, etc. At the same time, the human-machine interface can display the operating status information of the device in real time, including the current position of the linear pressure roller, the speed of the servo motor, the tension of the material film, etc., so that the operator can clearly understand the working status of the device and facilitate timely detection of problems and adjustments.

[0021] Example 2 Based on the embodiment 1, the transmission ratio between the servo motor 1 and the ball screw 4 is 1:1.

[0022] In this embodiment, every time the servo motor 1 rotates one circle, the ball screw 4 will also rotate one circle synchronously, thereby driving the nut 11 threadedly connected to the ball screw 4 and the linear roller 3 fixed to the nut 11 to produce a linear displacement of a pitch. Since the transmission ratio is simple and direct, without complex deceleration or acceleration links, the control system 7 can control the position of the linear roller 3 more intuitively and accurately. Each change in the rotation angle of the servo motor 1 can directly correspond to an accurate linear displacement of the linear roller 3, reducing the error that may be caused by the transmission ratio conversion, which is conducive to achieving more accurate roller position control in application scenarios with extremely high requirements for the control accuracy of the surface gap distance of the film 9, thereby ensuring the stability and consistency of product quality.

[0023] Example 3 The method for controlling the gap distance between the linear pressing roller and the surface of the material film disclosed in this embodiment adopts the above-mentioned control device for the gap distance between the linear pressing roller and the surface of the material film, and is specifically implemented according to the following steps: S1: Detect the minimum diameter r, maximum diameter R of the film 9 on the reel 5 and the gap distance X between the film 9 and the linear roller 3, and confirm the maximum distance L of the linear roller 3 when the film 9 is at the minimum diameter r; S2: Zeroing the absolute encoder 2, the servo motor 1 and the linear pressure roller 3; S3: The driver 6 controls the servo motor 1 to rotate one circle, confirming the pulse number k of the absolute encoder 2 when the servo motor 1 rotates one circle and the moving distance d of the linear pressure roller 3; S4: Calculate the position A of the linear pressure roller 3 when the gap distance between the linear pressure roller 3 and the film 9 is X, and calculate the pulse number a of the absolute encoder 2 from point O to point A of the linear pressure roller 3. The control system 7 controls the servo motor 1 to rotate according to the pulse number a to drive the linear pressure roller 3 to move to the set gap distance X between the linear pressure roller 3 and the film 9.

[0024] Example 4 On the basis of Example 3, the zeroing of the absolute value encoder 2 in S2 is: a zeroing instruction is sent to the absolute value encoder 2 through the control system 7, the absolute value encoder 2 records and stores the current position information as zero-position data, and at the same time, the position counting device or register inside the absolute value encoder 2 is cleared.

[0025] The linear roller 3 is adjusted to zero in S2 as follows: the linear roller 3 is moved to the end position of the ball screw 4 away from the end of the film 9, which is marked as point O, and the distance between point O and the maximum diameter R of the film 9 is L. When the linear roller 3 reaches point O, the servo motor 1 stops reversing; after the linear roller 3 is subsequently controlled to move to point A, the servo motor 1 stops rotating forward.

[0026] Example 5 On the basis of Example 3, the position A of the linear pressing roller 3 when the gap distance between the linear pressing roller 3 and the material film 9 is X is calculated in S4 as follows: OA=LX-(Rr) / 2 Wherein, OA represents the distance from point O to point A of the linear roller, L represents the maximum distance of the linear roller when the material film is of the minimum diameter, X represents the gap distance between the material film and the linear roller, R represents the maximum diameter of the material film, and r represents the minimum diameter of the material film.

[0027] The pulse number a of the absolute encoder 2 from point O to point A of the linear roller 3 is calculated in S4 as follows:

[0028] In the formula, a represents the number of pulses, OA represents the distance from point O to point A of the linear roller, d represents the moving distance of the linear roller when the servo motor rotates one circle, and k represents the number of pulses of the absolute encoder when the servo motor rotates one circle.

[0029] Example 6 In conjunction with Examples 1-5, the present invention is explained below in conjunction with specific numerical values.

[0030] like Figure 2 and Figure 3 , when the nut 11 is at Ⅰ, point O is the origin of the linear roller 3, and the pulse number of the absolute encoder 2 is 0; point B is the central axis of the reel 5, the minimum roll diameter of the film 9 is r, and the maximum distance of the linear roller 3 when the diameter of the film 9 is the smallest is L, that is, the distance of OF, the pitch of the ball screw 4 is 10mm, and the transmission ratio of the servo motor 1 and the ball screw 4 is 1:1. When the servo motor 1 rotates one circle, the ball screw 4 drives the linear roller 3 to move forward 10mm, and the pulse number change value of the absolute encoder 2 is 8388608, that is, when the nut 11 moves forward one circle, the pulse number of the absolute encoder 2 increases by 8388608, and when the absolute encoder 2 moves back one circle, the pulse number of the absolute encoder 2 decreases by 8388608, and the maximum pulse number of the absolute encoder 2 is L÷10×8388608; When the diameter of the material film 9 is R, the set gap distance is l, when the nut 11 is at II, the position of the linear pressure roller 3 is at point A, then the distance OA=Ll-(Rr) / 2; The PLC controller calculates the pulse number of the absolute encoder 2 as a=[Ll-(Rr)÷2]×8388608÷10, where L is the measured value, l is the human-machine interface setting value; R is the current diameter of the material film 9 during the operation of the equipment; and r is the minimum diameter of the material film 9.

[0031] When the control accuracy is determined to be plus or minus 1mm, the number of pulses occupied by 1mm is 838860.8. When the current number of pulses is a, the motor moves back 838861 pulses and repeats the cycle.

[0032] Finally, it should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device. In the absence of further restrictions, the elements defined by the sentence "comprise a ..." do not exclude the presence of other identical elements in the process, method, article or device including the elements.

[0033] The various embodiments in this specification are described in a progressive manner, and each embodiment focuses on the differences from other embodiments. The same or similar parts between the various embodiments can be referenced to each other.

[0034] The above description of the disclosed embodiments enables those skilled in the art to implement or use the present application. Various modifications to these embodiments will be apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present application. Therefore, the present application will not be limited to the embodiments shown herein, but will conform to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A device for controlling the gap distance between a linear pressure roller and a material film surface, comprising a linear pressure roller (3) and a material film (9) with clearance fit, wherein the material film (9) is mounted on a reel (5), and characterized in that: A nut (11) is fixedly connected to the linear pressure roller (3), the nut (11) is threadedly connected to a ball screw (4), one end of the ball screw (4) is connected to a servo motor (1), the servo motor (1) is connected to an absolute encoder (2), the servo motor (1) and the absolute encoder (2) are connected to a driver (6), the driver (6) is connected to a control system (7), and the control system (7) is connected to a human-machine interface (8).

2. The device for controlling the gap between the linear pressure roller and the surface of the film according to claim 1, characterized in that: The transmission ratio between the servo motor (1) and the ball screw (4) is 1:

1.

3. The device for controlling the gap between the linear pressure roller and the surface of the film according to claim 1, characterized in that: The control system (7) adopts a PLC controller.

4. A method for controlling the gap distance between a linear pressure roller and a material film surface, using the device for controlling the gap distance between a linear pressure roller and a material film surface according to any one of claims 1 to 3, characterized in that: Follow the steps below to implement it: S1: Detecting the minimum diameter r, the maximum diameter R of the film (9) on the reel (5) and the gap distance X between the film (9) and the linear pressing roller (3), and confirming the maximum distance L of the linear pressing roller (3) when the film (9) is at the minimum diameter r; S2: Zeroing the absolute encoder (2), the servo motor (1) and the linear pressure roller (3); S3: the driver (6) controls the servo motor (1) to rotate one circle, confirms the pulse number k of the absolute encoder (2) when the servo motor (1) rotates one circle and the moving distance d of the linear pressure roller (3); S4: Calculate the position A of the linear pressure roller (3) when the gap distance between the linear pressure roller (3) and the material film (9) is X, and calculate the pulse number a of the absolute encoder (2) of the linear pressure roller (3) from point O to point A. The control system (7) controls the servo motor (1) to rotate according to the pulse number a to drive the linear pressure roller (3) to move to a set gap distance X between the linear pressure roller (3) and the material film (9).

5. The method for controlling the gap distance between the linear pressing roller and the surface of the film according to claim 4, characterized in that: The zeroing of the absolute value encoder (2) in S2 is as follows: a zeroing instruction is sent to the absolute value encoder (2) through the control system (7), and the absolute value encoder (2) records and stores the current position information as zero-bit data, and at the same time, the position counting device or register inside the absolute value encoder (2) is cleared.

6. The method for controlling the gap distance between the linear pressing roller and the surface of the film according to claim 4, characterized in that: The zeroing of the linear pressure roller (3) in S2 is specifically as follows: the linear pressure roller (3) is moved to the end point position of the ball screw (4) away from one end of the material film (9), which is recorded as point O, and the distance between point O and the maximum diameter R of the material film (9) is L.

7. The method for controlling the gap distance between the linear pressure roller and the surface of the film according to claim 3, characterized in that: The calculation of the position A of the linear pressing roller (3) when the gap distance between the linear pressing roller (3) and the material film (9) is X in S4 is as follows: OA=LX-(Rr) / 2 Wherein, OA represents the distance from point O to point A of the linear roller, L represents the maximum distance of the linear roller when the material film is of the minimum diameter, X represents the gap distance between the material film and the linear roller, R represents the maximum diameter of the material film, and r represents the minimum diameter of the material film.

8. The method for controlling the gap distance between the linear pressure roller and the surface of the film according to claim 4, characterized in that: The pulse number a of the absolute encoder (2) of the linear pressure roller (3) from point O to point A is calculated in S4 as follows: In the formula, a represents the number of pulses, OA represents the distance from point O to point A of the linear roller, d represents the moving distance of the linear roller when the servo motor rotates one circle, and k represents the number of pulses of the absolute encoder when the servo motor rotates one circle.

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