UV illumination control method and system of reel-to-reel exposure machine

Abstract

The invention discloses a UV illumination control method and system for a reel-to-reel exposure machine. The method comprises the following steps: acquiring a real-time moving speed and a tension change value of a coiled material; when the tension change value is greater than the tension threshold value, predicting the deformation trend of the surface of the coiled material based on a nonlinear regression algorithm in combination with the real-time moving speed to obtain a deformation influence value; according to the deformation influence value, a PID control algorithm is adopted to adjust the UV light source, and a light intensity distribution value is obtained; according to the light intensity distribution value, a fuzzy control algorithm is adopted to calculate the output intensity requirement of the UV light source, and speed adjustment is carried out in combination with the real-time moving speed, so that optimized irradiation parameters are obtained; performing area judgment according to the optimized irradiation parameters to obtain an overexposure area and an underexposure area; and adjusting the intensity and distribution of the UV light source in the overexposure area and the underexposure area until the area exposure quality reaches a preset standard range. The method can realize real-time response regulation and control on tension and speed change of the coiled material, and solves the problem of non-uniform exposure dose.

Description

Technical Field

[0001] The present invention relates to the technical field of roll-to-roll exposure, and in particular to a UV lighting control method and system for a roll-to-roll exposure machine. Background Art

[0002] At present, with the roll-to-roll exposure process widely used in flexible electronics, printed circuit boards, flexible displays and other fields, the illumination uniformity and dynamic response ability of UV light sources have become important factors affecting the exposure quality. During the high-speed continuous movement of the coil, its tension and speed state change in real time with the working conditions. The traditional UV light source control method is difficult to achieve real-time linkage with the coil state, resulting in reduced exposure accuracy.

[0003] In one prior art, the irradiation angle and spot shape of the UV light source are statically controlled based on preset parameters, and fail to be dynamically adjusted according to the running state of the web. When the web speed changes suddenly or the tension fluctuates greatly, exposure deviations are likely to occur, such as spot offset, smearing, partial overexposure or underexposure, thereby affecting the imaging quality and processing yield of the pattern.

[0004] The existing technology cannot realize real-time light source control based on the web running status, resulting in uneven exposure dose. Summary of the invention

[0005] The present invention provides a UV lighting control method and system for a roll-to-roll exposure machine, so as to achieve real-time response and regulation of changes in web tension and speed, and solve the problem of uneven exposure dose.

[0006] In a first aspect, in order to solve the above technical problems, the present invention provides a UV lighting control method for a roll-to-roll exposure machine, comprising: Obtain the real-time moving speed and tension change values ​​of the coil; When the tension change value is greater than a preset tension change threshold, the deformation trend of the coil surface is predicted based on a nonlinear regression algorithm combined with the real-time moving speed to obtain a deformation influence value; According to the deformation influence value, a PID control algorithm is used to adjust the irradiation angle and spot shape parameters of the UV light source to obtain a light intensity distribution value; According to the light intensity distribution value, a fuzzy control algorithm is used to calculate the output intensity requirements of each area of ​​the UV light source, and a speed adjustment method is used in combination with the real-time moving speed to adjust the speed, thereby obtaining optimized irradiation parameters; According to the optimized irradiation parameters, an overexposed or underexposed area determination operation is performed to obtain an overexposed area and an underexposed area; The illumination intensity and light intensity distribution of the UV light source are adjusted for the overexposed area and the underexposed area until the exposure quality of the area reaches a preset standard range.

[0007] Preferably, when the tension change value is greater than a preset tension change threshold, the deformation trend of the coil surface is predicted based on a nonlinear regression algorithm combined with the real-time moving speed to obtain a deformation influence value, including: When the tension change value is greater than a preset tension change threshold, deformation parameters are calculated based on a nonlinear regression algorithm to obtain deformation amount, deformation direction, deformation speed and deformation distribution characteristics; Based on the deformation amount, the deformation direction, the deformation speed and the deformation distribution characteristics combined with the real-time moving speed, the influence of the deformation on the UV light source irradiation trajectory is calculated by an interpolation algorithm to obtain an offset of the light source trajectory; The offset is input into a pre-configured tension change prediction model to predict the influence of the deformation amount and obtain a deformation influence value.

[0008] Preferably, the PID control algorithm is used to adjust the irradiation angle and spot shape parameters of the UV light source according to the deformation influence value to obtain the light intensity distribution value, including: According to the deformation influence value, the deformation distribution of the coil is analyzed by using a finite element method to obtain a deformation distribution parameter; Inputting the deformation distribution parameter into a PID controller controlled by a PID algorithm to obtain a control output value for adjusting the UV light source; According to the control output value, adjusting the irradiation angle and spot shape parameters of the UV light source to obtain an adjusted light intensity value; Calculate the geometric value of the light spot shape based on the light spot geometry optimization algorithm combined with the light intensity value; When the geometric value is synchronized with the preset deformation distribution of the coil, the light intensity value corresponding to the geometric value is determined as the light intensity distribution value.

[0009] Preferably, the output intensity requirement of each area of ​​the UV light source is calculated using a fuzzy control algorithm according to the light intensity distribution value, and a speed adjustment method is used in combination with the real-time moving speed to adjust the speed, thereby obtaining optimized irradiation parameters, including: The output intensity requirement of each area of ​​the UV light source is calculated by using a fuzzy control algorithm combined with a preset fuzzy control rule library and the light intensity distribution value; Calculate the power allocation scheme of the UV light source based on a dynamic optimization algorithm combined with the output intensity requirement; Dynamically adjusting the light source irradiation parameters of the UV light source according to the power allocation scheme; Applying the light source irradiation parameters to a controller of the UV light source to continuously adjust the exposure dose of the web area until a preset exposure threshold is reached; When the exposure dose of the web area reaches a preset exposure threshold, the light source irradiation parameters corresponding to the exposure dose are determined as optimized irradiation parameters.

[0010] Preferably, the speed adjustment method is combined with the real-time moving speed to adjust the speed, so as to obtain the optimized irradiation parameters, and further includes: Calculate the speed change rate according to the real-time moving speed; When the speed change rate is greater than a preset speed threshold, a quadratic fitting algorithm is used to dynamically adjust the response time parameter, and a power allocation scheme of the UV light source is calculated based on the response time parameter; Dynamically adjusting the light source irradiation parameters of the UV light source according to the power allocation scheme; Applying the light source irradiation parameters to a controller of the UV light source to continuously adjust the exposure dose of the web area until a preset exposure threshold is reached; When the exposure dose of the web area reaches a preset exposure threshold, the light source irradiation parameters corresponding to the exposure dose are determined as optimized irradiation parameters.

[0011] Preferably, performing an overexposed or underexposed area determination operation according to the optimized irradiation parameters to obtain an overexposed area and an underexposed area includes: Applying the optimized irradiation parameters to a controller of the UV light source to obtain cumulative exposure values ​​for each area on the surface of the web; When the cumulative exposure value is greater than a preset overexposure threshold, determining the area corresponding to the cumulative exposure value as an overexposure area; When the accumulated exposure value is less than a preset underexposure threshold, the area corresponding to the accumulated exposure value is determined as an underexposure area.

[0012] Preferably, the operation of adjusting the illumination intensity and the light intensity distribution of the UV light source for the overexposed area and the underexposed area until the exposure quality of the area reaches a preset standard range includes: Extracting the cumulative exposure values ​​of the overexposed area and the underexposed area to obtain an overexposed exposure value and an underexposed exposure value; Calculating the differences between the overexposure value and the underexposure value and a preset standard threshold value respectively to obtain an exposure difference; The light source mode is dynamically optimized based on the exposure difference, a light source control parameter is generated, and the control parameter is applied to the controller of the UV light source. When the exposure difference is less than a preset difference threshold, it is determined that the exposure quality of the area reaches a preset standard range.

[0013] In a second aspect, the present invention provides a UV lighting control system for a roll-to-roll exposure machine, comprising: Data acquisition module, used to obtain the real-time moving speed and tension change value of the coil; A deformation prediction module, for predicting the deformation trend of the coil surface based on a nonlinear regression algorithm combined with the real-time moving speed to obtain a deformation influence value when the tension change value is greater than a preset tension change threshold; A light intensity distribution module is used to adjust the irradiation angle and spot shape parameters of the UV light source according to the deformation influence value by using a PID control algorithm to obtain a light intensity distribution value; An optimization parameter module is used to calculate the output intensity requirements of each area of ​​the UV light source according to the light intensity distribution value using a fuzzy control algorithm, and to adjust the speed using a speed adjustment method combined with the real-time moving speed, so as to obtain optimized irradiation parameters; An area determination module is used to perform an overexposed or underexposed area determination operation according to the optimized illumination parameters to obtain an overexposed area and an underexposed area; The quality optimization module is used to adjust the light intensity and light intensity distribution of the UV light source in the overexposed area and the underexposed area until the regional exposure quality reaches a preset standard range.

[0014] In a third aspect, the present invention also provides an electronic device, comprising a processor, a memory, and a computer program stored in the memory and configured to be executed by the processor, wherein when the processor executes the computer program, the UV lighting control method for the roll-to-roll exposure machine described in any one of the above is implemented.

[0015] In a fourth aspect, the present invention further provides a computer-readable storage medium, the computer-readable storage medium comprising a stored computer program, wherein when the computer program is running, the device where the computer-readable storage medium is located is controlled to execute any one of the UV lighting control methods for the roll-to-roll exposure machine described above.

[0016] Compared with the prior art, the present invention has the following beneficial effects: (1) The present invention discloses a UV lighting control method for a roll-to-roll exposure machine. The method obtains the real-time moving speed and tension change data of the coil, and when the tension change exceeds a preset threshold, the deformation trend of the coil surface is predicted based on a nonlinear regression algorithm, thereby obtaining a deformation influence value. The method combines the real-time speed information with the deformation parameters, further calculates the light source trajectory offset by interpolation, and inputs it into the tension change prediction model to ensure that the deformation analysis results are more real-time and accurate. The solution can effectively improve the trajectory control accuracy during UV irradiation and enhance the system's ability to respond to dynamic changes in coil deformation.

[0017] (2) Based on the deformation influence value, the present invention adopts PID control algorithm to dynamically adjust the irradiation angle and spot shape parameters of the UV light source, combines the finite element method to analyze the deformation distribution, and uses the spot geometry optimization algorithm to match the deformation structure of the coil, so that the light intensity distribution is consistent with the actual deformation of the coil. At the same time, the output intensity requirements of each area of ​​the UV light source are calculated by the fuzzy control algorithm, and combined with the real-time monitoring results of the speed change rate, the dynamic optimization algorithm is used to achieve fine distribution and adjustment of the light source power. This solution improves the sensitivity and stability of the light source response, and can effectively alleviate the problem of uneven exposure under high-speed operation or emergency stop and start conditions.

[0018] (3) In addition, the present invention also uses the optimized light source irradiation parameters to determine whether there are over-exposed or under-exposed areas on the surface of the web, and makes targeted fine adjustments to the abnormal areas until the exposure dose of each area is stabilized within the preset standard range. The UV light source irradiation intensity and light intensity distribution are dynamically adjusted through feedback control, and the control model parameters are updated in real time to achieve continuous optimization and steady-state control of exposure quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 It is a schematic flow chart of a UV lighting control method of a roll-to-roll exposure machine provided by a first embodiment of the present invention; Figure 2 It is a schematic structural diagram of a UV lighting control system of a roll-to-roll exposure machine provided in a second embodiment of the present invention. DETAILED DESCRIPTION

[0020] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0021] Reference Figure 1 The first embodiment of the present invention provides a UV lighting control method for a roll-to-roll exposure machine, comprising the following steps: S11, obtaining the real-time moving speed and tension change value of the coil; S12, when the tension change value is greater than a preset tension change threshold, based on a nonlinear regression algorithm combined with the real-time moving speed, predicting the deformation trend of the coil surface to obtain a deformation influence value; S13, according to the deformation influence value, using a PID control algorithm to adjust the irradiation angle and spot shape parameters of the UV light source to obtain a light intensity distribution value; S14, according to the light intensity distribution value, using a fuzzy control algorithm to calculate the output intensity requirements of each area of ​​the UV light source, and using a speed adjustment method combined with the real-time moving speed to adjust the speed, so as to obtain optimized irradiation parameters; S15, performing an overexposed or underexposed area determination operation according to the optimized illumination parameters to obtain an overexposed area and an underexposed area; S16, adjusting the light intensity and light intensity distribution of the UV light source for the overexposed area and the underexposed area until the regional exposure quality reaches a preset standard range.

[0022] In step S11, it is necessary to obtain the real-time moving speed and tension change value of the coil, including: First, in order to obtain the movement state of the coil, the present invention arranges high-precision speed sensors and tension sensors on the coil conveying path. The movement speed is measured by a rotary encoder or a laser velocimeter. Among them, the rotary encoder is installed at the end of the traction roller shaft, and the linear speed can be calculated in real time through the roller rotation angle and the known roller diameter. For example, when the encoder outputs 1000 pulses per revolution, the roller diameter is 100mm, and it rotates 10 times per second, the coil movement speed is about 31.4 m / min. In order to improve the accuracy, it is recommended to use an encoder with a resolution of not less than 1000 PPR (pulse per revolution), and configure a high-speed sampling module with a sampling frequency of not less than 100Hz.

[0023] Specifically, the measurement of tension changes uses a cantilever beam tension sensor or a wheel tension detection unit, which is installed on both sides of the coil tension adjustment section. When the coil tension changes, the sensor will output a corresponding voltage or current signal, which is converted into a numerical tension value by the signal conditioning module. Taking a typical application as an example, the tension range of the coil is set to 400N to 600N during normal operation. When the tension suddenly rises to 650N, that is, exceeds the preset tension change threshold of ±50N, the system will trigger the subsequent deformation prediction module.

[0024] In a specific embodiment, real-time moving speed and tension data are uniformly fed into a central controller through an industrial data acquisition card (such as NIDAQ), and are collected and recorded at a fixed period (for example, every 20ms). The system uses a sliding window averaging method or a Kalman filter algorithm to perform real-time smoothing on the collected data to eliminate occasional interference caused by mechanical vibration, etc., to ensure data stability and accuracy of the prediction model input.

[0025] Specifically, the purpose of obtaining this data is not only to monitor the current state of the web, but also to determine whether it has entered a non-steady-state operating condition (such as acceleration, deceleration or emergency stop), and to trigger the deformation prediction and light source control modules accordingly. In high-speed roll-to-roll exposure equipment, slight changes in the web's motion state will directly affect the accuracy and uniformity of the exposure pattern, so this step plays an important role in the system.

[0026] For example, in a production line for flexible circuit board exposure, the coil runs at a speed of 25 m / min, and the real-time tension data collected by the system is displayed as 510N, which meets the tension setting range. At this time, the control system maintains the current UV light source irradiation parameters unchanged. When the speed is increased to 40 m / min, the system monitors that the tension rises to 665N, exceeding the set threshold of 50N, and immediately triggers the nonlinear regression prediction module (S12) to calculate the deformation of the coil to ensure the exposure quality.

[0027] It should be noted that, in order to ensure the universality of parameter settings, the present invention recommends setting the tension change threshold to ±10% to ±15% of the standard tension of the coil. The specific value depends on the elastic modulus and thickness of the coil material (such as PET, PI, copper foil, etc.). For PET coils with a standard tension of 500N, the threshold can be set to ±50N. The speed fluctuation range should be limited to ±10%. Exceeding this range will cause exposure smear or underexposure risks.

[0028] In step S12, when the tension change value is greater than a preset tension change threshold, the deformation trend of the coil surface is predicted based on a nonlinear regression algorithm combined with the real-time moving speed to obtain a deformation influence value, including: When the tension change value is greater than a preset tension change threshold, deformation parameters are calculated based on a nonlinear regression algorithm to obtain deformation amount, deformation direction, deformation speed and deformation distribution characteristics; Based on the deformation amount, the deformation direction, the deformation speed and the deformation distribution characteristics combined with the real-time moving speed, the influence of the deformation on the UV light source irradiation trajectory is calculated by an interpolation algorithm to obtain an offset of the light source trajectory; The offset is input into a pre-configured tension change prediction model to predict the influence of the deformation amount and obtain a deformation influence value.

[0029] In a specific embodiment, the coil is affected by complex tension changes during the traction operation, especially when running at high speed, starting, braking or when the coil diameter suddenly changes, the tension fluctuates significantly. If these tension changes exceed a certain threshold, it is very easy to cause deformation of the coil surface, thereby interfering with the irradiation path and spot shape of the UV light source, and ultimately causing exposure deviation or pattern distortion. Therefore, in order to achieve feedforward compensation for UV irradiation control, the present invention obtains the deformation trend and impact degree of the coil surface in advance through modeling and algorithm prediction at the first time when the tension abnormality occurs.

[0030] First, it depends on the setting of the tension change threshold. This threshold is determined according to the material characteristics of the coil, mainly considering the tolerance between its elastic limit and the stable tension in operation. For example, for PET material with a thickness of 25 microns, the tension fluctuation tolerance before permanent deformation occurs is ±10%. If the normal tension is set to 500N, the system can set the tension change threshold to ±50N. This value takes into account the robustness of short-term impacts and can effectively intercept working conditions that cause deformation. When the real-time tension change exceeds this threshold, the system considers that the coil has entered a non-steady state and the deformation prediction mechanism needs to be triggered immediately.

[0031] Specifically, after detecting the tension anomaly, the system calls the built-in nonlinear regression model to predict and analyze the deformation trend of the coil surface. The nonlinear regression model is used to fit the nonlinear response relationship between tension change and coil deformation. Because this relationship is affected by multiple factors such as material properties, tension change rate, temperature, coil diameter, etc., it is difficult to accurately reflect it through a linear model. The present invention preferably uses the support vector regression (SVR) model to construct the mapping relationship because of its strong generalization ability and stable performance for small sample data. During the design stage, the system will collect the surface deformation variables of the coil under different tension conditions through experiments, and establish a data set as a model training sample, where the input is tension value, speed, tension change rate, etc., and the output is deformation state.

[0032] After the model is trained, it can receive tension input in real time during operation and output four key deformation parameters, namely deformation variable, deformation direction, deformation speed and deformation distribution characteristics. Among them, the deformation variable represents the maximum offset of the coil in a unit area, which is used to measure the severity of deformation; the deformation direction is used to determine the main direction of deformation, which is obtained based on the angle between the extension direction of the deformation area and the running path, and is used to determine the direction of compensation offset; the deformation speed is the speed of change of the deformation variable per unit time, which reflects the dynamic characteristics of deformation and has a reference significance for controlling the response time; and the deformation distribution characteristics are based on the multi-point prediction of the deformation variable results to reconstruct the two-dimensional distribution map of the deformation variable on the surface of the coil, which can describe the range and shape of the deformation area by fitting Gaussian distribution or beta function. Through the above parameters, the system basically restores the deformation structure of the coil when it is affected by tension fluctuations.

[0033] It should be noted that the nonlinear regression model of the present invention is used to predict the deformation parameters of the coil surface, and its input includes real-time tension value, tension change rate, current coil moving speed, historical tension sequence, equipment operation status parameters (such as tension control mode, traction roller speed, etc.). The output is a set of characteristic parameters directly related to deformation, including deformation amount, deformation direction, deformation speed and deformation distribution characteristics. In order to build this model, the system needs to collect data during the debugging stage or the early trial operation stage, and obtain the corresponding sample data of tension and deformation amount by installing high-speed tension sensors, speed encoders and coil deformation collection devices (such as laser displacement sensors, optical thickness gauges, etc.) on the equipment.

[0034] It should be noted that in terms of model selection, support vector regression (SVR) or multi-layer feedforward neural network (such as a three-layer BP neural network) is preferred. The SVR model has good nonlinear fitting ability and can handle small sample high-dimensional input. It is suitable for modeling complex nonlinear relationships between tension and deformation variables; while neural networks can show stronger expression capabilities in scenarios with sufficient samples and are suitable for actual environments with multi-factor coupling. The model is trained using supervised learning, with tension and velocity data as input and deformation measured data as output labels. During the training process, a loss function (such as mean absolute error or mean square error) is used to evaluate the deviation between the model output and the actual value, and the model parameters are iteratively updated through optimization algorithms (such as gradient descent or Adam).

[0035] It should be noted that the model training process needs to be fully iterated and cross-validated. When the model error on the training set tends to be stable, and the error on the validation set also reaches convergence, and there is no obvious overfitting or underfitting phenomenon, the training can be considered complete. In practice, if the error change for 10 consecutive rounds of iterations does not exceed the preset threshold (such as 0.5%), or the error of the validation set is stable within the target error tolerance (such as the mean absolute error is less than 0.2mm), the training is considered complete.

[0036] In a specific embodiment, after obtaining the deformation parameters, the system links them with the current moving speed of the coil to further evaluate the degree of interference of the deformation on the irradiation path of the UV light source. The coil moving speed is a key variable affecting the synchronization of exposure, and its relative value to the deformation speed determines the follow-up ability of the UV irradiation spot. The present invention introduces an interpolation algorithm to estimate the trajectory disturbance at this stage. Specifically, the system analyzes the relative displacement changes of the deformation points on the surface of the coil in the motion path in multiple consecutive time segments, and combines the real-time speed to judge the time and position of the deformed area entering the exposure area in the future, and finally obtains the expected offset of the irradiation trajectory. The interpolation process does not involve physical deformation modeling, but constructs a displacement estimation curve through historical samples and current predicted values. For example, cubic spline interpolation is used to reconstruct the offset trajectory of the deformation position over time, ensuring the continuity and smoothness of the compensation trajectory, and avoiding sudden jumps or defocusing of the UV light source during the compensation process.

[0037] Specifically, although the trajectory offset calculated above can guide the light source to adjust its position, it is not enough to quantify the comprehensive impact of deformation on exposure quality. To this end, the present invention introduces a deformation impact prediction model. The model uses a regression decision method to establish the association between tension change, trajectory offset, deformation parameters and exposure quality defects, and outputs a unified quantitative index "deformation impact value". This value is set as a floating point number between 0% and 100% to represent the impact level of deformation on exposure deviation risk under the current working conditions. The model can be constructed using random forest regression or lightweight neural network, and the training data comes from known exposure defect samples and tension anomaly data in the actual production line. In actual operation, the system inputs the currently calculated trajectory offset, deformation distribution characteristics, deformation speed, tension change rate, etc. into the model to obtain a predicted deformation impact value. If the value exceeds the set threshold (for example, 70%), the system will enter the UV light source compensation control process to quickly adjust the irradiation angle and spot shape.

[0038] For example, in an actual operation, the coil speed is 28 m / min, and the tension jumps from 490N to 550N in 5 seconds, exceeding the set threshold of 50N, and the system triggers the prediction module. The nonlinear regression model predicts concentrated deformation in the middle of the coil based on the historical tension-deformation data, with a deformation amount of 1.9mm, a deformation speed of 0.1mm / s, and a direction close to the vertical axis. Combined with the current speed, the interpolation algorithm estimates that the light source trajectory will shift to the right by about 1.2mm. After the prediction model is input, the system concludes that the deformation impact value is 74%, which is judged to be medium-to-high risk, and automatically calls the subsequent control module to adjust the light source irradiation path.

[0039] It should be noted that the deformation impact prediction model preset in the present invention is mainly used to map intermediate parameters such as trajectory offset, deformation distribution, and speed change into the final "deformation impact value", that is, a comprehensive indicator that can represent the exposure risk level in the current state. The establishment of this model requires the introduction of annotated data related to product quality, including: exposure defect areas (such as pattern dislocation, smear, blur, etc.) identified by the system under historical working conditions, and associated tension, speed, deformation and other parameter data. The model learns the intrinsic relationship between these variables and exposure results through training.

[0040] Specifically, in terms of modeling, it is recommended to use a random forest regression model or a lightweight neural network because it has strong feature selection and fault tolerance capabilities and is suitable for data with some missing or errors in industrial scenarios. Model training relies on large-scale quality labeled samples. The training goal is to enable the model to output a stable deformation impact value score (such as 75%) after receiving new prediction inputs (such as an offset of 1.5mm, a deformation distribution feature of eccentric type, a deformation speed of 0.12mm / s, etc.) for the control system to respond in a graded manner. The training termination judgment criteria for this model are similar to those mentioned above, and also need to be combined with the convergence of the training error and the verification error. When the model's prediction error for several typical samples in the past is stably maintained within 5%, and the actual control decision and exposure result match rate are higher than 95%, the model training can be considered to have reached the engineering availability level. After the training is completed, the model parameters will be solidified and uploaded to the control system for online reasoning in the subsequent operation stage.

[0041] In step S13, it is necessary to use a PID control algorithm to adjust the irradiation angle and spot shape parameters of the UV light source according to the deformation influence value to obtain a light intensity distribution value, including: According to the deformation influence value, the deformation distribution of the coil is analyzed by using a finite element method to obtain a deformation distribution parameter; Inputting the deformation distribution parameter into a PID controller controlled by a PID algorithm to obtain a control output value for adjusting the UV light source; According to the control output value, adjusting the irradiation angle and spot shape parameters of the UV light source to obtain an adjusted light intensity value; Calculate the geometric value of the light spot shape based on the light spot geometry optimization algorithm combined with the light intensity value; When the geometric value is synchronized with the preset deformation distribution of the coil, the light intensity value corresponding to the geometric value is determined as the light intensity distribution value.

[0042] First, the system determines the degree of interference caused by the current web surface deformation on the exposure quality based on the deformation impact value obtained in step S12. If the value exceeds the system preset risk threshold (for example, set to 70%), it means that the deformation has caused a significant offset or energy imbalance in the UV light source irradiation area. The system will immediately activate the finite element analysis module to perform spatial structural modeling on the current web state to predict the detailed distribution of its surface deformation.

[0043] In a specific embodiment, finite element analysis (FEM) is a commonly used engineering modeling method, which indirectly reflects the overall stress state of the entire structure by dividing a continuous structure (such as a coil) into a limited number of small areas (i.e., units) and solving the mechanical response on these small areas. In the present invention, FEM is used to establish a two-dimensional stress-strain field model, that is, a region of interest (e.g., a rectangular region of 100 mm in length and 50 mm in width) is selected on the surface of the coil as a calculation object, and the distribution of deformation variables in the region is simulated and derived.

[0044] Specifically, the system first constructs boundary conditions and initial loads based on the tension change values ​​collected by the sensor, the coil movement speed, deformation speed and direction, etc. The tension change is defined as the boundary stress applied to the longitudinal edge of the model. The deformation direction forms an angle with the coil running direction, which is used to define the main deformation direction. The movement speed determines the load action time and dynamic inertia boundary conditions. If the coil is running at high speed (for example, greater than 25 m / min), the system will consider the dynamic load effect and introduce speed-related inertia terms.

[0045] In a specific embodiment, the system meshes the area, preferably using quadrilateral units, each unit size is 1mm × 1mm, and 5000 discrete units can be formed to achieve local capture accuracy of deformation. The denser the grid, the higher the simulation accuracy, but the computing resources also increase accordingly. The present invention adopts a weighted adaptive grid strategy in industrial implementation, that is, the grid is automatically refined in the area where the predicted deformation is concentrated, and the coarser unit is maintained in the edge stable area to balance the computing efficiency and accuracy. During the solution process, the system obtains the deformation of each point in the overall area by solving the stress-strain response of each unit after loading tension. The solution results include the following two types of core outputs: Deformation Matrix: records the deformation value (in mm) of each unit in the two-dimensional area of ​​the coil surface to form a complete numerical distribution map. The matrix reflects the intensity change of the deformation in space, which can be visualized by heat map for subsequent shape spot matching. Deformation Direction Field: records the direction angle (in °) of the main deformation of each unit to form a vector field. This information can be used to determine whether the irradiation direction of the light source needs to be deflected, thereby improving the consistency of energy projection. For example, in an actual calculation, after the tension in the right area of ​​the coil increased from 480N to 545N, the finite element analysis showed that there was a deformation band of about 15mm wide and 60mm long in the right area, with a maximum deformation of 2.1mm and a direction angle of about 80° (i.e., close to perpendicular to the direction of coil movement). This long strip of deformation will cause the UV light source's spot in this area to deviate seriously from the center. If no compensation is made, it is very easy to cause insufficient exposure dose in this area.

[0046] In a specific embodiment, the system encodes the deformation characteristics of the region into "deformation distribution parameters" based on the above matrix and direction field, including: maximum value, average value, area, main direction, boundary contour, deformation gradient, etc. These parameters are then input into the PID controller to drive the dynamic adjustment of the light source irradiation angle and spot shape to ensure that the UV spot can achieve accurate coverage and light energy distribution compensation in the deformed area.

[0047] In a specific embodiment, the deformation distribution parameters obtained by the above analysis are used as feedback input, and the system is connected to a controller based on the PID algorithm for adjustment calculation. The PID controller is a commonly used closed-loop control algorithm. Its core idea is to calculate the control amount according to the "current error (P)", "error accumulation (I)" and "error change rate (D)", and adjust the output of the target execution system. In the present invention, the system sets the spot shape and irradiation angle under the ideal state as the target value, compares the actual deformation distribution with the target state, and calculates the "deviation amount" of the current exposure path. For example, there is obvious stretching in a certain area of ​​the coil, resulting in incomplete coverage of the original spot. The system compares the deformation amount with the preset spot profile and finds that there is an angle deviation and area mismatch. The PID controller combines the proportional gain (Kp), integral gain (Ki) and differential gain (Kd) parameters to calculate the response amplitude, cumulative deviation compensation and pre-judgment adjustment items respectively, and generates a control output value, which represents the required adjustment angle change amplitude (unit angle) and spot scaling factor (geometric parameter), that is, how much the UV light source needs to "rotate" and "compress / stretch" to adapt to the current deformation state.

[0048] In a specific embodiment, the PID parameters can be set by simulation debugging or automatic tuning. For example, the Kp, Ki, and Kd parameters are tuned in a step response manner before the equipment is put online to ensure that the control system has the characteristics of fast response, no large overshoot, and minimum residual under various tension fluctuations.

[0049] In a specific embodiment, after the control output value is determined, the system sends it to the execution unit of the UV light source. The light source angle can be adjusted by an electric rotation module or a micro servo mechanism, and its response speed is controlled within 0.1 seconds, which can meet the requirements of high-speed exposure synchronization. At the same time, the spot shape parameters can be adjusted by adjusting the variable lens group, deformable reflector or CNC grating to achieve zoom and shape adjustment, forming a variety of geometric contours from circular to elliptical, fan-shaped, etc. For example, if the PID output indicates that the irradiation angle needs to be shifted to the right by 3 degrees and the spot needs to be stretched horizontally by 20%, the system drives the servo motor to rotate 3 degrees through the controller, and at the same time controls the spot shaping module to adjust the deformation of the major axis of the ellipse to ensure that the energy coverage in the deformation area is complete and the angle of incidence is correct.

[0050] In a specific embodiment, after the system completes the dynamic adjustment of the UV light source irradiation angle and the spot shape, in order to ensure that the adjustment result accurately matches the actual deformation state of the coil surface, the system confirms the current spot state in real time through a feedback mechanism. This feedback process can be achieved in two ways: one is to use an industrial camera and an image acquisition device installed on the light source output channel or above the coil surface to collect the irradiation image in real time, and combine the image processing algorithm (such as edge recognition, center positioning, contour extraction, etc.) to obtain the actual contour of the current spot; the second is to model the physical relationship between the known light source structure, adjustment parameters and optical path in the irradiation system, and use the calculation model to derive the theoretical geometric shape of the current spot. Regardless of the method, the system models the current spot shape as a two-dimensional elliptical geometric figure, and extracts the following parameters as core indicators: major axis length, minor axis length, elliptical flattening (i.e., major-minor axis ratio), the position of the center of gravity of the spot in the coordinate system, and edge smoothness. Among them, edge smoothness is used to determine whether there is an obvious discontinuous transition or energy mutation area in the spot. If there is a burr-like or irregular contour, further optical focusing or contour calibration is required.

[0051] Specifically, after the system obtains the current spot geometry parameters, it needs to align and compare them spatially with the target deformation area obtained by the finite element method. During the alignment analysis, the system evaluates its "spatial coverage matching degree" based on the coordinate error between the center point of the spot and the center of gravity of the deformation area, as well as the degree of geometric overlap between the elliptical outline and the deformation boundary. The matching degree is obtained by counting the overlapping area ratio of the spot area and the target deformation area. If the overlap rate reaches or exceeds 95%, it is considered that the spatial coverage has met the compensation requirements. At the same time, the system also needs to verify whether the light intensity energy distribution of the current spot is uniform in space. To this end, the system counts the light intensity of multiple sampling points in the spot area, calculates the difference ratio between the central light intensity and the edge light intensity, and sets it to an allowable fluctuation range of ±10%. If the test results show that the energy distribution is within this range, it means that the system maintains a smooth transition of the irradiation energy while adjusting the shape and angle of the spot, and there is no local overexposure or energy attenuation.

[0052] Specifically, if both of the above conditions are met, that is, (1) the spatial coverage matching degree is ≥ 95%, and (2) the light intensity energy uniformity deviation is ≤ ±10%, the system confirms that the current geometric light spot and the target deformation area have achieved effective synchronous compensation. At this time, the system solidifies the current light spot shape parameters and the light intensity values ​​corresponding to each area, and outputs them to the control core as the final "light intensity distribution value" for the next stage of fuzzy control algorithm to further optimize power allocation. For example, in actual production, when a coil runs to the 37th meter position, the system identifies that the lower area (approximately located in the lower 1 / 3 area in the width direction) has undergone tensile deformation in the transverse direction. FEM analysis shows that the maximum deformation of this area is 2.0 mm, the coverage range is approximately 20 mm × 80 mm, and the direction deviates from the longitudinal direction by about 85°. The PID controller outputs an adjustment command based on this: deflect the UV light source irradiation angle to the right by 5°, and expand the light spot horizontal axis by 30% to form an elliptical structure covering the deformation area. After the adjustment is completed, the image system transmits the current spot image back. The system analyzes that the overlap rate between its contour and deformation area reaches 98%, and the difference between the center and edge light intensity is 7.2%. Both indicators meet the preset synchronization judgment standards, and the system confirms that the adjustment is effective. The current light intensity distribution value is adopted as the final compensation solution and pushed to the fuzzy control algorithm to perform power optimization control.

[0053] In step S14, it is necessary to calculate the output intensity requirements of each area of ​​the UV light source according to the light intensity distribution value using a fuzzy control algorithm, and use a speed adjustment method combined with the real-time moving speed to adjust the speed, thereby obtaining optimized irradiation parameters, including: The output intensity requirement of each area of ​​the UV light source is calculated by using a fuzzy control algorithm combined with a preset fuzzy control rule library and the light intensity distribution value; Calculate the power allocation scheme of the UV light source based on a dynamic optimization algorithm combined with the output intensity requirement; Dynamically adjusting the light source irradiation parameters of the UV light source according to the power allocation scheme; Applying the light source irradiation parameters to a controller of the UV light source to continuously adjust the exposure dose of the web area until a preset exposure threshold is reached; When the exposure dose of the web area reaches a preset exposure threshold, the light source irradiation parameters corresponding to the exposure dose are determined as optimized irradiation parameters.

[0054] First, the system performs structured processing on the light intensity distribution value output in the previous step, and maps it into multiple two-dimensional irradiation areas corresponding to the spatial layout of the UV light source array module. Each area has two basic parameters: one is the "current actual light intensity value", which is obtained by the light source power control feedback or the light intensity sensor in real time; the other is the "target light intensity reference value", which is calculated by the aforementioned deformation prediction and PID compensation module, representing the energy distribution value that the area should obtain under the theoretical optimal state. By subtracting the current value from the target value, the system obtains the "light intensity deviation"; and by subtracting the deviation value from the deviation of the previous time period, the "light intensity deviation change rate" is further obtained.

[0055] Specifically, the above two values ​​together constitute the input variables of the fuzzy controller. In order to facilitate fuzzy processing, the present invention divides the value range of each input variable into five levels, namely: negative large, negative medium, zero, positive medium, and positive large. For example, the light intensity deviation below -15% is judged as "negative large", between -15% and -5% is "negative medium", within ±5% is "zero", and so on. These level divisions are modeled through triangular or trapezoidal membership functions, so that the input variables can have a certain "membership degree" in multiple levels at the same time.

[0056] Specifically, the system determines the corresponding output adjustment strategy by searching the preset fuzzy rule base according to the fuzzy level of the input variable. Each rule describes the corresponding output level under a set of input conditions, for example: Rule 1: IF the deviation is "positive large" AND the change rate is "positive medium", THEN the output is "enhanced large"; Rule 2: IF the deviation is "zero" AND the change rate is "zero", THEN the output is "no change"; Rule 3: IF the deviation is "negative medium" AND the change rate is "negative large", THEN the output is "weakened medium". These rule bases can be set by engineers based on experience during the system design phase, or they can be optimized through online learning in a data-driven manner during the operation of the equipment. Every time the system receives a new deviation value, it activates all matching rules through the fuzzy reasoning mechanism and calculates the comprehensive membership of each output level. After fuzzy reasoning, the system needs to convert the output level into a specific executable value. To this end, the system uses defuzzification processing methods (such as the centroid method, the maximum membership method, etc.) to convert the fuzzy output set into a clear digital quantity, that is, the intensity adjustment value required for the area, expressed as a percentage. For example, if the result after deblurring is "an increase of 8%", the system will increase the current output intensity of the UV light source in the area accordingly.

[0057] In order to specifically illustrate the control process, an example in practical application is given below: In a certain coil operation condition, the system detects that the current light intensity in the middle area is 850 mW / cm², and according to the deformation compensation calculation, the target irradiation intensity in this area is 950 mW / cm², so the light intensity deviation is +100 mW / cm², which is about +11.7%. The deviation of this area in the previous cycle was +60 mW / cm², so the rate of change was +40 mW / cm², about +4.7%. The system attributes the deviation to "exactly in the middle" and the rate of change to "exactly in the middle". According to the rule base matching, the output level is obtained as "enhanced in the middle", and the final adjustment instruction "enhanced by 10%" is obtained after defuzzification. The controller then sends the instruction to the light source control module, and the UV channel current corresponding to this area is increased from the original 3.0A to 3.3A, realizing accurate compensation of the irradiation intensity. In addition, in order to enhance the adaptability of the system, the present invention supports an adaptive update mechanism for fuzzy rules and membership functions. During long-term operation, the system can record the exposure results after each fuzzy control output, compare and analyze them with the actual measured dose deviation, and identify whether there is a rule deviation or unreasonable membership division. Once a problem is identified, the system can automatically adjust some rule weights or input division points through gradient adjustment or based on reinforcement learning algorithms to improve the accuracy and robustness of the controller during long-term operation.

[0058] In a specific implementation, since the output of the fuzzy controller is independently calculated based on the local light intensity deviation, multiple regions simultaneously request to increase power or reduce output, and the total power capacity of the system, the physical limitations of the light source module, the thermal stability, and the exposure tolerance of the material cannot be ignored, it is necessary to introduce a global power coordination mechanism after the fuzzy control to prevent the overall system from being unstable due to overly aggressive local control. Therefore, the present invention introduces a global power optimization method based on a dynamic optimization algorithm, which maximizes the use of system resources and ensures the rationality of energy distribution and exposure consistency while meeting the exposure compensation requirements of all regions.

[0059] Specifically, the optimization mechanism uses the output power of each UV light source array module as the optimization variable to construct an optimization problem model containing multiple objectives and constraints. The optimization objectives include but are not limited to: minimizing the power consumption of the entire machine to improve energy efficiency and extend the life of the light source; maximizing exposure uniformity to ensure that the exposure dose difference on the surface of the web is minimized; minimizing the light source response time to improve the system's adaptability to high-speed web operation; controlling the output peak of a single module to avoid problems such as heat accumulation or light source overload. The constraints include the maximum output power limit of a single module, the temperature operating limit of the UV light source, and the maximum allowable dose of UV energy on the surface of the web material. By setting these constraints, the system can ensure operational safety and reliability while achieving control goals.

[0060] In a specific implementation, the system regards the expected intensity adjustment value of each area output by the fuzzy controller as a "reference power target", forming a high-dimensional vector as the guiding direction of the optimization problem. Subsequently, according to the current state of the system, historical operating data and external input variables (such as ambient temperature, current coil material type, etc.), the system runs a dynamic optimization algorithm in the set variable space to obtain a set of optimal power allocation schemes. The preferred optimization algorithms of the present invention include particle swarm optimization algorithm (PSO), genetic algorithm (GA) or L-BFGS algorithm based on quasi-Newton method. The above algorithms all have high-dimensional search capabilities and good convergence characteristics, and can quickly obtain approximate optimal solutions that meet multiple constraints under complex objective functions.

[0061] For example, taking the particle swarm optimization algorithm as an example, each "particle" represents a complete set of power allocation schemes. By simulating the movement and experience learning process of individuals in the group, the particles continuously search for the optimal position in the solution space; the system calculates the objective function value in each round of iteration, including the total power consumption function, the regional exposure uniformity evaluation function and the power balance function, and evaluates the current scheme. If the objective value is better than the previous round, it is retained as the current optimal solution, otherwise the particle swarm parameters are adjusted to continue searching. This process continues until the objective function changes below the set threshold (such as 0.5%) or the maximum number of iterations (such as 100 times) is reached. The optimization result is a set of power allocation ratios covering all UV light source modules. For example, under a certain working condition, the system recognizes that the central area needs to increase the irradiation intensity by 10%, while the left and right areas are reduced by 5% respectively. However, at this time, the central module is close to the maximum power limit, and continued enhancement will cause overload. During the execution of the optimization algorithm, it was found that keeping the power in the middle unchanged and moderately increasing the power in the edge area by 3% can maintain the overall exposure uniformity within ±5%, while reducing the total power consumption of the system by 2% compared with the initial solution. The alternative allocation solution was finally determined to be the current optimal solution. This "compensatory adjustment" can effectively avoid the problem of failing to achieve the fuzzy control output target due to local power limitations.

[0062] Specifically, after the optimization plan is generated, the system will send the corresponding power setting parameters to each UV light source control module one by one, and complete the dynamic switching of parameters in combination with the specific hardware execution structure (such as constant current source control, PWM dimming, voltage and current integrated regulation, etc.). The whole process can be completed within 100ms, ensuring that the system operates at a level close to real-time response. At the same time, the power allocation plan will be saved as a power configuration model under the current working conditions, so that it can be directly called under similar working conditions in the future, improving the system operation efficiency and response stability.

[0063] In a specific implementation, after the optimization is completed, the system converts the global power allocation scheme into a specific control instruction set that can be recognized and executed by the light source control system, and sends the power output value to each UV light source module by region. The control instructions include but are not limited to: power output setting, current setting value, voltage control signal, PWM (pulse width modulation) duty cycle parameters, analog dimming voltage value, etc. The system adopts a centralized or distributed control architecture to ensure that each light source area module can quickly respond to the control signal based on its own operating status to achieve refined power regulation.

[0064] Specifically, for different types of UV light sources, the system supports a variety of control interfaces and dimming mechanisms. For example, for mainstream LED array UV light sources, the system controls the operating current of each LED channel through a precision current driver to achieve direct intensity control. This method has fast response and high linearity, and is suitable for high-precision exposure processes that have strict control requirements on energy density. In order to protect the long-term stability of the LED, the system also sets a limit value for the output current of each channel, and dynamically adjusts the current upper limit based on the historical operating time, taking into account both output intensity and life management.

[0065] Specifically, for LED systems that have both analog dimming and PWM digital dimming functions, the system controller will adopt a dual-channel dimming strategy based on power requirements and response timing: analog voltage signals are used for coarse adjustment to achieve rapid and substantial power output changes; PWM signals are used for fine adjustment to achieve fine control through duty cycle fine-tuning. This keeps the light spot transition smooth during the switching process and avoids sudden local exposure changes caused by too fast changes.

[0066] Specifically, for traditional mercury lamps or laser UV light sources, the present invention controls them through the driving voltage, dimming current or Q switch frequency of the high-voltage ignition controller or laser power module. These light sources have a slightly slower response time, but the system can adjust the control instructions in advance through a delay prediction strategy to improve the overall synchronization and control accuracy of the system.

[0067] Specifically, the control instructions are sent from the main control system to the drive control unit of each light source module through a high-speed communication bus (such as CAN, Modbus, RS485, EtherCAT, etc.). Thanks to the high real-time performance of modern industrial communication protocols, the entire control instruction issuance and execution cycle is controlled between 5 and 50 milliseconds, and the shortest response can reach 1 to 2 milliseconds, which is suitable for dynamic compensation control in a high-speed coil movement environment. After the instruction is executed, each UV module enters the adjustment state according to the new power setting, and the system maintains the irradiation configuration and continuously monitors whether the output intensity of each area reaches the optimization target. The present invention preferably sets a light intensity feedback sensor (such as a UV detection diode array or a fluorescent response material) under each light source array or on the back of the coil, and detects in real time whether the irradiation energy meets the set dose requirements by sampling and reading back.

[0068] It should be noted that if the system detects that the light intensity deviation of individual areas exceeds the set threshold (such as ±8%), the local fine-tuning compensation mechanism is immediately triggered, and the fuzzy controller is called again to make incremental adjustments to the area and update the power output value. This feedback closed-loop control mechanism allows the system to stably maintain the balance and consistency of exposure doses in each area even under the influence of complex factors such as equipment aging, ambient temperature fluctuations, or changes in light source characteristics. For example, in an actual operation, the power of the central area output by the optimization module is set to 1200mW / cm², and the system sets the duty cycle to 80% through the PWM control signal, corresponding to a current output of 3.2A. After the control command is issued, the feedback sensor detects that the UV light intensity in this area is only 1150mW / cm², which is 4.2% different from the target. The control system automatically increases the PWM duty cycle to 84%, and the current is increased to 3.35A, completing the closed-loop fine-tuning, and finally stabilizes the light intensity in the range of 1178~1215mW / cm² to achieve the control target.

[0069] In a specific implementation, in order to verify whether the irradiation parameters after the UV light source is adjusted have achieved the desired exposure control effect, the present invention introduces an exposure dose detection module in the UV lighting system, which is used to monitor and dynamically feedback the cumulative exposure (in mJ / cm²) of each area on the surface of the web in real time. The module calculates the cumulative amount of UV energy per unit area to determine whether the current exposure dose meets the preset processing requirements, thereby verifying and correcting the light source power adjustment strategy.

[0070] Specifically, in terms of hardware implementation, the exposure dose detection module can adopt a variety of structural forms. Preferably, a number of UV photodetector arrays are arranged below the UV irradiation system or on the back of the coil, and their response bands match the main emission bands of the light source (such as 365nm, 385nm, 405nm, etc.), and the sampling values ​​are calculated by time accumulation through an integration circuit or a digital signal processing chip; in some special materials or environments, the system can also use a photosensitive coating comparator to calculate the corresponding UV dose by detecting the degree of color change of the photosensitive layer, which is suitable for low-cost continuous monitoring; for high-precision control requirements, the present invention also supports the use of an online coil fluorescence response recognition system, which calculates the local area UV energy absorption value through laser scanning irradiation and fluorescence reflection intensity collection, and realizes high-resolution two-dimensional dose monitoring.

[0071] Specifically, during operation, the system integrates and samples the exposure dose within each control cycle, and performs time-weighted accumulation in combination with the system control cycle (such as every 100ms) to obtain the current cumulative exposure of each area. Subsequently, this value will be compared with the pre-set target dose range. For example, the cumulative exposure required by a certain photosensitive material is 400±20 mJ / cm², that is, the system takes 380 to 420 mJ / cm² as the acceptable range. If the current exposure of a certain area is still lower than the lower limit (such as only 365 mJ / cm²), the system will immediately feedback the dose deviation value of the area (here -35 mJ / cm²) to the fuzzy controller and power optimization module, triggering a new round of local intensity adjustment instructions, and the system will enter a closed-loop correction process. In order to take into account both the control effect and the system stability, the present invention sets the maximum feedback round to three rounds, that is, if a certain area still does not enter the target range after three adjustments, the system will trigger an abnormal alarm mechanism to prompt the operator to check the light source status, photosensitive material batch or equipment operating environment. Such anomalies are common in situations such as aging of light sources, lens contamination, and photosensitivity failure of materials. Alarms can be issued through the HMI interface, sound and light indicators, or MES system docking, and logs are recorded for traceability. If the exposure dose in all areas is within the set target range, the system considers that the current light source power configuration and dimming strategy are valid under this working condition, and solidifies the current parameter combination (including power distribution, irradiation angle, response time, PWM duty cycle, etc.) into an "optimized irradiation parameter model". The model can be stored together with the corresponding coil specifications, operating speed, material type and other associated tags. The system will directly call the model when encountering similar working conditions in the future, skipping the fuzzy-optimization-feedback loop, greatly improving the operating efficiency and system response speed. For example, on a printed electronics production line, the coil speed is 30 m / min, and the system sets the exposure dose to 400 mJ / cm². During continuous operation, the system detected that the cumulative exposure in a certain area was only 375 mJ / cm², and the system triggered the first fine-tuning, increasing the output power of the area by 6%. After another detection, it was still 386 mJ / cm², and the system triggered the second round of fine-tuning and further increased the PWM duty cycle by 5%. Finally, after the third round of adjustment, the exposure reached 398 mJ / cm². The system confirmed that it was qualified and stored the configuration model in the database with the label "High-speed and low-tension working conditions-blue film-30m / min". If a similar state is entered again in subsequent production, the system can directly call out the model to achieve disturbance-free switching and fast and stable control.

[0072] In a specific implementation, after calculating the output intensity requirements of each area of ​​the UV light source using a fuzzy control algorithm according to the light intensity distribution value to obtain optimized irradiation parameters, the method further includes: Calculate the speed change rate according to the real-time moving speed; When the speed change rate is greater than a preset speed threshold, a quadratic fitting algorithm is used to dynamically adjust the response time parameter, and a power allocation scheme of the UV light source is calculated based on the response time parameter; Dynamically adjusting the light source irradiation parameters of the UV light source according to the power allocation scheme; Applying the light source irradiation parameters to a controller of the UV light source to continuously adjust the exposure dose of the web area until a preset exposure threshold is reached; When the exposure dose of the web area reaches a preset exposure threshold, the light source irradiation parameters corresponding to the exposure dose are determined as optimized irradiation parameters.

[0073] In a specific embodiment, the system will perform preliminary exposure optimization based on the light intensity distribution value collected in real time. On this basis, the system uses a fuzzy control algorithm to calculate the output intensity requirements of each UV light source area to obtain optimized irradiation parameters. At this time, the system's goal is to ensure uniform distribution of exposure dose on the surface of the web and minimize local overexposure or underexposure by dynamically adjusting the irradiation angle, spot shape and light source power distribution of the UV light source according to the light intensity distribution.

[0074] Specifically, in some high-speed and sudden operation scenarios, static optimization that only relies on light intensity distribution cannot meet process requirements. At this time, the system will further calculate the speed change rate based on the real-time moving speed of the coil. The speed change rate refers to the amplitude of the speed change of the coil per unit time, reflecting the sudden change of the coil's motion state. By calculating the acceleration or deceleration of the coil, the system can determine whether it is currently in a non-steady-state condition such as an emergency stop, emergency start, or high-speed sudden change.

[0075] Specifically, when the system detects that the speed change rate is greater than the preset threshold, it means that the web is experiencing high-speed changes or emergencies, resulting in instability in exposure dose and exposure time, which may cause uneven exposure, pattern smearing or other quality problems. In this case, the system starts the dynamic optimization mechanism and uses a quadratic fitting algorithm to fit and analyze the speed-time series of the web. The algorithm predicts the speed change trend in the next few seconds based on historical data and dynamically adjusts the response time parameters of the UV light source. By predicting the future acceleration or deceleration trend of the web, the system can make a prejudgment of the light source power adjustment in advance, ensuring that when the web speed changes drastically, the energy output of the light source can be adjusted synchronously to avoid exposure imbalance caused by delayed light source response.

[0076] It should be noted that the response time parameters include a variety of control factors, such as power startup delay, PWM regulation response lag, light source drive current change delay, etc. These parameters will be dynamically optimized according to the speed change trend predicted by the system. For example, when it is predicted that the web will accelerate in the next few seconds, the system will shorten the response time of the light source module in advance to reduce the underexposure problem caused by too short exposure time during the acceleration process; if it is predicted that the web will enter the deceleration stage, the system can appropriately delay the response time to avoid overexposure of local areas caused by too fast power adjustment.

[0077] In a specific embodiment, based on the adjusted response time parameters, the system recalculates and generates a new power allocation scheme. This scheme further optimizes the power output of each UV light source module to ensure that the light source can accurately provide the required exposure energy during the web speed change. For example, when the web accelerates, the system will increase the power output of the light source and reduce the adjustment delay of the light source; when the web decelerates, the system will reduce the light source power and extend the response time to avoid overexposure.

[0078] Specifically, once the system generates a new power allocation scheme, the adjusted light source irradiation parameters will be immediately applied to the UV light source controller. These control instructions include adjusting the current, changing the PWM duty cycle, adjusting the spot shape or offset angle, etc., to ensure that the exposure dose reaches the preset standard range. In order to verify the adjustment effect, the system will continuously monitor the cumulative exposure dose of each area of ​​the web and compare it with the preset exposure target in real time.

[0079] Specifically, when the exposure dose of the web area successfully reaches the preset exposure threshold, the system will confirm that the adjusted light source parameters are effective and the exposure compensation of the local area has been completed. Finally, after multiple rounds of adjustment and correction, the system defines this set of parameters as the "optimized irradiation parameters" under the current working conditions and stores them in the control model database for quick call under similar working conditions. This optimization process not only improves the consistency of exposure quality, but also enhances the system's ability to adapt to different operating modes.

[0080] For example, during a production run, the web speeds up from 25 m / min to 35 m / min, with a speed change rate of 5 m / min², exceeding the preset ±2.5 m / min² threshold. The system predicts that the speed will continue to accelerate to 38 m / min in the next 5 seconds. To prevent uneven exposure, the system shortens the response time from 1.5 seconds to 0.8 seconds, while adjusting the power of the edge area by 15%. At this point, the light source can synchronously follow the web speed change to ensure that the exposure effect remains uniform.

[0081] It should be noted that in high-speed dynamic operation scenarios, the moving speed of the coil changes instantaneously due to factors such as tension fluctuations, unstable winding / unwinding systems, uneven materials or mechanical vibrations. When the coil speed is accelerated or decelerated significantly, it will directly cause the action time of the UV exposure energy per unit area to change, thereby causing regional exposure dose fluctuations, and then causing pattern blur, smearing, underexposure or overexposure. In order to improve the system's ability to adapt to such disturbances, the present invention further introduces a speed change rate feedback mechanism in the UV lighting control system to dynamically adjust the light source response parameters and achieve synchronous matching of "speed-energy".

[0082] Specifically, during system operation, the coil speed is collected in real time by a high-precision rotary encoder or linear speed sensor, and the sampling frequency is preferably 50~200Hz to ensure sensitive capture of sudden changes. The system calculates the speed data of the current moment and the previous time period to obtain the instantaneous speed change rate (i.e., acceleration or deceleration) in m / min². Furthermore, the system uses the speed data of the past few consecutive seconds to construct a "speed-time" discrete sequence, and uses a quadratic fitting algorithm to perform regression modeling on the sequence, extract the current speed change trend (such as linear growth, slow decline, fluctuation, etc.), and predict the speed trend range in the short future time.

[0083] Specifically, the system sets a speed disturbance identification threshold, such as ±2.5 m / min², as a basis for identifying abnormal operating conditions. Once the speed change rate is detected to exceed the threshold, the system considers that the current operation is in a "high dynamic disturbance state" and immediately activates the speed disturbance prediction module. According to the fitting model results, if the prediction shows that the coil will continue to accelerate in the next 3 to 5 seconds, it means that the exposure time per unit area will continue to shorten. If no compensation adjustment is made, it is easy to cause underexposure; if it is displayed as a deceleration state, it will cause energy accumulation, resulting in local overexposure.

[0084] Specifically, in order to cope with such dynamic changes, the present invention defines a set of light source response time parameters, including but not limited to: power output start-up delay time (such as relay closing time), PWM regulation response delay (such as duty cycle change effective time), LED drive on-off response time (such as MOS tube conduction time), thermal stability delay time, etc. The system dynamically modifies these response parameters according to the speed prediction trend: shorten the response time in the acceleration state to increase the UV energy adjustment response rate; extend the response rhythm in the deceleration state to avoid energy fluctuations caused by too fast power switching.

[0085] Specifically, the optimized response time parameters will be input into the power distribution optimization module as correction values, and will be calculated in conjunction with the current power adjustment instructions to form a set of compensation power configurations that adapt to speed disturbances. This configuration not only adjusts the total light intensity, but also modifies the "response curve shape" of power changes, such as changing the dimming change from "slow change type" to "steep rise type" or "forward advance type" to ensure that the energy distribution changes synchronously with the speed. For example, during a coil operation, the system detected that the speed rose rapidly from 25 m / min to 35 m / min within 2 seconds, with a speed change rate of +5 m / min², exceeding the set threshold of ±2.5 m / min². The system immediately started the fitting analysis and predicted that the speed would further rise to 38 m / min in 5 seconds. To cope with this accelerating trend, the system decided to shorten the response time of the UV light source from the original 1.5 seconds to 0.8 seconds, trigger the leading edge of the power adjustment curve in advance, and increase the power following coefficient of the edge area by 15% to adapt to the offset of the light spot relative to the movement trajectory of the web, thereby avoiding the problem of smearing or underexposure caused by "light spot lag".

[0086] Specifically, after the adjustment is implemented, the system synchronously verifies the irradiation effect through the light intensity feedback channel and the exposure dose detection module. If it is detected that the cumulative dose of all areas has been restored to the target range, the system will record the response parameter configuration and power adjustment strategy as the "optimal response configuration" in the current operating condition model for rapid call under the same speed disturbance in the future, thereby shortening the system's adaptive process time and improving response efficiency.

[0087] In step S15, it is necessary to perform an overexposed or underexposed area determination operation according to the optimized illumination parameters to obtain an overexposed area and an underexposed area, including: Applying the optimized irradiation parameters to a controller of the UV light source to obtain cumulative exposure values ​​for each area on the surface of the web; When the cumulative exposure value is greater than a preset overexposure threshold, determining the area corresponding to the cumulative exposure value as an overexposure area; When the accumulated exposure value is less than a preset underexposure threshold, the area corresponding to the accumulated exposure value is determined as an underexposure area.

[0088] First, after the optimization of the irradiation parameters is completed, the present invention sets a special over-exposed and under-exposed area identification process. This process performs a full-frame detection of the cumulative exposure of all exposed areas on the surface of the web, and combines the preset energy dose tolerance threshold to determine whether each area has an irradiation energy deviation problem, and divides it into a normal area, an over-exposed area or an under-exposed area accordingly, providing data support for subsequent light source fine-tuning control and model correction.

[0089] Specifically, after the UV light source outputs energy according to the optimized irradiation parameters, the system obtains the actual exposure effect through the UV exposure dose detection module integrated on the back or top of the web. The module consists of multiple high-sensitivity UV light sensor arrays, each sensor corresponding to a spatial position segment, which can continuously sample each position point of the web during the exposure segment, and obtain the total irradiation energy value received per unit area by integral calculation, in units of mJ / cm². If no direct sensing device is installed on the web, the system can also estimate the light intensity value and irradiation time by analog method, and obtain the actual measurement value after correction in combination with the web running speed.

[0090] Specifically, the system divides the surface of the web into several grid-shaped detection units in space. For example, a web with a width of 600 mm is divided into small areas of 20 mm × 20 mm each, forming a total of about 900 sampling areas. Each area is compared with the dose threshold set in the system according to the UV cumulative exposure value of its corresponding position to determine whether it deviates from the target energy range. To achieve this comparison process, the present invention sets two sets of key thresholds: overexposure threshold and underexposure threshold. These two sets of thresholds are set symmetrically around the target exposure dose to form a "tolerance band" that allows energy fluctuations.

[0091] Specifically, there are various ways to set the threshold, which is closely related to the type of photosensitive material used in the coil, the exposure process requirements and the subsequent curing characteristics. For example, for electronic thin film circuit materials, the target exposure dose is set to 400 mJ / cm². In order to control the error within ±5%, the system sets the overexposure threshold to 420 mJ / cm² and the underexposure threshold to 380 mJ / cm². For precision mask processes or high-resolution pattern exposure requirements, the tolerance is narrowed to ±2.5%, and the threshold is only in the range of 390~410 mJ / cm². The threshold can be set directly by the user in the process configuration interface, or it can be automatically loaded by the system calling the historical process database, and it can even be dynamically derived through an algorithm based on the material model and the photosensitivity response curve.

[0092] Specifically, in actual operation, the system automatically compares the exposure value of each grid area with the above threshold. When the exposure value of a certain area is greater than the overexposure threshold, it means that the area has received excessive energy, and the system marks it as an "overexposed area"; when the exposure value is lower than the underexposure threshold, it means that the energy is insufficient, resulting in incomplete pattern transfer, and the system marks it as an "underexposed area"; and all areas between the two thresholds are considered "qualified exposure areas". This recognition process is based on spatial coordinates, specifically locates the abnormal area, and generates a two-dimensional exposure deviation map for use by the next feedback compensation module.

[0093] For example, during a mass production process, the system detected that the exposure dose of a grid in the middle area of ​​the wide web reached 448 mJ / cm², while its target dose was 400 mJ / cm² and the overexposure threshold was set at 420 mJ / cm², so the system marked the area as overexposed; at the same time, the dose detected in the upper right corner was only 374 mJ / cm², which was lower than the underexposure threshold of 380 mJ / cm² and was also identified as underexposed. The system aggregates these results into an "abnormal area list" and displays them in the user monitoring interface in the form of color markings, with red indicating overexposure, blue indicating underexposure, and green indicating normal areas, and uses them as feedback input parameters for subsequent compensation control modules to process.

[0094] In step S16, it is necessary to adjust the illumination intensity and light intensity distribution of the UV light source for the overexposed area and the underexposed area until the exposure quality of the area reaches a preset standard range, including: Extracting the cumulative exposure values ​​of the overexposed area and the underexposed area to obtain an overexposed exposure value and an underexposed exposure value; Calculating the differences between the overexposure value and the underexposure value and a preset standard threshold value respectively to obtain an exposure difference; The light source mode is dynamically optimized based on the exposure difference, a light source control parameter is generated, and the control parameter is applied to the controller of the UV light source. When the exposure difference is less than a preset difference threshold, it is determined that the exposure quality of the area reaches a preset standard range.

[0095] First, the system extracts the cumulative exposure values ​​of the identified overexposed and underexposed areas. These values ​​are collected in real time by the UV dose detection module, reflecting the UV energy received per unit area, and are the direct basis for evaluating the exposure effect. The system compares this value with the preset target exposure dose and calculates the exposure difference for each abnormal area. For example, if the cumulative exposure of an area is 428 mJ / cm², and the standard target dose of the material is 400 mJ / cm², the exposure difference is +28 mJ / cm², indicating overexposure; if the value is 368 mJ / cm², the difference is -32 mJ / cm², indicating underexposure.

[0096] In practical applications, the present invention preferably adopts the following setting method to determine the preset target exposure dose value and the allowable error range (i.e., the preset standard range): for medium-sensitivity photosensitive materials (such as ordinary UV-curing coatings, electronic thin film materials, etc.), the recommended target exposure dose is 400 mJ / cm², and the allowable error range is set to ±20 mJ / cm², that is, the allowable interval is 380 mJ / cm² to 420 mJ / cm²; for high-sensitivity or micro-pattern exposure materials (such as photoresist for mask plates, high-definition PI films, etc.), the recommended target value is 450 mJ / cm², and the error range is reduced to ±10 mJ / cm², that is, the range is 440-460mJ / cm²; the specific setting method of the threshold value can be through recipe input, process parameter file import or automatic call by the system embedded material database.

[0097] Specifically, the system compares the actual exposure value with the target value according to the above settings. If the absolute value of the difference is higher than the allowable error range, it is regarded as "exposure failure" and needs to enter the compensation adjustment process.

[0098] In a specific embodiment, the system uses the exposure difference of each area as an input variable, combined with the current light source output parameters of the area, and enters the light source model dynamic optimization unit. The control model in the present invention supports multi-dimensional adjustment methods, including: output intensity adjustment: by adjusting the driving current or PWM duty cycle, the energy of the light source in the area is increased or decreased; irradiation angle adjustment: optimizing the inclination of the light source to adapt to the micro-deformation of the coil surface to ensure effective energy concentration; spot geometry adjustment: adjusting the major axis / minor axis ratio and offset position of the ellipse to ensure that the spot matches the target area; exposure time fine-tuning (if synchronous trigger control is supported): the exposure time can be locally extended or shortened in a dynamic system; light source response parameter refinement: such as early start, high-speed power control, to achieve rapid compensation in the time domain.

[0099] For example, taking the output intensity adjustment as an example, if the exposure value of a certain area is 370 mJ / cm², the target is 400mJ / cm², and the underexposure is 30 mJ / cm², according to the system experience model or linear proportional method, the system can set a dose increase of about 4 mJ / cm² for every 1% power increase, and the power needs to be increased by about 7.5%. The system increases the current PWM duty cycle from 70% to about 75%, adjusts the drive current from 2.8A to 3.0A, and adjusts the spot lateral expansion by 0.5mm to expand the irradiation coverage.

[0100] In a specific embodiment, the optimized parameters are sent to the light source controller via the bus communication interface to complete the hardware-level fine adjustment. The system then continues to perform a secondary detection of the adjustment area through the light intensity monitoring module and recalculates the current exposure difference.

[0101] In a specific embodiment, the present invention sets an exposure difference threshold to determine whether the adjustment is effective, and it is recommended to be set to ±2.5% of the target dose. Taking the target of 400 mJ / cm² as an example, the exposure difference tolerance range is ±10mJ / cm². Only when the difference after adjustment is lower than the threshold, that is, the final dose is between 390-410 mJ / cm², the system considers that the exposure quality of the area has met the standard. If the requirements are still not met, the system can repeat up to two rounds of fine-tuning. If the standard is still not met, an early warning is triggered, indicating that the light source performance has declined or the material is abnormal. For example, in a specific implementation case, the initial exposure value of the upper right corner of the web was 372 mJ / cm². The system adjusted the PWM from 72% to 77% for the first time, and the dose was increased to 388 mJ / cm². The second round of fine-tuning increased the duty cycle to 79%, and the final dose reached 396 mJ / cm². The difference was -4 mJ / cm², which met the set standard of ±10 mJ / cm². The system confirmed that the exposure met the standard and wrote the compensation plan into the "local optimization model" database for subsequent rapid automatic correction of similar deformation situations.

[0102] It should be noted that in the present invention, the preset standard range is an important basis for determining whether each exposure area meets the process requirements. With the target exposure dose as the center value, a floating dose allowable range is set to define the "normal exposure", "overexposure" or "underexposure" state. The setting of this standard range is not only directly related to the accuracy of exposure control, but also determines whether the system needs to trigger the compensation mechanism for secondary adjustment. Therefore, its configuration should be executable, traceable and adaptive.

[0103] Specifically, the setting of the preset standard range is determined based on a combination of three factors. The first is the photosensitivity response characteristics of the material itself. Different photosensitive materials have different tolerances to UV irradiation doses. For example, ordinary UV-curable resins have a high tolerance to fluctuations in exposure doses, and the acceptable dose deviation is ±20 mJ / cm². If the target value is 400 mJ / cm², the preset standard range is 380–420 mJ / cm². For dry film photoresist materials used for high-precision graphic transfer, the exposure error needs to be controlled at ±10 mJ / cm² or less to meet the requirements of pattern edge clarity and fine line consistency. At this time, if the target exposure dose is 450 mJ / cm², the standard range is set to 440–460 mJ / cm².

[0104] Specifically, the second influencing factor is the process level of the product. The system supports automatic loading of corresponding process templates according to different production tasks, corresponding to different levels of error tolerance. For example, the exposure dose tolerance of conventional grade products can be set to ±5% of the target value for stable control during mass processing; while for precision processes or functional film samples, the tolerance can be controlled to ±2.5% or even lower to achieve high contrast and high reduction pattern quality. Users can also manually set this range in the system control interface to meet the needs of special processes or experimental products.

[0105] Specifically, the third type of setting basis comes from the dynamic correction capability of the system's operating status. When the system detects that it is currently in a high-speed operating state, or there are unstable operating conditions such as frequent starts and stops, the exposure time of the web will fluctuate. To avoid misjudgment, the present invention can automatically expand the standard range appropriately, such as expanding the standard range by 5 mJ / cm² when the speed change rate exceeds 4 m / min², thereby enhancing the system's fault tolerance to dynamic disturbances; conversely, when the system runs stably for more than a certain period (such as running continuously for 10 minutes without disturbance), it will automatically return to the default accuracy range to ensure that the exposure control is always in the optimal state.

[0106] Specifically, in the system execution judgment logic, the surface of the web is divided into several two-dimensional area units. The system collects the cumulative exposure dose of each area and compares it with the current preset standard range. When an actual value exceeds the upper limit of the standard (such as >420 mJ / cm²), the area is marked as "overexposed"; if it is lower than the lower limit (such as <380 mJ / cm²), it is judged as "underexposed"; only when the actual value falls within this range, the system confirms that the exposure of the area is qualified. The judgment result will directly affect whether the local fine-tuning control process in step S16 is triggered later. For example, in a certain mass production process, the system identifies the web material as a medium-sensitivity UV photosensitive layer, the target exposure dose is set to 400 mJ / cm², the allowable deviation is ±20 mJ / cm², and the system sets the standard range to 380–420 mJ / cm². The cumulative exposure value collected in a certain area is 368 mJ / cm², which is lower than the lower limit of 12 mJ / cm². The system marks it as an underexposed area and triggers the local optimization process. The value of another area is 414mJ / cm², which is within the standard range. The system determines that its exposure is qualified and no adjustment is required.

[0107] In summary, the present invention provides a UV lighting control method and system for a roll-to-roll exposure machine to achieve real-time response and regulation of changes in web tension and speed, and solve the problem of uneven exposure dose.

[0108] Reference Figure 2 A second embodiment of the present invention provides a UV lighting control system for a roll-to-roll exposure machine, comprising: Data acquisition module, used to obtain the real-time moving speed and tension change value of the coil; A deformation prediction module, for predicting the deformation trend of the coil surface based on a nonlinear regression algorithm combined with the real-time moving speed to obtain a deformation influence value when the tension change value is greater than a preset tension change threshold; A light intensity distribution module is used to adjust the irradiation angle and spot shape parameters of the UV light source according to the deformation influence value by using a PID control algorithm to obtain a light intensity distribution value; An optimization parameter module is used to calculate the output intensity requirements of each area of ​​the UV light source according to the light intensity distribution value using a fuzzy control algorithm, and to adjust the speed using a speed adjustment method combined with the real-time moving speed, so as to obtain optimized irradiation parameters; An area determination module is used to perform an overexposed or underexposed area determination operation according to the optimized illumination parameters to obtain an overexposed area and an underexposed area; The quality optimization module is used to adjust the light intensity and light intensity distribution of the UV light source in the overexposed area and the underexposed area until the regional exposure quality reaches a preset standard range.

[0109] It should be noted that the UV lighting control system of a roll-to-roll exposure machine provided in an embodiment of the present invention is used to execute all the process steps of the UV lighting control method of a roll-to-roll exposure machine in the above embodiment. The working principles and beneficial effects of the two correspond one to one, and therefore will not be repeated here.

[0110] The embodiment of the present invention further provides an electronic device. The electronic device includes: a processor, a memory, and a computer program stored in the memory and executable on the processor, such as an area determination program. When the processor executes the computer program, the steps of the UV lighting control method of each roll-to-roll exposure machine described above are implemented, such as Figure 1 Alternatively, when the processor executes the computer program, the functions of the modules / units in the above-mentioned device embodiments are realized, such as the area determination module.

[0111] Exemplarily, the computer program may be divided into one or more modules / units, which are stored in the memory and executed by the processor to implement the present invention. The one or more modules / units may be a series of computer program instruction segments capable of implementing specific functions, which are used to describe the execution process of the computer program in the electronic device.

[0112] The electronic device may be a computing device such as a desktop computer, a notebook, a PDA, and a smart tablet. The electronic device may include, but is not limited to, a processor and a memory. Those skilled in the art will appreciate that the above components are merely examples of electronic devices and do not constitute a limitation on the electronic device. The electronic device may include more or fewer components than the above components, or may combine certain components, or different components. For example, the electronic device may also include input and output devices, network access devices, buses, etc.

[0113] The processor may be a central processing unit (CPU), other general-purpose processors, digital signal processors (DSP), application-specific integrated circuits (ASIC), field-programmable gate arrays (FPGA) or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc. A general-purpose processor may be a microprocessor or any conventional processor, etc. The processor is the control center of the electronic device, and uses various interfaces and lines to connect various parts of the entire electronic device.

[0114] The memory can be used to store the computer program and / or module, and the processor realizes various functions of the electronic device by running or executing the computer program and / or module stored in the memory, and calling the data stored in the memory. The memory can mainly include a program storage area and a data storage area, wherein the program storage area can store an operating system, an application required for at least one function (such as a sound playback function, an image playback function, etc.), etc.; the data storage area can store data created according to the use of the mobile phone (such as audio data, a phone book, etc.), etc. In addition, the memory can include a high-speed random access memory, and can also include a non-volatile memory, such as a hard disk, a memory, a plug-in hard disk, a smart memory card (Smart Media Card, SMC), a secure digital (Secure Digital, SD) card, a flash card (Flash Card), at least one disk storage device, a flash memory device, or other volatile solid-state storage devices.

[0115] Wherein, if the module / unit integrated in the electronic device is implemented in the form of a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on such an understanding, the present invention implements all or part of the processes in the above-mentioned embodiment method, and can also be completed by instructing the relevant hardware through a computer program. The computer program can be stored in a computer-readable storage medium, and the computer program can implement the steps of the above-mentioned various method embodiments when executed by the processor. Wherein, the computer program includes computer program code, and the computer program code can be in source code form, object code form, executable file or some intermediate form. The computer-readable medium may include: any entity or device capable of carrying the computer program code, recording medium, U disk, mobile hard disk, disk, optical disk, computer memory, read-only memory (ROM, Read-Only Memory), random access memory (RAM, Random Access Memory), electric carrier signal, telecommunication signal and software distribution medium. It should be noted that the content contained in the computer-readable medium can be appropriately increased or decreased according to the requirements of legislation and patent practice in the jurisdiction. For example, in some jurisdictions, according to legislation and patent practice, computer-readable media do not include electric carrier signals and telecommunication signals.

[0116] It should be noted that the device embodiments described above are merely schematic, wherein the units described as separate components may or may not be physically separated, and the components displayed as units may or may not be physical units, that is, they may be located in one place, or they may be distributed on multiple network units. Some or all of the modules may be selected according to actual needs to achieve the purpose of the scheme of this embodiment. In addition, in the accompanying drawings of the device embodiments provided by the present invention, the connection relationship between the modules indicates that there is a communication connection between them, which may be specifically implemented as one or more communication buses or signal lines. A person of ordinary skill in the art may understand and implement it without paying any creative effort.

[0117] The specific embodiments described above further illustrate the purpose, technical solutions and beneficial effects of the present invention. It should be understood that the above description is only a specific embodiment of the present invention and is not intended to limit the scope of protection of the present invention. It is particularly pointed out that for those skilled in the art, any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention should be included in the scope of protection of the present invention.

Claims

1. A UV lighting control method for a roll-to-roll exposure machine, characterized in that: include: Obtain the real-time moving speed and tension change values ​​of the coil; When the tension change value is greater than a preset tension change threshold, the deformation trend of the coil surface is predicted based on a nonlinear regression algorithm combined with the real-time moving speed to obtain a deformation influence value; According to the deformation influence value, a PID control algorithm is used to adjust the irradiation angle and spot shape parameters of the UV light source to obtain a light intensity distribution value; According to the light intensity distribution value, a fuzzy control algorithm is used to calculate the output intensity requirement of each area of ​​the UV light source, thereby obtaining optimized irradiation parameters; According to the optimized irradiation parameters, an overexposed or underexposed area determination operation is performed to obtain an overexposed area and an underexposed area; The illumination intensity and light intensity distribution of the UV light source are adjusted for the overexposed area and the underexposed area until the exposure quality of the area reaches a preset standard range.

2. The UV lighting control method of a roll-to-roll exposure machine according to claim 1, characterized in that: When the tension change value is greater than a preset tension change threshold, the deformation trend of the coil surface is predicted based on a nonlinear regression algorithm combined with the real-time moving speed to obtain a deformation influence value, including: When the tension change value is greater than a preset tension change threshold, deformation parameters are calculated based on a nonlinear regression algorithm to obtain deformation amount, deformation direction, deformation speed and deformation distribution characteristics; Based on the deformation amount, the deformation direction, the deformation speed and the deformation distribution characteristics combined with the real-time moving speed, the influence of the deformation on the UV light source irradiation trajectory is calculated by an interpolation algorithm to obtain an offset of the light source trajectory; The offset is input into a pre-configured tension change prediction model to predict the influence of the deformation amount and obtain a deformation influence value.

3. The UV lighting control method of a roll-to-roll exposure machine according to claim 1, characterized in that: The method of adjusting the irradiation angle and the light spot shape parameters of the UV light source by using a PID control algorithm according to the deformation influence value to obtain the light intensity distribution value includes: According to the deformation influence value, the deformation distribution of the coil is analyzed by using a finite element method to obtain a deformation distribution parameter; Inputting the deformation distribution parameter into a PID controller controlled by a PID algorithm to obtain a control output value for adjusting the UV light source; According to the control output value, adjusting the irradiation angle and spot shape parameters of the UV light source to obtain an adjusted light intensity value; Calculate the geometric value of the light spot shape based on the light spot geometry optimization algorithm combined with the light intensity value; When the geometric value is synchronized with the preset deformation distribution of the coil, the light intensity value corresponding to the geometric value is determined as the light intensity distribution value.

4. The UV lighting control method of a roll-to-roll exposure machine according to claim 1, characterized in that: The output intensity requirement of each area of ​​the UV light source is calculated using a fuzzy control algorithm according to the light intensity distribution value, thereby obtaining optimized irradiation parameters, including: The output intensity requirement of each area of ​​the UV light source is calculated by using a fuzzy control algorithm combined with a preset fuzzy control rule library and the light intensity distribution value; Calculate the power allocation scheme of the UV light source based on a dynamic optimization algorithm combined with the output intensity requirement; Dynamically adjusting the light source irradiation parameters of the UV light source according to the power allocation scheme; Applying the light source irradiation parameters to a controller of the UV light source to continuously adjust the exposure dose of the web area until a preset exposure threshold is reached; When the exposure dose of the web area reaches a preset exposure threshold, the light source irradiation parameters corresponding to the exposure dose are determined as optimized irradiation parameters.

5. The UV lighting control method of a roll-to-roll exposure machine according to claim 4, characterized in that: After calculating the output intensity requirements of each area of ​​the UV light source using a fuzzy control algorithm according to the light intensity distribution value to obtain optimized irradiation parameters, the method further includes: Calculate the speed change rate according to the real-time moving speed; When the speed change rate is greater than a preset speed threshold, a quadratic fitting algorithm is used to dynamically adjust the response time parameter, and a power allocation scheme of the UV light source is calculated based on the response time parameter; Dynamically adjusting the light source irradiation parameters of the UV light source according to the power allocation scheme; Applying the light source irradiation parameters to a controller of the UV light source to continuously adjust the exposure dose of the web area until a preset exposure threshold is reached; When the exposure dose of the web area reaches a preset exposure threshold, the light source irradiation parameter corresponding to the exposure dose is determined as the current optimized irradiation parameter.

6. The UV lighting control method of a roll-to-roll exposure machine according to claim 1, characterized in that: The step of performing an overexposed or underexposed area determination operation according to the optimized illumination parameters to obtain an overexposed area and an underexposed area includes: Applying the optimized irradiation parameters to a controller of the UV light source to obtain cumulative exposure values ​​for each area on the surface of the web; When the cumulative exposure value is greater than a preset overexposure threshold, determining the area corresponding to the cumulative exposure value as an overexposure area; When the accumulated exposure value is less than a preset underexposure threshold, the area corresponding to the accumulated exposure value is determined as an underexposure area.

7. The UV lighting control method of a roll-to-roll exposure machine according to claim 1, characterized in that: The operation of adjusting the illumination intensity and the light intensity distribution of the UV light source for the overexposed area and the underexposed area until the exposure quality of the area reaches a preset standard range includes: Extracting the cumulative exposure values ​​of the overexposed area and the underexposed area to obtain an overexposed exposure value and an underexposed exposure value; Calculating the differences between the overexposure value and the underexposure value and a preset standard threshold value respectively to obtain an exposure difference; The light source mode is dynamically optimized based on the exposure difference, a light source control parameter is generated, and the control parameter is applied to the controller of the UV light source. When the exposure difference is less than a preset difference threshold, it is determined that the exposure quality of the area reaches a preset standard range.

8. A UV lighting control system for a roll-to-roll exposure machine, characterized in that: include: Data acquisition module, used to obtain the real-time moving speed and tension change value of the coil; A deformation prediction module, for predicting the deformation trend of the coil surface based on a nonlinear regression algorithm combined with the real-time moving speed to obtain a deformation influence value when the tension change value is greater than a preset tension change threshold; A light intensity distribution module is used to adjust the irradiation angle and spot shape parameters of the UV light source according to the deformation influence value by using a PID control algorithm to obtain a light intensity distribution value; An optimization parameter module is used to calculate the output intensity requirements of each area of ​​the UV light source according to the light intensity distribution value using a fuzzy control algorithm, and to adjust the speed using a speed adjustment method combined with the real-time moving speed, so as to obtain optimized irradiation parameters; An area determination module is used to perform an overexposed or underexposed area determination operation according to the optimized illumination parameters to obtain an overexposed area and an underexposed area; The quality optimization module is used to adjust the light intensity and light intensity distribution of the UV light source in the overexposed area and the underexposed area until the regional exposure quality reaches a preset standard range.

9. An electronic device, characterized in that: The invention comprises a processor, a memory and a computer program stored in the memory and configured to be executed by the processor, wherein when the processor executes the computer program, the UV lighting control method of the roll-to-roll exposure machine as described in any one of claims 1 to 7 is implemented.

10. A computer-readable storage medium, characterized in that: The computer-readable storage medium includes a stored computer program, wherein when the computer program is executed, the device where the computer-readable storage medium is located is controlled to execute the UV lighting control method of the roll-to-roll exposure machine according to any one of claims 1 to 7.

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