UV Illumination Control Method and System for a Roll-to-Roll Exposure Machine

Abstract

The present invention discloses a UV illumination control method and system for a roll-to-roll exposure machine. The method includes obtaining the real-time moving speed and the tension change value of the coil material; when the tension change value is greater than the tension threshold, predicting the deformation trend on the surface of the coil material based on the non-linear regression algorithm in combination with the real-time moving speed to obtain a deformation influence value; adjusting the UV light source by using a PID control algorithm according to the deformation influence value to obtain a light intensity distribution value; calculating the required output intensity of the UV light source by using a fuzzy control algorithm according to the light intensity distribution value, and combining with the real-time moving speed to perform speed adjustment, so as to obtain optimized irradiation parameters; performing area determination according to the optimized irradiation parameters to obtain overexposed areas and underexposed areas; adjusting the intensity and distribution of the UV light source for the overexposed areas and underexposed areas until the area exposure quality reaches the preset standard range. This method can achieve real-time response regulation of the tension and speed changes of the coil material, and solve the problem of uneven exposure dose.

Description

Technical Field

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

[0002] Currently, in the context that the roll-to-roll exposure process is widely used in fields such as flexible electronics, printed circuit boards, and flexible displays, 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 web material, its tension and speed states change in real time according to the working conditions. The traditional UV light source control method is difficult to achieve real-time linkage with the web material state, resulting in a decrease in exposure accuracy.

[0003] In an existing technology, the irradiation angle and spot shape of the UV light source are statically controlled based on preset parameters and cannot be dynamically adjusted according to the running state of the web material. When the web material speed suddenly changes or the tension fluctuates greatly, exposure deviations are likely to occur, such as problems like spot offset, ghosting, local overexposure or underexposure, thus affecting the imaging quality of the pattern and the processing yield.

[0004] The prior art cannot achieve real-time light source control based on the running state of the web material, resulting in uneven exposure dose. Summary of the Invention

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

[0006] In a first aspect, to solve the above technical problems, the present invention provides a UV illumination control method for a roll-to-roll exposure machine, including:

[0007] Obtaining the real-time moving speed and the tension change value of the web material;

[0008] When the tension change value is greater than a preset tension change threshold, predicting the deformation trend on the surface of the web material based on a non-linear regression algorithm in combination with the real-time moving speed to obtain a deformation influence value;

[0009] According to the deformation influence value, adjusting the irradiation angle and spot shape parameters of the UV light source by using a PID control algorithm to obtain a light intensity distribution value;

[0010] According to the light intensity distribution value, calculating the output intensity requirements of each region of the UV light source by using a fuzzy control algorithm, and performing speed adjustment in combination with the real-time moving speed by using a speed adjustment method to obtain optimized irradiation parameters;

[0011] According to the optimized irradiation parameters, performing an overexposure or underexposure region determination operation to obtain an overexposure region and an underexposure region;

[0012] Perform operations to adjust the illumination intensity and light intensity distribution of the UV light source on the overexposed area and the underexposed area until the area exposure quality reaches the preset standard range.

[0013] Preferably, when the tension change value is greater than the preset tension change threshold, based on the non - linear regression algorithm and combined with the real - time moving speed, predict the deformation trend of the coil surface to obtain the deformation influence value, including:

[0014] When the tension change value is greater than the preset tension change threshold, perform deformation parameter calculation based on the non - linear regression algorithm to obtain the deformation amount, deformation direction, deformation speed, and deformation distribution characteristics;

[0015] Based on the deformation amount, deformation direction, deformation speed, and deformation distribution characteristics, and combined with the real - time moving speed, calculate the influence degree of deformation on the irradiation trajectory of the UV light source through the interpolation algorithm to obtain the offset of the light source trajectory;

[0016] Input the offset into the pre - configured tension change prediction model to predict the influence degree of the deformation amount and obtain the deformation influence value.

[0017] Preferably, according to the deformation influence value, use the PID control algorithm to adjust the irradiation angle and spot shape parameters of the UV light source to obtain the light intensity distribution value, including:

[0018] According to the deformation influence value, use the finite element method to analyze the deformation distribution of the coil to obtain the deformation distribution parameters;

[0019] Input the deformation distribution parameters into the PID controller controlled by the PID algorithm to obtain the control output value for adjusting the UV light source;

[0020] According to the control output value, adjust the irradiation angle and spot shape parameters of the UV light source to obtain the adjusted light intensity value;

[0021] Based on the spot geometric shape optimization algorithm and combined with the light intensity value, calculate the geometric value of the spot shape;

[0022] When the geometric value is synchronized with the preset deformation distribution of the coil, determine the light intensity value corresponding to the geometric value as the light intensity distribution value.

[0023] Preferably, according to the light intensity distribution value, use the fuzzy control algorithm to calculate the output intensity requirements of each area of the UV light source, and use the speed adjustment method combined with the real - time moving speed to perform speed adjustment, so as to obtain the optimized irradiation parameters, including:

[0024] 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;

[0025] Calculate the power allocation scheme of the UV light source based on a dynamic optimization algorithm combined with the output intensity requirement;

[0026] Dynamically adjusting the light source irradiation parameters of the UV light source according to the power allocation scheme;

[0027] 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;

[0028] 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.

[0029] 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:

[0030] Calculate the speed change rate according to the real-time moving speed;

[0031] 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;

[0032] Dynamically adjusting the light source irradiation parameters of the UV light source according to the power allocation scheme;

[0033] 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;

[0034] 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.

[0035] 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:

[0036] 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;

[0037] 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;

[0038] 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.

[0039] Preferably, the operation of adjusting the illumination intensity and light intensity distribution of the UV light source for the overexposed area and the underexposed area until the area exposure quality reaches the preset standard range includes:

[0040] Extract the cumulative exposure values of the overexposed area and the underexposed area to obtain the overexposure value and the underexposure value;

[0041] Calculate the differences between the overexposure value and the underexposure value and the preset standard threshold respectively to obtain the exposure differences;

[0042] Based on the exposure differences, dynamically optimize the light source mode, generate light source control parameters, and apply the control parameters to the controller of the UV light source. When the exposure difference is less than the preset difference threshold, it is determined that the area exposure quality reaches the preset standard range.

[0043] In a second aspect, the present invention provides a UV illumination control system for a roll-to-roll exposure machine, including:

[0044] A data acquisition module for acquiring the real-time moving speed and the tension change value of the coil material;

[0045] A deformation prediction module for predicting the deformation trend of the surface of the coil material based on a non-linear 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;

[0046] A light intensity distribution module for adjusting the irradiation angle and the 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;

[0047] An optimization parameter module for calculating the output intensity requirements of each area of the UV light source by using a fuzzy control algorithm according to the light intensity distribution value, and performing speed adjustment by using a speed adjustment method combined with the real-time moving speed to obtain optimized irradiation parameters;

[0048] An area determination module for performing an overexposure or underexposure area determination operation according to the optimized irradiation parameters to obtain an overexposed area and an underexposed area;

[0049] A quality optimization module for adjusting the illumination intensity and the light intensity distribution of the UV light source for the overexposed area and the underexposed area until the area exposure quality reaches the preset standard range.

[0050] In a third aspect, the present invention further provides an electronic device, including a processor, a memory, and a computer program stored in the memory and configured to be executed by the processor. When the processor executes the computer program, it implements the UV illumination control method of the roll-to-roll exposure machine described in any one of the above.

[0051] In a fourth aspect, the present invention also provides a computer-readable storage medium, which includes a stored computer program. When the computer program runs, it controls the device where the computer-readable storage medium is located to execute the UV illumination control method of the roll-to-roll exposure machine described in any one of the above.

[0052] Compared with the prior art, the present invention has the following beneficial effects:

[0053] (1) The present invention discloses a UV illumination control method for a roll-to-roll exposure machine. By obtaining the real-time moving speed and tension change data of the coil material, and when the tension change exceeds a preset threshold, based on the non-linear regression algorithm, the deformation trend of the surface of the coil material is predicted, and then the deformation influence value is obtained. This method combines real-time speed information with deformation parameters, further calculates the light source trajectory offset through interpolation, and inputs it into the tension change prediction model to ensure that the deformation analysis result is more real-time and accurate. This solution can effectively improve the trajectory control accuracy during UV irradiation and enhance the response ability of the system to the dynamic changes of the deformation of the coil material.

[0054] (2) Based on the deformation influence value, the present invention uses the 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 material, so that the light intensity distribution is consistent with the actual deformation of the coil material. At the same time, by calculating the output intensity requirements of each region of the UV light source through the fuzzy control algorithm, and combining the real-time monitoring results of the speed change rate, the fine allocation and adjustment of the light source power are realized through the dynamic optimization algorithm. 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 sudden start-stop conditions.

[0055] (3) In addition, the present invention also judges whether there are overexposed or underexposed areas on the surface of the coil material through the optimized light source irradiation parameters, and makes targeted fine adjustments to the abnormal areas until the exposure dose of each area is stable within the preset standard range. The irradiation intensity and light intensity distribution of the UV light source are dynamically adjusted through the feedback control method, and the control model parameters are updated in real time to realize the continuous optimization and steady-state control of the exposure quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0056] Figure 1 is a schematic flow chart of the UV illumination control method for a roll-to-roll exposure machine provided by the first embodiment of the present invention;

[0057] Figure 2 is a schematic structural diagram of the UV illumination control system for a roll-to-roll exposure machine provided by the second embodiment of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0058] Next, in combination with the accompanying drawings in the embodiments of the present invention, the technical solutions in the embodiments of the present invention will be clearly and completely described. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0059] Referring to Figure 1 , the first embodiment of the present invention provides a UV illumination control method for a roll-to-roll exposure machine, including the following steps:

[0060] S11, obtaining the real-time moving speed and the tension change value of the coil material;

[0061] S12, when the tension change value is greater than a preset tension change threshold, predicting the deformation trend on the surface of the coil material based on a non-linear regression algorithm in combination with the real-time moving speed to obtain a deformation influence value;

[0062] S13, according to the deformation influence value, adjusting the irradiation angle and the spot shape parameters of the UV light source by using a PID control algorithm to obtain a light intensity distribution value;

[0063] S14, according to the light intensity distribution value, calculating the output intensity requirements of each region of the UV light source by using a fuzzy control algorithm, and performing speed adjustment in combination with the real-time moving speed by using a speed adjustment method to obtain optimized irradiation parameters;

[0064] S15, according to the optimized irradiation parameters, performing an overexposure or underexposure region determination operation to obtain an overexposure region and an underexposure region;

[0065] S16, adjusting the light intensity and the light intensity distribution of the UV light source for the overexposure region and the underexposure region until the regional exposure quality reaches a preset standard range.

[0066] In step S11, it is necessary to obtain the real-time moving speed and the tension change value of the coil material, including:

[0067] First, in order to obtain the moving state of the coil material, high-precision speed sensors and tension sensors are arranged on the coil material conveying path in the present invention. The measurement of the moving speed uses 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 rotation angle of the roller and the known roller diameter. For example, when the encoder outputs 1000 pulses per revolution, the roller diameter is 100 mm, and it rotates 10 revolutions per second, the moving speed of the coil material 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 (pulses per revolution) and configure a high-speed sampling module with a sampling frequency of not less than 100 Hz.

[0068] Specifically, the measurement of the tension change uses a cantilever beam type tension sensor or a wheel type 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 through a signal conditioning module. Taking a typical application as an example, the tension range of the coil during normal operation is set to 400N - 600N. When the tension suddenly rises to 650N, that is, when it exceeds the preset tension change threshold of ±50N, the system will trigger the subsequent deformation prediction module.

[0069] In a specific embodiment, the real-time moving speed and tension data are uniformly imported into the 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 the sliding window averaging method or the Kalman filtering algorithm to perform real-time smoothing processing on the collected data to exclude accidental interferences caused by mechanical vibrations, etc., and ensure the data stability and the accuracy of the input of the prediction model.

[0070] Specifically, the purpose of obtaining these data is not only to monitor the current state of the coil, but more importantly, to determine whether it enters an unsteady operating condition (such as acceleration, deceleration, or sudden stop), and trigger the deformation prediction and light source control module accordingly. In a high-speed roll-to-roll exposure device, the slightest change in the movement state of the coil will directly affect the accuracy and uniformity of the exposure pattern. Therefore, this step has an important position in the system.

[0071] Exemplarily, 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 shows 510N, which is within 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 non-linear regression prediction module (S12) to calculate the deformation of the coil to ensure the exposure quality.

[0072] It should be noted that to ensure the universality of parameter settings, the present invention recommends setting the tension change threshold to ±10% - ±15% of the standard tension of the coil, and the specific value depends on the elastic modulus and thickness of the coil material (such as PET, PI, copper foil, etc.). For a PET coil with a standard tension of 500N, the threshold can be set to ±50N. The speed fluctuation range should be limited within ±10%, otherwise it will cause the risk of exposure ghosting or under-exposure.

[0073] In step S12, when the tension change value is greater than the preset tension change threshold, it is necessary to predict the deformation trend of the coil surface based on the non-linear regression algorithm combined with the real-time moving speed to obtain a deformation influence value, including:

[0074] When the value of the tension change is greater than a preset tension change threshold, calculate the deformation parameters based on the non-linear regression algorithm to obtain the deformation amount, deformation direction, deformation speed, and deformation distribution characteristics;

[0075] Based on the deformation amount, the deformation direction, the deformation speed, and the deformation distribution characteristics, combined with the real-time moving speed, calculate the influence degree of the deformation on the irradiation trajectory of the UV light source through an interpolation algorithm to obtain the offset of the light source trajectory;

[0076] Input the offset into a pre-configured tension change prediction model to predict the influence degree of the deformation amount and obtain a deformation influence value.

[0077] In a specific embodiment, during the traction operation of the coil material, it is affected by complex tension changes. Especially during high-speed operation, start-up, braking, or sudden change in the coil diameter, the tension fluctuates significantly. If these tension changes exceed a certain threshold, it is very likely to cause deformation on the surface of the coil material, which in turn interferes with the irradiation path and spot shape of the UV light source, and ultimately results in exposure deviation or pattern distortion. Therefore, in order to achieve the feedforward compensation of the UV irradiation control, the present invention, at the first moment when the tension anomaly occurs, through modeling and algorithm prediction, obtains in advance the deformation trend and influence degree that appear on the surface of the coil material.

[0078] First of all, it depends on the setting of the tension change threshold. This threshold is determined according to the material characteristics of the coil material, mainly considering the tolerance between its elastic limit and the stable operating tension. For example, for a PET material with a thickness of 25 microns, its tension floating tolerance before permanent deformation is ±10%. If the normal tension is set to 500N, the system can set the tension change threshold to ±50N. This value not only considers the robustness of short-term impacts but also can effectively intercept the working conditions that cause deformation. When the real-time tension change exceeds this threshold, the system considers that the coil material enters an unstable state and needs to immediately trigger the deformation prediction mechanism.

[0079] Specifically, after detecting the tension anomaly, the system calls the built-in non-linear regression model to predict and analyze the deformation trend on the surface of the coil material. The non-linear regression model is used to fit the non-linear response relationship between the tension change and the deformation of the coil material. Since this relationship is affected by many factors such as material properties, tension change rate, temperature, and coil diameter, it is difficult to accurately reflect through a linear model. The present invention preferably uses a support vector regression (SVR) model to construct this mapping relationship because of its strong generalization ability and stable performance for small sample data. During the design stage of the system, the deformation amounts on the surface of the coil material under different tension conditions are collected through experiments to establish a data set as the model training sample, where the inputs are tension values, speeds, tension change rates, etc., and the output is the deformation state.

[0080] After the model training is completed, it can receive tension input in real time during operation and output four key deformation parameters, namely deformation amount, deformation direction, deformation speed, and deformation distribution characteristics. Among them, the deformation amount represents the maximum offset of the coil in a unit area and is used to measure the severity of deformation; the deformation direction is used to judge 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 judge the compensation offset direction; the deformation speed is the change speed of the deformation amount per unit time, reflecting the dynamic characteristics of deformation and having reference significance for the control response time; while the deformation distribution characteristic is to reconstruct the two-dimensional distribution map of the deformation amount on the coil surface based on the predicted deformation amount results at multiple points, and the range and shape of the deformation area can be described by fitting a Gaussian distribution or a beta function, etc. Through the above parameters, the system basically restores the deformation structure of the coil when affected by tension fluctuations.

[0081] It should be noted that the non-linear regression model of the present invention is used to predict the deformation parameters of the coil surface, and its inputs include real-time tension value, tension change rate, current coil moving speed, historical tension sequence, equipment operation state 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 construct 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 acquisition devices (such as laser displacement sensors, optical thickness gauges, etc.) on the equipment.

[0082] It should be noted that in terms of model selection, it is preferably to use support vector regression (SVR) or multi-layer feedforward neural network (such as three-layer BP neural network). The SVR model has good non-linear fitting ability, can handle small sample high-dimensional inputs, and is suitable for modeling the complex non-linear relationship between tension and deformation amount; while the neural network can show stronger expression ability in scenarios with sufficient samples and is suitable for actual environments with multi-factor coupling. The model is trained in a supervised learning manner, with tension and speed data as inputs and measured deformation 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 an optimization algorithm (such as gradient descent or Adam).

[0083] It should be noted that the model training process needs to go through sufficient iterations and cross-validation. When the error of the model on the training set tends to be stable, and at the same time, the error on the validation set also converges and there is no obvious overfitting or underfitting phenomenon, it can be regarded as the training completed. In practice, if the error change in 10 consecutive iterations does not exceed a preset threshold (such as 0.5%), or the validation set error is stable within the target error tolerance (such as the mean absolute error is less than 0.2mm), it is judged that the training is completed.

[0084] In a specific embodiment, after obtaining the deformation parameters, the system links them with the current moving speed of the coil, and further evaluates the interference degree of the deformation on the irradiation path of the UV light source. The moving speed of the coil, as a key variable affecting the exposure synchronization, the relative value between it and the deformation speed determines the following ability of the UV irradiation spot. The present invention introduces an interpolation algorithm at this stage to estimate the trajectory perturbation. Specifically, the system analyzes the relative displacement changes of the deformation points on the coil surface in the movement path in multiple consecutive time segments, combines with the real-time speed, judges the time and position when the deformation area enters the exposure area in the future, and finally obtains the predicted offset of the irradiation trajectory. This 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.

[0085] Specifically, although the calculated trajectory offset can guide the adjustment of the light source position, it is not sufficient to quantify the comprehensive influence degree of the deformation on the exposure quality. Therefore, the present invention introduces a deformation influence prediction model. This model uses a regression decision method to establish the correlation between the tension change, trajectory offset, deformation parameters and exposure quality defects, and outputs a unified quantification index "deformation influence value". This value is set as a floating point number between 0% and 100%, which is used to represent the influence level of the deformation on the exposure deviation risk under the current working conditions. The model can be constructed by using random forest regression or lightweight neural network, and the training data comes from the known exposure defect samples and tension abnormal data in the actual production line. During the actual operation of the system, the currently calculated trajectory offset, deformation distribution characteristics, deformation speed, tension change rate, etc. are input into the model to obtain the predicted deformation influence value. If this value exceeds the set threshold (such as 70%), the system will enter the UV light source compensation control process to quickly adjust the irradiation angle and spot shape.

[0086] Exemplarily, in an actual operation, the coil speed is 28 m / min, the tension jumps from 490 N to 550 N within 5 seconds, exceeding the set threshold of 50 N, and the system triggers the prediction module. The non-linear regression model predicts that there is a concentrated deformation in the middle of the coil according to the historical tension-deformation data, the deformation amount is 1.9 mm, the deformation speed is 0.1 mm / s, and the direction is close to the longitudinal axis. Combining with the current speed, the interpolation algorithm estimates that the light source trajectory will shift to the right by about 1.2 mm. Then, after inputting into the prediction model, the system obtains a deformation influence value of 74%, determines it as medium-high risk, and automatically calls the subsequent control module to adjust the light source irradiation path.

[0087] It should be noted that the preset deformation influence prediction model of the present invention is mainly used to map intermediate parameters such as trajectory offset, deformation distribution, and speed change into the final "deformation influence value", that is, a comprehensive index that can represent the exposure risk level under the current state. The establishment of this model requires the introduction of annotation data related to product quality, specifically including: the exposure defect areas identified by the system under historical working conditions (such as pattern misalignment, ghosting, blurring, etc.), and the associated parameter data such as tension, speed, and deformation. The model learns the internal relationship between these variables and the exposure result through training.

[0088] Specifically, in terms of the modeling method, it is recommended to use a random forest regression model or a lightweight neural network, because they have strong feature selection ability and fault tolerance ability, and are suitable for data with partial missing or errors in industrial scenarios. The model training depends on a large number of mass annotation samples. The training goal is to enable the model to output a stable deformation influence value score (such as 75%) after receiving new prediction inputs (such as an offset of 1.5 mm, a deformation distribution feature of eccentric type, a deformation speed of 0.12 mm / s, etc.), for the control system to perform hierarchical response. For the training termination judgment criterion of this model, similar to the above, it is also necessary to combine the convergence of the training error and the verification error. When the prediction error of the model for a number of typical samples in the past is stably maintained within 5%, and the coincidence rate between the actual control decision and the exposure result is higher than 95%, it can be considered that the model training reaches the engineering available level. The model parameters after training will be solidified and uploaded to the control system for online inference in the subsequent operation stage.

[0089] In step S13, it is necessary 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:

[0090] According to the deformation influence value, analyze the deformation distribution of the coil by using the finite element method to obtain the deformation distribution parameters;

[0091] Input the deformation distribution parameters into a PID controller controlled by a PID algorithm to obtain the control output value for adjusting the UV light source;

[0092] According to the control output value, adjust the irradiation angle and spot shape parameters of the UV light source to obtain the adjusted light intensity value;

[0093] Based on the spot geometric shape optimization algorithm and the light intensity value, calculate the geometric value of the spot shape;

[0094] When the geometric value is synchronized with the preset deformation distribution of the coil, determine the light intensity value corresponding to the geometric value as the light intensity distribution value.

[0095] First, based on the deformation influence value obtained in step S12, the system determines the degree of interference caused by the current deformation on the surface of the coil to the exposure quality. If this value exceeds the risk threshold preset by the system (for example, set to 70%), it indicates that the deformation has caused obvious deviation or energy imbalance in the UV light source irradiation area. The system will immediately enable the finite element analysis module to perform spatial structure modeling on the current coil state to predict the detailed distribution of its surface deformation.

[0096] In a specific embodiment, finite element analysis (FEM) is a commonly used engineering modeling method. It indirectly reflects the overall stress state of the entire structure by dividing a continuous structure (such as a coil) into a finite number of small regions (i.e., elements) and solving the mechanical response on these small regions. In the present invention, FEM is used to establish a two-dimensional stress-strain field model, that is, a region of interest (such as a rectangular region with a length of 100 mm and a width of 50 mm) is selected on the surface of the coil as the calculation object, and the distribution of the deformation amount in this region is simulated and deduced.

[0097] Specifically, the system first constructs boundary conditions and initial loads based on the tension change value, coil movement speed, deformation speed and direction collected by the sensor. The tension change amount 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, and the movement speed determines the load application time and dynamic inertial boundary conditions. If the coil is running at a high speed (for example, greater than 25 m / min), the system will consider the dynamic load effect and introduce a velocity-related inertia term.

[0098] In a specific embodiment, the system divides the area into a grid, preferably using quadrilateral elements, each with a size of 1mm × 1mm, which can form 5000 discrete elements to achieve the local capture accuracy of deformation. The denser the grid, the higher the simulation accuracy, but the corresponding computational resources also increase. The present invention adopts a weighted adaptive grid strategy in industrial implementation, that is, automatically refining the grid in the area where the predicted deformation is concentrated, while maintaining coarser elements in the edge stable area to balance computational efficiency and accuracy. During the solution process, the system obtains the deformation amount of each point in the overall area by solving the stress-strain response of each element after loading the tension. The solution results include the following two types of core outputs: Deformation Matrix: Records the deformation amount values (in mm) of each element in the two-dimensional area of the coil surface, forming a complete numerical distribution map. This matrix reflects the intensity change of deformation in space and can be visualized through a heat map for subsequent shape spot matching. Deformation Direction Field: Records the direction angle (in °) of the main deformation of each element, forming a vector field. This information can be used to determine whether the light source irradiation direction needs to be deflected accordingly, so as to improve the energy projection consistency. For example, in an actual calculation, after the tension on the right side of the coil rises from 480N to 545N, a deformation band with a width of about 15mm and a length of about 60mm is found in the middle right area through finite element analysis, with a maximum deformation amount of 2.1mm and a direction angle of about 80° (i.e., close to perpendicular to the moving direction of the coil). Such a long and narrow deformation area will cause the light spot of the UV light source to deviate seriously from the center in this area. If no compensation is made, it is very easy to cause insufficient exposure dose in this area.

[0099] In a specific embodiment, the system encodes the deformation characteristics of the area into "deformation distribution parameters" according to the above matrix and direction field, including: maximum deformation amount, 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, ensuring that the UV spot can accurately cover the deformed area and compensate for the light energy distribution.

[0100] In a specific embodiment, the deformation distribution parameters obtained from the above analysis are used as feedback inputs, 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, and its core idea is to calculate the control quantity 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 ideal spot shape and irradiation angle as the target values, compares the actual deformation distribution with the target state, and calculates the "deviation amount" of the current exposure path. For example, in a certain area of the coil, there is obvious stretching, resulting in incomplete coverage of the original spot. The system compares the deformation amount with the preset spot contour and finds that there are angle deviations and area mismatches. The PID controller combines the proportional gain (Kp), integral gain (Ki), and derivative 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 angle change amplitude (unit angle) and spot scaling factor (geometric parameter) for adjustment, that is, how much the UV light source needs to "rotate" and "compress / stretch" to adapt to the current deformation state.

[0101] In a specific embodiment, the PID parameters can be set by simulation debugging or automatic tuning methods. For example, before the equipment is put into operation, the Kp, Ki, and Kd parameters are tuned in a step response manner to ensure that the control system has the characteristics of fast response, no large overshoot, and minimum residual error under various tension fluctuations.

[0102] 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 variable lens groups, deformable mirrors, or numerically controlled gratings, etc. to achieve zooming and shape adjustment, forming various geometric contours from circular to elliptical, fan-shaped, etc. For example, if the PID output indicates that the irradiation angle needs to be shifted 3 degrees to the right and the spot is stretched 20% horizontally, 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 long axis of the ellipse to ensure complete energy coverage and correct angle incidence within the deformed area.

[0103] In a specific embodiment, after the system completes the dynamic adjustment of the UV light source irradiation angle and spot shape, to ensure that the adjustment result precisely matches the actual deformation state of the coil surface, the system uses a feedback mechanism to confirm the current spot state in real time. This feedback process can be achieved in two ways: One is to use an industrial camera and an image acquisition device installed in the light source output channel or above the coil surface to collect the irradiation image in real time, and combine image processing algorithms (such as edge recognition, center positioning, contour extraction, etc.) to obtain the actual contour of the current spot; The other 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 deduce the theoretical geometric shape of the current spot. Regardless of which method is used, 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, ellipticity (i.e., the ratio of the major and minor axes), the position of the spot centroid in the coordinate system, and edge smoothness. Among them, edge smoothness is used to determine whether there are obvious discontinuous transitions or energy mutation regions in the spot. If there are burr-like or irregular contours, further optical focusing or contour calibration is required.

[0104] Specifically, after the system obtains the current spot geometric parameters, it needs to perform a spatial alignment comparison with the target deformation region obtained by the finite element method. During the alignment analysis process, the system evaluates its "spatial coverage matching degree" based on the coordinate error between the spot center point and the centroid of the deformation region, as well as the geometric overlap degree between the elliptical contour and the deformation boundary. This matching degree is obtained by statistically calculating the ratio of the overlapping area between the spot region and the target deformation region. 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 in space is uniform. For this purpose, the system statistically calculates the light intensity at multiple sampling points within the spot region, calculates the difference ratio between the central light intensity and the edge light intensity, and sets an allowable fluctuation range of ±10%. If the detection result shows that the energy distribution is within this range, it means that while the system adjusts the spot shape and angle, it also maintains a smooth transition of the irradiation energy without local overexposure or energy attenuation.

[0105] Specifically, if both of the above two conditions are met, that is, (1) the spatial coverage matching degree ≥ 95%, and (2) the deviation of light intensity energy uniformity ≤ ±10%, the system will confirm that the current geometric light spot and the target deformation area have achieved effective synchronous compensation. At this time, the system will solidify the current light spot shape parameters and the light intensity values corresponding to each area, and output them as the final "light intensity distribution value" to the control core for further optimizing the power distribution by the fuzzy control algorithm in the next stage. For example, in actual production, when a coil runs to the 37-meter position, the system identifies that a tensile deformation occurs in the middle and lower area (about the lower 1 / 3 area in the width direction) along the transverse direction. FEM analysis shows that the maximum deformation in this area is 2.0 mm, the coverage range is about 20 mm × 80 mm, and the direction deviates from the longitudinal direction by about 85°. Based on this, the PID controller outputs an adjustment command: deflect the irradiation angle of the UV light source 5° to the right, and at the same time expand the horizontal axis of the light spot by 30% to form an elliptical structure to cover the deformation area. After the adjustment is completed, the image system transmits the current light spot image back. The system analyzes that the overlap rate between its contour and the deformation area reaches 98%, and the light intensity difference between the center and the edge is 7.2%. Both indicators meet the preset synchronous judgment criteria. The system confirms that the adjustment is effective, and the current light intensity distribution value is adopted as the final compensation plan and pushed to the fuzzy control algorithm to perform power optimization control.

[0106] 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, and use the speed adjustment method combined with the real-time moving speed to perform speed adjustment, so as to obtain the optimized irradiation parameters, including:

[0107] Use the fuzzy control algorithm combined with the preset fuzzy control rule library and the light intensity distribution value to calculate the output intensity requirements of each area of the UV light source;

[0108] Based on the dynamic optimization algorithm combined with the output intensity requirements, calculate the power distribution plan of the UV light source;

[0109] According to the power distribution plan, dynamically adjust the light source irradiation parameters of the UV light source;

[0110] Apply the light source irradiation parameters to the controller of the UV light source, and continuously adjust the exposure dose of the coil area until the preset exposure threshold is reached;

[0111] When the exposure dose of the coil area reaches the preset exposure threshold, determine the light source irradiation parameters corresponding to the exposure dose as the optimized irradiation parameters.

[0112] First, the system structurally processes the light intensity distribution values output in the previous step and maps them to multiple two-dimensional irradiation regions corresponding to the spatial layout of the UV light source array module. Each region has two basic parameters: one is the "current actual light intensity value", which is obtained by real-time acquisition through light source power control feedback or a light intensity sensor; the other is the "target light intensity reference value", which is calculated by the aforementioned deformation prediction and PID compensation module and represents the energy distribution value that the region should obtain in the theoretically optimal state. By subtracting the current value from the target value, the system obtains the "light intensity deviation"; and by taking the difference between this deviation value and the deviation in the previous time period, the "light intensity deviation change rate" is further obtained.

[0113] Specifically, the above two values together constitute the input variables of the fuzzy controller. For the convenience of 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, when the light intensity deviation is below -15%, it is determined as "negative large", between -15% and -5% as "negative medium", within ±5% as "zero", and so on. These level divisions are modeled through triangular or trapezoidal membership functions, enabling the input variables to simultaneously have a certain "membership degree" in multiple levels.

[0114] Specifically, the system determines the corresponding output adjustment strategy by looking up the preset fuzzy rule base according to the fuzzy levels of the input variables. 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 stage, or can be optimized through online learning in a data-driven manner during the operation of the device. Every time the system receives a new deviation value, it activates all matching rules through the fuzzy inference mechanism and calculates the comprehensive membership degree of each output level. After fuzzy inference, the system needs to convert the output level into a specific executable numerical value. For this purpose, the system uses a defuzzification method (such as the centroid method, the maximum membership degree method, etc.) to convert the fuzzy output set into a definite digital quantity, that is, the intensity adjustment value required for this region, expressed as a percentage. For example, if the result "increase by 8%" is obtained after defuzzification, the system will correspondingly increase the current output intensity of the UV light source in this region.

[0115] To specifically illustrate this control process, the following is an example in practical applications:

[0116] 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.

[0117] 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.

[0118] 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.

[0119] In a specific implementation, the system regards the adjusted expected intensity values of each region output by the fuzzy controller as "reference power targets", forming a high-dimensional vector, which serves as the guiding direction for the optimization problem. Subsequently, based on the current state of the system, historical operation data, and external input variables (such as ambient temperature, current coil material type, etc.), the system runs a dynamic optimization algorithm within the set variable space to obtain a set of optimal power distribution schemes. The preferred optimization algorithms of the present invention include the Particle Swarm Optimization (PSO), Genetic Algorithm (GA), or the L-BFGS algorithm based on the quasi-Newton method. The above algorithms all possess high-dimensional search capabilities and good convergence characteristics, and can quickly obtain approximate optimal solutions that meet various constraints under complex objective functions.

[0120] Exemplarily, taking the Particle Swarm Optimization algorithm as an example, each "particle" represents a complete set of power distribution schemes. By simulating the movement and experience learning process of individuals in the population, the particles continuously search for the optimal position in the solution space; the system calculates the objective function values in each round of iteration, including the total power consumption function, the regional exposure uniformity evaluation function, and the power balance function, etc., to evaluate 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 the search. This process continues until the change in the objective function is lower than 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 distribution ratios, covering all UV light source modules. For example, under a certain specific working condition, the system identifies that the irradiation intensity in the middle region needs to be increased by 10%, while the left and right regions are reduced by 5% respectively. However, at this time, the middle module is already close to the maximum power limit, and continuing to increase it will cause overload. During the execution of the optimization algorithm, it is found that keeping the power in the middle unchanged and moderately increasing the power in the edge regions by 3% can maintain the overall exposure uniformity within ±5%, and at the same time, the total power consumption of the system is reduced by 2% compared to the initial scheme. Finally, this alternative distribution scheme is determined as the current optimal solution. Such a "compensatory adjustment" can effectively avoid the problem of being unable to complete the fuzzy control output target due to local power limitations.

[0121] Specifically, after the optimization scheme 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 the parameters in combination with the specific hardware execution structure (such as constant current source control, PWM dimming, voltage-current integrated regulation, etc.). The entire process can be completed within 100 ms, ensuring that the system operates at a nearly real-time response level. At the same time, this power distribution scheme will be saved as the power configuration model under the current working condition for direct calling in subsequent similar working conditions, improving the operation efficiency and response stability of the system.

[0122] In a specific implementation, after optimization, the system converts the global power distribution scheme into a specific control instruction set that the light source control system can recognize and execute, and distributes 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 set value, voltage control signal, PWM (pulse width modulation) duty cycle parameter, 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 state and achieve refined power regulation.

[0123] Specifically, for different types of UV light sources, the system supports multiple control interfaces and dimming mechanisms. For example, for the mainstream LED array type UV light source, the system controls the working current of each LED channel through a precision current driver to achieve direct intensity control. This method has a fast response and high linearity, and is suitable for high-precision exposure processes with strict control requirements for energy density. 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 duration, taking into account both output intensity and life management.

[0124] Specifically, for an LED system that has both analog dimming and PWM digital dimming functions, the system controller will comprehensively adopt a dual-channel dimming strategy according to the power demand and response timing: the analog voltage signal is used for coarse adjustment to achieve a rapid and large change in power output; the PWM signal is used for fine adjustment to achieve fine control through duty cycle fine-tuning. This can keep the spot transition smooth during the switching process and avoid local exposure mutations caused by too rapid changes.

[0125] Specifically, for traditional mercury lamps or laser UV light sources, the present invention controls them through the drive voltage, dimming current or Q-switch frequency of the high-voltage ignition controller or laser power module. The response time of these light sources is slightly slower, 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.

[0126] Specifically, the control instructions are sent by the master 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 cycle of issuing and executing the entire control instruction 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 web moving environment. After the instruction is executed, each UV module enters an adjustment state according to the new power setting, and the system maintains this irradiation configuration and continuously monitors whether the output intensity of each region reaches the optimization target. The present invention preferably sets a light intensity feedback sensor (such as a UV detection diode array or a fluorescence response material) below each light source array or on the back of the web, and real-time detects whether the irradiation energy meets the set dose requirement through sampling and reading back.

[0127] It should be noted that if the system detects that the light intensity deviation in individual areas exceeds the set threshold (such as ±8%), the local fine-tuning compensation mechanism will be immediately triggered, and the fuzzy controller will be called again to perform incremental adjustment on this area and update the power output value. This feedback closed-loop control mechanism enables the system to stably maintain the balance and consistency of the exposure dose in each area even under the influence of complex factors such as equipment aging, environmental temperature fluctuations, or light source characteristic changes. For example, in a certain actual operation, the power setting for the middle area output by the optimization module is 1200 mW / cm², and the system sets the duty cycle to 80% through the PWM control signal, corresponding to a current output of 3.2 A. After the control instruction is issued, the feedback sensor detects that the UV light intensity in this area is only 1150 mW / cm², with a 4.2% deviation from the target. The control system automatically increases the PWM duty cycle to 84% and the current to 3.35 A, completes the closed-loop fine-tuning, and finally stabilizes the light intensity in the range of 1178 - 1215 mW / cm² to achieve the control target.

[0128] In a specific implementation, in order to verify whether the irradiation parameters after the UV light source adjustment achieve the desired exposure control effect, the present invention introduces an exposure dose detection module in the UV illumination system to monitor and dynamically feedback the cumulative exposure dose (in mJ / cm²) of each area on the surface of the coil in real time. This module calculates the cumulative amount of UV energy per unit area to determine whether the current exposure dose meets the preset processing technology requirements, thereby realizing the verification and correction of the light source power adjustment strategy.

[0129] Specifically, in terms of hardware implementation, the exposure dose detection module can adopt various structural forms. Preferably, several UV photodetector arrays are arranged below the UV irradiation system or on the back of the coil, whose response wavelength band matches the main emission wavelength band of the light source (such as 365 nm, 385 nm, 405 nm, etc.), and the sampling values are calculated by time integration through an integration circuit or a digital signal processing chip; in some special materials or environments, the system can also adopt a photosensitive coating comparator to estimate 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 to estimate the local area UV energy absorption value through laser scanning irradiation and fluorescence reflection intensity collection to achieve high-resolution two-dimensional dose monitoring.

[0130] Specifically, during operation, the system integrally samples the exposure dose within each control cycle and performs time-weighted accumulation in combination with the system control cycle (such as every 100 ms) to obtain the current cumulative exposure amount in each area. Subsequently, this value will be compared with the pre-set target dose range. For example, the required cumulative exposure amount for 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 amount in 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 this area (here -35 mJ / cm²) to the fuzzy controller and the power optimization module, triggering a new round of local intensity adjustment instructions, and the system will thus enter the closed-loop correction process. To balance the control effect and 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, the batch of photosensitive materials, or the equipment operating environment. Such abnormalities are common in situations such as light source aging, lens fouling, and material photosensitivity failure. The alarm can be issued through the HMI interface, the sound and light indicator, or the docking method of the MES system, and the log will be recorded for traceability. If the exposure doses of all areas enter the set target range, the system will consider that the current light source power configuration and dimming strategy are effective under this working condition, and solidify the current parameter combination (including power distribution, irradiation angle, response time, PWM duty cycle, etc.) into the "optimized irradiation parameter model". This model can be stored together with the associated tags such as the corresponding coil specifications, running speed, material types, etc. The system will directly call this model when encountering a similar working condition in the future, skipping the fuzzy-optimization-feedback cycle, greatly improving the operation 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 monitors that the cumulative exposure amount in a certain area is only 375 mJ / cm², and the system triggers the first fine adjustment to increase the output power of this area by 6%; after re-detection, it is still 386 mJ / cm², and the system triggers the second round of fine adjustment and further increases the PWM duty cycle by 5%. Finally, after the third adjustment, the exposure amount reaches 398 mJ / cm², and the system confirms it as qualified and stores the configuration model of this time in the database with the label of "high-speed low-tension working condition - blue film - 30 m / min". If the subsequent production enters a similar state again, the system can directly call this model to achieve disturbance-free switching and fast and stable control.

[0131] In a specific implementation, after calculating the output intensity requirements of each area of the UV light source by using the fuzzy control algorithm according to the light intensity distribution value to obtain the optimized irradiation parameters, the method further includes:

[0132] Calculating the rate of change of speed according to the real-time moving speed;

[0133] When the rate of change of the speed is greater than a preset speed threshold, a quadratic fitting algorithm is adopted to dynamically adjust the response time parameter, and a power distribution scheme of the UV light source is calculated based on the response time parameter;

[0134] Dynamically adjust the light source irradiation parameters of the UV light source according to the power distribution scheme;

[0135] Apply the light source irradiation parameters to the controller of the UV light source, and continuously adjust the exposure dose of the coil area until the preset exposure threshold is reached;

[0136] When the exposure dose of the coil area reaches the preset exposure threshold, determine the light source irradiation parameters corresponding to the exposure dose as the optimized irradiation parameters.

[0137] In a specific embodiment, the system performs preliminary exposure optimization according to 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, so as to obtain the optimized irradiation parameters. At this time, the goal of the system is to ensure uniform distribution of the exposure dose on the surface of the coil 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.

[0138] Specifically, in some high-speed and sudden operation scenarios, static optimization relying only on the light intensity distribution cannot meet the process requirements. At this time, the system further calculates the rate of change of the speed according to the real-time moving speed of the coil. The rate of change of the speed refers to the amplitude of the speed change of the coil per unit time, which reflects the sudden change of the movement state of the coil. By calculating the acceleration or deceleration of the coil, the system can judge whether it is in a non-steady state working condition such as sudden stop, sudden start or high-speed mutation.

[0139] Specifically, when the system detects that the rate of change of the speed is greater than the preset threshold, it means that the coil is experiencing high-speed changes or emergencies, resulting in instability of the exposure dose and exposure time, which may in turn cause uneven exposure, pattern ghosting or other quality problems. In this case, the system starts a dynamic optimization mechanism and uses a quadratic fitting algorithm to perform fitting analysis on the speed-time series of the coil. This algorithm predicts the speed change trend in the next few seconds based on historical data and dynamically adjusts the response time parameter of the UV light source. By predicting the future acceleration or deceleration trend of the coil, the system can make a pre-judgment on the light source power adjustment in advance, ensuring that when the coil speed changes violently, the energy output of the light source can be adjusted synchronously, avoiding exposure imbalance caused by light source response delay.

[0140] It should be noted that the response time parameters include various 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 predicted speed change trend of 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 under-exposure problem caused by too short exposure time during the acceleration process; if it is predicted that the web enters the deceleration stage, the system can appropriately delay the response time to avoid over-exposure in local areas caused by too fast power regulation.

[0141] In a specific embodiment, based on the adjusted response time parameters, the system recalculates and generates a new power distribution scheme. This scheme will further optimize the power output of each UV light source module to ensure that the light source can accurately provide the required exposure energy during the speed change of the web. 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; while when decelerating, the system will reduce the light source power and extend the response time to avoid over-exposure.

[0142] Specifically, once the system generates a new power distribution 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. 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.

[0143] 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 complete the exposure compensation for the local area. Finally, after multiple rounds of adjustment and correction, the system will set this group of parameters as the "optimized irradiation parameters" under the current working conditions and store them in the control model database for quick call in similar working conditions. This optimization process not only improves the consistency of exposure quality but also enhances the adaptive ability of the system to different operating modes.

[0144] Exemplarily, during a certain production process, the web accelerates from 25 m / min to 35 m / min, and the speed change rate reaches 5 m / min², exceeding the preset threshold of ±2.5 m / min². 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 and adjusts the power of the edge area to increase by 15%. At this time, the light source can synchronously follow the speed change of the web to ensure that the exposure effect remains uniform.

[0145] It should be noted that in a high-speed dynamic operation scenario, the moving speed of the coil material undergoes instantaneous changes due to factors such as tension fluctuations, instability of the winding / unwinding system, material non-uniformity, or mechanical vibrations. When the coil material speed undergoes a large acceleration or deceleration, it will directly cause a change in the action time of the UV exposure energy per unit area, resulting in fluctuations in the regional exposure dose, and further leading to phenomena such as pattern blurring, ghosting, under-exposure, or over-exposure. To enhance the system's adaptive ability to such disturbances, the present invention further introduces a speed change rate feedback mechanism in the UV illumination control system to dynamically adjust the light source response parameters and achieve synchronous matching of "speed - energy".

[0146] Specifically, during system operation, the coil material speed is collected in real time through a high-precision rotary encoder or a linear speed sensor, and the sampling frequency is preferably 50 - 200 Hz to ensure sensitive capture of sudden changes. The system calculates the instantaneous speed change rate (i.e., acceleration or deceleration), with the unit of m / min², by calculating the speed data at the current moment and the previous time period. Further, the system constructs a "speed - time" discrete sequence using the speed data of the past consecutive seconds, and uses a quadratic fitting algorithm to perform regression modeling on this sequence, extracts the current speed change trend (such as linear growth, slow decline, fluctuating oscillation, etc.), and predicts the speed trend range in the short term in the future.

[0147] Specifically, the system sets a speed disturbance recognition threshold, such as ±2.5 m / min², as the judgment basis for identifying abnormal operating states. Once it is detected that the speed change rate exceeds this threshold, the system immediately considers the current operation to be in a "high-dynamic disturbance state", and at this time, the speed disturbance prediction module is immediately activated. According to the results of the fitting model, if the prediction shows that the coil material will continue to accelerate in the next 3 - 5 seconds, it means that the irradiation time per unit area will continue to shorten, and if no compensation adjustment is made, it is likely to cause under-exposure; if it shows a deceleration state, it will cause energy accumulation and lead to local over-exposure.

[0148] Specifically, to cope with this dynamic change, 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 adjustment response delay (such as the time when the duty cycle change takes effect), LED drive on / off response time (such as MOS transistor conduction time), thermal stability delay time, etc. The system dynamically modifies these response parameters according to the speed prediction trend: shortening the response time in the acceleration state to enhance the response rate of UV energy adjustment; extending the response rhythm in the deceleration state to avoid energy fluctuations caused by too fast power switching.

[0149] 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".

[0150] 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.

[0151] 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:

[0152] 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;

[0153] 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;

[0154] 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.

[0155] 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.

[0156] 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 above the coil material. This module consists of multiple high-sensitivity UV light sensor arrays. Each sensor monitors a spatial position segment correspondingly, and can continuously sample each position point of the coil material during the process of passing through the exposure segment. By means of integral calculation, the total irradiation energy value received per unit area is obtained, and the unit is mJ / cm². If there is no direct sensing device installed on the coil material, the system can also estimate the integral of the light intensity value and the irradiation time through a simulation method, and obtain the actual measurement value after correction in combination with the running speed of the coil material.

[0157] Specifically, the system divides the surface of the coil material into several grid-like detection units in space. For example, a coil material with a width of 600 mm is divided into small areas of 20 mm × 20 mm per grid, 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 corresponding to its position, so as to judge whether it deviates from the target energy range at present. To achieve this comparison process, the present invention sets two groups of key thresholds: overexposure threshold and underexposure threshold. These two groups of thresholds are symmetrically set around the target exposure dose, forming a "tolerance band" that allows energy fluctuations.

[0158] Specifically, the threshold setting method is diverse and is closely related to the type of photosensitive material used in the coil material, the requirements of the exposure process, and the subsequent curing characteristics. For example, for electronic thin film circuit materials, the target exposure dose is set to 400 mJ / cm². 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 cases where the precision mask process or the high-resolution pattern exposure requirements are more stringent, the tolerance is narrowed to ±2.5%. At this time, the threshold is only in the range of 390 - 410 mJ / cm². The threshold can be directly set by the user in the process configuration interface, can also be automatically loaded by the system calling the historical process database, and can even be dynamically deduced through an algorithm based on the material model and the photosensitive response curve.

[0159] Specifically, during actual operation, the system automatically compares the exposure value of each grid area with the above thresholds. When the exposure value of a certain area is greater than the overexposure threshold, it indicates that the area receives excessive energy, and the system marks it as an "overexposure area"; when the exposure value is lower than the underexposure threshold, it indicates that the energy is insufficient, resulting in incomplete pattern transfer, and the system marks it as an "underexposure area"; while all areas between the two thresholds are regarded as "qualified exposure areas". This recognition process is based on spatial coordinates, specifically locates the abnormal areas, and generates a two-dimensional exposure deviation map for the next feedback compensation module to use.

[0160] Exemplarily, during a mass production process, the system detected that the exposure dose of a certain grid in the middle region of the web width reached 448 mJ / cm², while its target dose was 400 mJ / cm², and the overexposure threshold was set at 420 mJ / cm². Therefore, the system marked this region as overexposed. At the same time, the detected dose at the upper right corner was only 374 mJ / cm², lower than the underexposure threshold of 380 mJ / cm², and was also identified as underexposed. The system summarized these results to form an "abnormal area list" and displayed it in the form of color markings on the user monitoring interface. Red indicates overexposure, blue indicates underexposure, and green indicates the normal area, and these are used as feedback input parameters for subsequent compensation control modules to process.

[0161] 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 the preset standard range, including:

[0162] Extract the cumulative exposure values of the overexposed area and the underexposed area to obtain the overexposure value and the underexposure value;

[0163] Calculate the differences between the overexposure value and the underexposure value and the preset standard threshold respectively to obtain the exposure differences;

[0164] Based on the exposure differences, dynamically optimize the light source mode, generate light source control parameters, and apply the control parameters to the controller of the UV light source. When the exposure difference is less than the preset difference threshold, it is determined that the exposure quality of the area reaches the preset standard range.

[0165] First, the system extracts the cumulative exposure values of the identified overexposed area and underexposed area. These values are collected in real time by the UV dose detection module, which reflects the ultraviolet energy received per unit area and is 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 a certain area is 428 mJ / cm², and the standard target dose of this material is 400 mJ / cm², then the exposure difference is +28 mJ / cm², representing overexposure; if the value is 368 mJ / cm², then the difference is -32 mJ / cm², representing underexposure.

[0166] In practical applications, the present invention preferably determines the preset target exposure dose value and the allowable error range (i.e., the preset standard range) in the following setting manner: For photosensitive materials with medium sensitivity (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 from 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 440–460 mJ / cm²; The specific setting method of the threshold can be input through the formula, imported from the process parameter file, or automatically called by the system's built-in material database.

[0167] Specifically, according to the above settings, the system compares the actual exposure value with the target value. If the absolute value of the difference is higher than the allowable error range, it is regarded as "unqualified exposure" and needs to enter the compensation adjustment process.

[0168] In a specific embodiment, the system uses the exposure difference of each region as an input variable, combines the current light source output parameters of this region, 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 drive current or PWM duty cycle, increase or decrease the light source energy of this region; Irradiation angle adjustment: Optimize the light source inclination angle to adapt to the micro-deformation of the coil surface and ensure that the effective energy is concentrated; Spot geometric shape adjustment: Adjust the ratio of the long axis / short axis of the ellipse and the offset position to ensure that the spot matches the target area; Exposure time fine-tuning (if synchronous trigger control is supported): In a dynamic system, the exposure time can be locally extended or shortened; Refinement of light source response parameters: Such as starting in advance, high-speed power up and down control, to achieve fast compensation in the time domain.

[0169] Exemplarily, taking the output intensity adjustment as an example, if the exposure value of a certain region is 370 mJ / cm², the target is 400 mJ / cm², and the under-exposure is 30 mJ / cm². According to the system experience model or the linear ratio method, the system can set that every 1% increase in power brings about a 4 mJ / cm² dose increase, so 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 2.8 A to 3.0 A, and at the same time adjusts the lateral expansion of the spot by 0.5 mm to expand the irradiation coverage range.

[0170] In a specific embodiment, the optimized parameters will be sent to the light source controller through the bus communication interface to complete the fine adjustment at the hardware level. The system then continues to perform a secondary detection on the adjusted region through the light intensity monitoring module and recalculates the current exposure difference.

[0171] In a specific embodiment, the present invention sets an exposure difference threshold for determining whether the adjustment is effective, which is preferably set at ±2.5% of the target dose. Taking the target of 400 mJ / cm² as an example, the allowable range of exposure difference is ±10 mJ / cm². Only when the difference after adjustment is lower than this threshold, that is, the final dose is between 390–410 mJ / cm², does the system consider that the exposure quality of this area meets the standard. If the requirements are still not met, the system can repeat the fine-tuning up to two rounds. If it still cannot meet the standard, a warning is triggered to indicate that there is a decrease in light source performance or material abnormality. For example, in a specific implementation case, the initial exposure value in the upper right corner area of the coil is 372 mJ / cm². The system first adjusts the PWM from 72% to 77%, and the dose increases to 388 mJ / cm². In the second round of fine-tuning, the duty cycle is increased to 79%, and the final dose reaches 396 mJ / cm², with a difference of -4 mJ / cm², meeting the set standard of ±10 mJ / cm². The system confirms that the exposure meets the standard and writes this compensation scheme into the "local optimization model" database for rapid automatic correction and call in subsequent similar deformation situations.

[0172] 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 central value, a floating dose allowable range is set to define the states of "normal exposure", "overexposure" or "underexposure". 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 a compensation mechanism for secondary adjustment. Therefore, its configuration should have executability, traceability and self-adaptability.

[0173] Specifically, the setting of the preset standard range is determined based on a comprehensive consideration of three types of factors. The first type is the photosensitive response characteristics of the material itself. Different photosensitive materials have different dose tolerances for UV irradiation. For example, ordinary UV curable resins have a relatively high tolerance to fluctuations in exposure dose, 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 pattern transfer, the exposure error needs to be controlled within ±10 mJ / cm² or less to meet the requirements of pattern edge clarity and microcircuit consistency. At this time, if the target exposure dose is 450 mJ / cm², the standard range is set to 440–460 mJ / cm².

[0174] Specifically, the second type of influencing factor is the process grade of the product. The system supports automatically loading the corresponding process templates according to different production tasks, corresponding to different levels of error tolerances. For example, the exposure dose tolerance for products of the regular grade can be set to ±5% of the target value for stable control during mass production; while for precision processes or functional film layer samples, the tolerance can be controlled to ±2.5% or even lower to achieve high-contrast and high-fidelity pattern quality. The user can also manually set this range in the system control interface to meet the requirements of special processes or experimental products.

[0175] Specifically, the third type of setting basis comes from the dynamic correction ability of the system operation status. When the system detects that it is in a high-speed operation state or there are unstable operation conditions such as frequent start and stop, it causes fluctuations in the light exposure time of the coil. To avoid misjudgment, the present invention can automatically expand the standard range appropriately. For example, when the speed change rate exceeds 4 m / min², the standard range is expanded by 5 mJ / cm² to enhance the system's fault tolerance for dynamic disturbances; conversely, when the system runs stably for more than a certain period (such as continuous operation for 10 minutes without disturbance), it automatically returns to the default accuracy range to ensure that the exposure control is always in the optimal state.

[0176] Specifically, in the system execution determination logic, the surface of the coil is divided into several two-dimensional region units. The system collects the cumulative exposure dose of each region 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), this region is marked as "overexposed"; if it is lower than the lower limit (such as <380 mJ / cm²), it is determined as "underexposed"; only when the actual value falls within this range, the system confirms that the exposure of this region is qualified. This determination result will directly affect whether to trigger the local fine-tuning control process in step S16. For example, during a mass production process, the system identifies that the coil material is a medium-sensitivity UV photosensitive layer, the target exposure dose is set to 400 mJ / cm², and the allowable deviation is ±20 mJ / cm². The system sets the standard range to 380–420 mJ / cm². The cumulative exposure value collected in a certain region is 368 mJ / cm², which is 12 mJ / cm² lower than the lower limit value. The system marks it as an underexposed region and triggers the local optimization process; the value in another region is 414 mJ / cm², which is within the standard range, and the system determines that its exposure is qualified and no adjustment is required.

[0177] In summary, the present invention provides a UV illumination control method and system for a roll-to-roll exposure machine to achieve real-time response regulation of the coil tension and speed changes and solve the problem of uneven exposure dose.

[0178] Referring to Figure 2 , the second embodiment of the present invention provides a UV illumination control system for a roll-to-roll exposure machine, including:

[0179] A data acquisition module for acquiring the real-time moving speed and the tension change value of the coil material;

[0180] A deformation prediction module for predicting the deformation trend on the surface of the coil material based on a non-linear regression algorithm in combination 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;

[0181] An optical intensity distribution module for adjusting the irradiation angle and the spot shape parameters of a UV light source according to the deformation influence value by using a PID control algorithm to obtain an optical intensity distribution value;

[0182] An optimization parameter module for calculating the output intensity requirements of each region of the UV light source by using a fuzzy control algorithm according to the optical intensity distribution value, and performing speed adjustment in combination with the real-time moving speed by using a speed adjustment method to obtain optimized irradiation parameters;

[0183] A region determination module for performing an overexposure or underexposure region determination operation according to the optimized irradiation parameters to obtain an overexposure region and an underexposure region;

[0184] A quality optimization module for adjusting the illumination intensity and the optical intensity distribution of the UV light source for the overexposure region and the underexposure region until the region exposure quality reaches a preset standard range.

[0185] It should be noted that a UV illumination 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 a UV illumination control method of a roll-to-roll exposure machine in the above embodiment, and the working principles and beneficial effects of the two correspond one by one, so details will not be described herein again.

[0186] An 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 a region determination program. When the processor executes the computer program, the steps in the embodiments of the above UV illumination control method of each roll-to-roll exposure machine are implemented, such as Figure 1 the step S11 shown. Alternatively, when the processor executes the computer program, the functions of each module / unit in the above device embodiments are implemented, such as the region determination module.

[0187] Exemplarily, the computer program may be divided into one or more modules / units. The one or more modules / units are stored in the memory and executed by the processor to complete the present invention. The one or more modules / units may be a series of computer program instruction segments capable of performing specific functions, and the instruction segments are used to describe the execution process of the computer program in the electronic device.

[0188] The electronic device may be a computing device such as a desktop computer, a notebook, a palm computer, and a smart tablet. The electronic device may include, but is not limited to, a processor and a memory. Those skilled in the art can understand that the above components are only examples of the electronic device and do not constitute a limitation on the electronic device. It may include more or fewer components than the above, or combine certain components, or different components. For example, the electronic device may also include input / output devices, network access devices, a bus, etc.

[0189] The so-called processor may be a Central Processing Unit (CPU), or may also be other general-purpose processors, Digital Signal Processors (DSPs), Application Specific Integrated Circuits (ASICs), Field-Programmable Gate Arrays (FPGAs), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc. The general-purpose processor may be a microprocessor or the processor may also be any conventional processor, etc. The processor is the control center of the electronic device and connects various parts of the entire electronic device through various interfaces and lines.

[0190] The memory may be used to store the computer program and / or module. The processor realizes various functions of the electronic device by running or executing the computer program and / or module stored in the memory, and by calling the data stored in the memory. The memory may mainly include a program storage area and a data storage area. Among them, the program storage area may store an operating system, application programs required for at least one function (such as a sound playback function, an image playback function, etc.); the data storage area may store data created according to the use of the mobile phone (such as audio data, a phone book, etc.). In addition, the memory may include high-speed random access memory, and may also include non-volatile memory, such as a hard disk, a memory, a plug-in hard disk, a Smart Media Card (SMC), a Secure Digital (SD) card, a Flash Card, at least one magnetic disk storage device, a flash memory device, or other volatile solid-state storage devices.

[0191] Among them, if the modules / units integrated in the electronic device are implemented in the form of software functional units and sold or used as independent products, they can be stored in a computer-readable storage medium. Based on such an understanding, to implement all or part of the processes in the above-described embodiment methods of the present invention, it can also be completed by a computer program instructing relevant hardware. The computer program can be stored in a computer-readable storage medium. When the computer program is executed by a processor, the steps of the above-described various method embodiments can be implemented. Among them, the computer program includes computer program code, and the computer program code can be in the form of source code, object code, executable file, or some intermediate form, etc. The computer-readable medium can include: any entity or device capable of carrying the computer program code, recording medium, USB flash drive, mobile hard disk, magnetic disk, optical disc, computer memory, read-only memory (ROM), random access memory (RAM), electrical carrier signal, telecommunication signal, and software distribution medium, etc. It should be noted that the content included 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, the computer-readable medium does not include electrical carrier signals and telecommunication signals.

[0192] It should be noted that the device embodiments described above are merely illustrative. The units described as separate components may or may not be physically separated. The components shown as units may or may not be physical units, that is, they may be located in one place or distributed to multiple network units. Some or all of the modules can be selected according to actual needs to achieve the purpose of the solution 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 can be specifically implemented as one or more communication buses or signal lines. Those of ordinary skill in the art can understand and implement it without creative effort.

[0193] The specific embodiments described above have further elaborated on the purpose, technical solution, and beneficial effects of the present invention. It should be understood that the above description is only the specific embodiments of the present invention and is not used to limit the protection scope of the present invention. It is particularly pointed out that for those skilled in the art, any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.

Claims

1. A UV illumination control method for a roll-to-roll exposure machine, characterized in that, Including: Obtaining the real-time moving speed and the numerical value of the tension change of the coil material; When the numerical value of the tension change is greater than a preset tension change threshold value, predicting the deformation trend of the surface of the coil material based on a non-linear regression algorithm combined with the real-time moving speed to obtain a deformation influence value; According to the deformation influence value, adjusting the irradiation angle and the spot shape parameters of the UV light source by using a PID control algorithm to obtain a light intensity distribution value; According to the light intensity distribution value, calculating the output intensity requirements of each area of the UV light source by using a fuzzy control algorithm to obtain optimized irradiation parameters; According to the optimized irradiation parameters, performing an overexposure or underexposure area determination operation to obtain an overexposure area and an underexposure area; Adjusting the light intensity and the light intensity distribution of the UV light source for the overexposure area and the underexposure area until the area exposure quality reaches a preset standard range.

2. The UV illumination control method of the roll-to-roll exposure machine according to claim 1, characterized in that The step of, when the numerical value of the tension change is greater than a preset tension change threshold value, predicting the deformation trend of the surface of the coil material based on a non-linear regression algorithm combined with the real-time moving speed to obtain a deformation influence value, includes: When the numerical value of the tension change is greater than a preset tension change threshold value, calculating deformation parameters based on a non-linear regression algorithm to obtain a deformation amount, a deformation direction, a deformation speed and a deformation distribution characteristic; Based on the deformation amount, the deformation direction, the deformation speed and the deformation distribution characteristic combined with the real-time moving speed, calculating the influence degree of the deformation on the irradiation trajectory of the UV light source by using an interpolation algorithm to obtain an offset of the light source trajectory; Inputting the offset into a pre-configured tension change prediction model to perform a prediction of the influence degree of the deformation amount to obtain a deformation influence value.

3. The UV illumination control method of the roll-to-roll exposure machine according to claim 1, wherein, The step of, according to the deformation influence value, adjusting the irradiation angle and the spot shape parameters of the UV light source by using a PID control algorithm to obtain a light intensity distribution value, includes: According to the deformation influence value, analyzing the deformation distribution of the coil material by using a finite element method to obtain deformation distribution parameters; Inputting the deformation distribution parameters 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 the spot shape parameters of the UV light source to obtain an adjusted light intensity value; Calculating the geometric value of the spot shape based on a spot geometric shape optimization algorithm combined with the light intensity value; When the geometric value is synchronized with the preset deformation distribution of the coil material, determining the light intensity value corresponding to the geometric value as the light intensity distribution value.

4. The UV illumination control method of the roll-to-roll exposure machine according to claim 1, characterized in that The step of, according to the light intensity distribution value, calculating the output intensity requirements of each area of the UV light source by using a fuzzy control algorithm to obtain optimized irradiation parameters, includes: Calculating the output intensity requirements of each area of the UV light source by using a fuzzy control algorithm combined with a preset fuzzy control rule base combined with the light intensity distribution value; Calculating a power distribution scheme of the UV light source based on a dynamic optimization algorithm combined with the output intensity requirements; According to the power distribution scheme, dynamically adjusting the light source irradiation parameters of the UV light source; Applying the light source irradiation parameters to the controller of the UV light source and continuously adjusting the exposure dose of the coil material area until a preset exposure threshold value is reached; When the exposure dose in the coil area reaches the preset exposure threshold, determine the light source irradiation parameters corresponding to the exposure dose as the optimized irradiation parameters.

5. The UV illumination control method of the roll-to-roll exposure machine according to claim 4, wherein, After calculating the output intensity requirements of each area of the UV light source using the fuzzy control algorithm based on the light intensity distribution value to obtain the optimized irradiation parameters, the method further includes: Calculate the rate of change of speed according to the real-time moving speed; When the rate of change of speed is greater than the preset speed threshold, adopt the quadratic fitting algorithm to dynamically adjust the response time parameter, and calculate the power distribution scheme of the UV light source based on the response time parameter; Dynamically adjust the light source irradiation parameters of the UV light source according to the power distribution scheme; Apply the light source irradiation parameters to the controller of the UV light source, and continuously adjust the exposure dose in the coil area until it reaches the preset exposure threshold; When the exposure dose in the coil area reaches the preset exposure threshold, determine the light source irradiation parameters corresponding to the exposure dose as the current optimized irradiation parameters.

6. The UV illumination control method of the roll-to-roll exposure machine according to claim 1, characterized in that The operation of determining overexposed or underexposed areas according to the optimized irradiation parameters to obtain overexposed areas and underexposed areas includes: Apply the optimized irradiation parameters to the controller of the UV light source to obtain the cumulative exposure values of each area on the surface of the coil; When the cumulative exposure value is greater than the preset overexposure threshold, determine the area corresponding to the cumulative exposure value as the overexposed area; When the cumulative exposure value is less than the preset underexposure threshold, determine the area corresponding to the cumulative exposure value as the underexposed area.

7. The UV illumination control method of the roll-to-roll exposure machine according to claim 1, characterized in that The operation of adjusting the light intensity and light intensity distribution of the UV light source for the overexposed area and the underexposed area until the area exposure quality reaches the preset standard range includes: Extract the cumulative exposure values of the overexposed area and the underexposed area to obtain the overexposure value and the underexposure value; Calculate the differences between the overexposure value and the underexposure value and the preset standard threshold respectively to obtain the exposure differences; Dynamically optimize the light source mode based on the exposure differences to generate light source control parameters, and apply the control parameters to the controller of the UV light source. When the exposure difference is less than the preset difference threshold, determine that the area exposure quality reaches the preset standard range.

8. A UV illumination control system for a roll-to-roll exposure machine, characterized in that, Including: A data acquisition module for acquiring the real-time moving speed and the tension change value of the coil; A deformation prediction module for predicting the deformation trend on the surface of the coil based on the non-linear regression algorithm combined with the real-time moving speed to obtain the deformation influence value when the tension change value is greater than the preset tension change threshold; A light intensity distribution module for adjusting the irradiation angle and spot shape parameters of the UV light source using the PID control algorithm according to the deformation influence value to obtain the light intensity distribution value; An optimization parameter module for calculating the output intensity requirements of each area of the UV light source using the fuzzy control algorithm according to the light intensity distribution value, and performing speed adjustment by combining the speed adjustment method with the real-time moving speed to obtain the optimized irradiation parameters; An area determination module for performing overexposed or underexposed area determination operations according to the optimized irradiation parameters to obtain overexposed areas and underexposed areas; A quality optimization module is used to adjust the illumination intensity and light intensity distribution of the UV light source for the overexposed area and the underexposed area until the area exposure quality reaches a preset standard range.

9. An electronic device, characterized in that, It includes a processor, a memory, and a computer program stored in the memory and configured to be executed by the processor. When the processor executes the computer program, it implements the UV illumination control method of the roll-to-roll exposure machine according to any one of claims 1 to 7.

10. A computer-readable storage medium, characterized in that, The computer-readable storage medium includes a stored computer program. When the computer program runs, it controls the device where the computer-readable storage medium is located to execute the UV illumination control method of the roll-to-roll exposure machine according to any one of claims 1 to 7.

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