A system and method for simultaneous measurement of multiple areal density gauges

Abstract

The application provides a system and method for synchronous measurement of multiple areal density measuring instruments, and relates to the technical field of synchronous measurement. The system comprises N areal density measuring instruments, each of which is respectively provided with a fixed position color mark sensor and a measuring head color mark sensor; a length measuring encoder for recording encoder information for identifying color mark positions; a controller for calibrating the front and rear instrument spacing by using the spacing between the two color marks in front of the instrument and the spacing between the two color marks behind the instrument; a first displacement sensor for measuring the surface of the substrate to obtain substrate position information, a second displacement sensor for measuring the edge of the substrate to obtain the edge distance, a laser ranging sensor installed on the rear instrument of the double instrument unit and distributed along the coating direction to measure the distance to the surface of the substrate to obtain the actual position of the substrate in the coating direction; and the controller is further used for controlling the rear instrument to perform synchronous measurement when the actual position is greater than or equal to the sum of the pre-stored position and the front and rear instrument spacing. The control method is simple and convenient for synchronous trajectory.

Description

Technical Field

[0001] This invention relates to the field of synchronous measurement technology, and in particular to a system and method for synchronous measurement using multiple surface density measuring instruments. Background Technology

[0002] Online detection of electrode areal density is a crucial process inspection step in the lithium-ion battery coating production process. The quality of electrode coating affects the consistency and safety of battery capacity. The lithium-ion battery electrode coating process requires online monitoring of electrode coating areal density to provide real-time information on electrode coating quality, enabling intelligent adjustment of the coating process based on big data analysis.

[0003] Patent CN114200079A discloses an electrode coating tracking measurement system and method. The system includes a controller, a first measuring device, a second measuring device, and a roller encoder. The controller is connected to the first measuring device, the second measuring device, and the roller encoder. The controller is used to acquire pulse signals and calculate the number of first pulses generated by the roller encoder after the first measuring device starts scanning and before the second measuring device starts scanning. When the number of first pulses is equal to a first preset value, the controller controls the second measuring device to start scanning. Because the measurement system uses one controller to control multiple measuring devices, it can reduce the communication delay between multiple measuring devices, ensure that the starting position of multiple scans is the same, and thus guarantee the accuracy of the measurement. At the same time, using a roller encoder to calculate the transmission length of the pole piece and control the scanning of the second measuring device can ensure that the scanning of the first and second measuring devices plays the same role. For multi-unit measurement and synchronous control of multiple measuring devices, using one controller and roller encoder results in a heavy computational burden on the controller and high real-time requirements for the operation of multiple threads. Moreover, if the field controller malfunctions, the roller encoder loses pulses, or a measuring device stops and resets abnormally, the entire multi-unit system will crash. Therefore, the synchronous fault tolerance between multiple units is poor, and the system robustness is insufficient.

[0004] Patent 202510073949.2 discloses a method, apparatus, equipment, and medium for synchronous measurement of areal density. The method includes: obtaining the travel length L1 between a first areal density meter and a second areal density meter during synchronous operation; obtaining the travel length L2 between the first and second areal density meters during actual operation; and determining the compensation value ΔL for the second areal density meter based on L1 and L2, where ΔL = (L1 - L2) / 2. In the actual measurement process, the second areal density meter is compensated by the compensation value ΔL, ensuring that the scanning trajectories of the first and second areal density meters overlap, thus allowing for accurate calculation of the coating's areal density. Only the belt direction during normal production of electrode coating, the longitudinal distance and compensation value of the two measuring instruments were considered. However, the measuring head (X-ray generator and X-ray detector) of the areal density measuring instrument is a transverse reciprocating scan. The reciprocating motion requires reversal time, and the measuring head needs to return to the origin periodically for zero-point calibration and standard sheet verification. The start time and position of the measuring head of each measuring instrument are closely related to the longitudinal coordinate value. Considering the possibility of electrode belt deviation, the transverse coordinate start position of the measuring head is not fixed each time, otherwise the scanning trajectory cannot be synchronized.

[0005] Therefore, this invention proposes a system and method for simultaneous measurement using multiple surface density measuring instruments. Summary of the Invention

[0006] This invention provides a system and method for simultaneous measurement using multiple surface density measuring instruments to solve the aforementioned technical problems.

[0007] This invention provides a system for simultaneous measurement using multiple areal density measuring instruments, comprising:

[0008] N areal density measuring instruments are provided, and each areal density measuring instrument is equipped with a fixed position color mark sensor and a measuring head color mark sensor. The N measuring instruments are arranged into N-1 dual-frame units.

[0009] The length encoder is used to mark the front frame with a marker pen when the coating machine is turned on normally in length measurement mode. The encoder information is recorded when the marker moves to the positions of the front frame measuring head color mark, the front frame fixed color mark, the rear frame fixed color mark, and the rear frame measuring head color mark. The distance between the two color marks on the front frame, the distance between the front and rear frames, and the distance between the two color marks on the rear frame are calibrated.

[0010] The controller is used to calibrate the distance between the front and rear frames using the distance between the two color marks on the front frame and the distance between the two color marks on the rear frame, and to control the coating machine to start working.

[0011] The first displacement sensor is set on the areal density measuring instrument to measure the substrate surface to obtain substrate position information. At the same time, based on the second displacement sensor set on the areal density measuring instrument, the substrate edge is measured to obtain the edge distance. Based on the substrate position information and the edge distance, the zero boundary position of the rear frame is automatically adjusted.

[0012] Laser rangefinders are mounted on the rear frame of the dual-frame unit and distributed along the coating direction. They are used to measure the distance to the substrate surface as the substrate passes by, thereby obtaining the actual position of the substrate in the coating direction.

[0013] The controller is also used to control the rear frame to start scanning along the scanning trajectory of the first frame at the same scanning speed and the same starting position when the actual position is greater than or equal to the sum of the pre-stored position and the distance between the front and rear frames, so as to achieve synchronous measurement.

[0014] Preferably, the controller is further configured to, in multi-frame synchronous mode, if the rear frame is waiting at the zero boundary position, at this time, the rear frame obtains a longitudinal coordinate value that is greater than the sum of the longitudinal coordinate of the front frame and the upper threshold, control the rear frame to abandon the current motion cycle, and wait for the next cycle motion signal of the front frame before continuing to move.

[0015] Preferably, the controller is further configured to, in length measurement mode, abandon modifying the distance between the front and rear frames when the absolute value of the difference between the measured distance between the two fixed color marks and the distance calibrated in length measurement mode is less than a preset value.

[0016] Preferably, the zero boundary is set on the outside of the substrate;

[0017] Each shelf density measuring instrument is set with the same scanning speed, reversal time and scanning width, and the reversal time is set to more than 1 second, and the timing period of the reversal time timer is 1 ms;

[0018] N≥5, and the N-frame surface density measuring instrument includes the detection of substrate surface density, single-sided wet film, single-sided dry film, double-sided wet film, and double-sided dry film.

[0019] Preferably, the original front and rear frame spacing L = L1 + L2 - L3 + L4, where L1 represents the spacing between the two color marks on the front frame, L2 represents the spacing between this frame and the front frame, L3 represents the spacing between the two color marks on the rear frame, and L4 represents the corrected front and rear frame spacing.

[0020] After each dynamic distance correction, the distance between the front and rear frames is obtained according to L1+Ld-L3+L4, where Ld represents the dynamic measurement of the two fixed color mark values.

[0021] Preferably, during synchronous operation, the stopping position of the rear frame measuring instrument in a single cycle of forward scanning is determined by the scanning width; the stopping position in reverse scanning is determined by the stored position of the front frame thickness gauge from the edge of the substrate.

[0022] Preferred options also include:

[0023] The main station is used to send status signals to the control board of each areal density measuring instrument. When the control board receives the status signal, it turns off the automatic start mode.

[0024] The relationship determination module is used to determine the control interaction relationship between the master station and each density surface measuring instrument, and to determine whether there is a control signal with a control interaction failure number greater than or equal to a set value. If so, it is determined that there is a control interaction failure relationship for the corresponding density surface measuring instrument.

[0025] The control chart determination module is used to determine the actuator based on the control signal in the corresponding density surface measuring instrument and the other controllable signals matched with the actuator, and to further interactively mine to obtain an initial control chart, wherein the initial control chart includes the controlled effective coefficient of each other controllable signal;

[0026] A secondary interactive mining process is performed on the initial control graph to obtain an extended control graph, wherein the extended control graph contains the controlled effective coefficients of each extended functional device based on the corresponding remaining controllable signals;

[0027] The replacement module is used to provide replacement reminders based on the replacement probability of the execution function device according to the initial control diagram and the extended control diagram, respectively.

[0028] Preferred options also include:

[0029] The drawing module is used to receive the distance measured by the laser rangefinder when the substrate passes by, simultaneously measure the distance to the surface of the substrate, and draw the surface along the distribution of the coating direction to obtain the first distance surface of the substrate;

[0030] The locking module is used to project the first distance surface and the calibration distance surface of the laser rangefinder sensor into a standard coordinate system, and lock the abnormal points in the first distance surface in combination with the shape of the substrate.

[0031] If the number of abnormal points is 0, then the distance measured to the substrate surface remains unchanged;

[0032] If the number of abnormal points is 1, then the abnormal point is adjusted once by 0.1 mm.

[0033] Otherwise, determine the normal vector of the sub-face that forms a triangle with any three points in the first distance plane, and find the first normal vector R1 corresponding to the smallest face from all sub-faces, where at least one of the three points is an outlier.

[0034] The face construction module is used to filter out the three normal points that are closest to the abnormal points of the smallest face and the abnormal points of the second smaller face and form a triangle, and to form the corresponding first reference triangle and second reference triangle.

[0035] Angle determination module is used to determine the first angle J1 between the first reference triangle and the first normal vector R1 and the second angle J2 between the second reference triangle and the first normal vector R1. At the same time, based on the two-dimensional plane formed by the normal vectors of the first and second reference triangles, the third angle J3 with the horizontal plane is obtained.

[0036] The unit determination module is used to determine the unit adjustment distance if the directions of the first included angle J1 and the second included angle J2 are consistent, based on the absolute difference between the first vertical distance from the abnormal point of the minimum face to the first reference face and the second vertical distance to the second reference face, and the absolute difference between the included angles J1 and J2.

[0037] Otherwise, the unit adjustment distance is obtained by summing the first vertical distance from the anomaly point of the minimum face to the first reference face and the second vertical distance to the second reference face, the sum of the angles between the first included angle J1 and the second included angle J2, and combining the third included angle J3.

[0038] The optical module is adjusted to determine the actual position of each abnormal point by adjusting the distance between the abnormal point and the three nearest normal points, based on the concavity ratio of each abnormal point and the unit adjustment distance.

[0039] This invention provides a method for simultaneous measurement using multiple areal density measuring instruments, comprising:

[0040] Step 1: In length measurement mode, start the coating machine normally. Mark the front frame with a marker pen and record the encoder information of the marker moving to the front frame measuring head color mark, the front frame fixed color mark, the rear frame fixed color mark, and the rear frame measuring head color mark. Calibrate the distance between the two color marks on the front frame, the distance between the front and rear frames, and the distance between the two color marks on the rear frame. There are N frames of surface density measuring instruments, and each frame of surface density measuring instrument is equipped with a fixed position color mark sensor and a measuring head color mark sensor. The N measuring instruments are arranged into N-1 dual-frame units.

[0041] Step 2: Use the spacing between the two color marks on the front frame and the two color marks on the rear frame to calibrate the spacing between the front and rear frames, and then control the coating machine to start working;

[0042] Step 3: The substrate position information is obtained by measuring the substrate surface based on the first displacement sensor set on the areal density measuring instrument. At the same time, the edge distance of the substrate is obtained by measuring the substrate edge based on the second displacement sensor set on the areal density measuring instrument. The zero boundary position of the rear frame is automatically adjusted according to the substrate position information and the edge distance.

[0043] Step 4: As the substrate passes by, the actual position of the substrate in the coating direction is obtained by measuring the distance to the substrate surface using a laser rangefinder.

[0044] Step 5: When the actual position is greater than or equal to the sum of the pre-stored position and the distance between the front and rear frames, control the rear frame to start scanning along the scanning trajectory of the first frame at the same scanning speed and the same starting position to achieve synchronous measurement.

[0045] Compared with the prior art, the beneficial effects of this application are as follows:

[0046] The technical solution proposed in this invention constructs a synchronous scanning measurement system with multiple dual-frame measuring instruments. The control method is simple, and the transmitted data and status information are abundant. Each measuring instrument uses two color mark sensors, fully utilizing the positional coordinate information of the electrode strip length direction and the transverse scanning direction of the measuring head, facilitating synchronized trajectory. The hardware connection for data transmission is reliable. In particular, the transmission of high-frequency signals such as encoder high-speed pulses and color mark status uses fiber optics, avoiding interference in complex electromagnetic environments. The synchronous measurement trajectory error between multiple instruments is less than 3mm.

[0047] Other features and advantages of the invention will be set forth in the following description, and will be apparent in part from the description, or may be learned by practicing the invention. The objects and other advantages of the invention may be realized and obtained by means of the structures particularly pointed out in the written description and the accompanying drawings.

[0048] The technical solution of the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. Attached Figure Description

[0049] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used in conjunction with embodiments of the invention to explain the invention and do not constitute a limitation thereof. In the drawings:

[0050] Figure 1 This is a structural diagram of a system for synchronous measurement using multiple areal density measuring instruments according to an embodiment of the present invention;

[0051] Figure 2 This is a flowchart illustrating a method for simultaneous measurement using multiple areal density measuring instruments according to an embodiment of the present invention;

[0052] Figure 3This is a communication structure diagram of the main station and each measuring instrument in an embodiment of the present invention;

[0053] Figure 4 This is a structural diagram of a dual-frame unit in an embodiment of the present invention;

[0054] Figure 5 This is a distance measurement diagram from an embodiment of the present invention;

[0055] Figure 6 This is a scanning path diagram in an embodiment of the present invention;

[0056] Figure 7 This is a flowchart of the synchronous measurement process in an embodiment of the present invention. Detailed Implementation

[0057] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.

[0058] This invention provides a system for simultaneous measurement using multiple areal density measuring instruments, such as... Figure 1 As shown, it includes:

[0059] N areal density measuring instruments are provided, and each areal density measuring instrument is equipped with a fixed position color mark sensor and a measuring head color mark sensor. The N measuring instruments are arranged into N-1 dual-frame units.

[0060] The length encoder is used to mark the front frame with a marker pen when the coating machine is turned on normally in length measurement mode. The encoder information is recorded when the marker moves to the positions of the front frame measuring head color mark, the front frame fixed color mark, the rear frame fixed color mark, and the rear frame measuring head color mark. The distance between the two color marks on the front frame, the distance between the front and rear frames, and the distance between the two color marks on the rear frame are calibrated.

[0061] The controller is used to calibrate the distance between the front and rear frames using the distance between the two color marks on the front frame and the distance between the two color marks on the rear frame, and to control the coating machine to start working.

[0062] The first displacement sensor is set on the areal density measuring instrument to measure the substrate surface to obtain substrate position information. At the same time, based on the second displacement sensor set on the areal density measuring instrument, the substrate edge is measured to obtain the edge distance. Based on the substrate position information and the edge distance, the zero boundary position of the rear frame is automatically adjusted.

[0063] Laser rangefinders are mounted on the rear frame of the dual-frame unit and distributed along the coating direction. They are used to measure the distance to the substrate surface as the substrate passes by, thereby obtaining the actual position of the substrate in the coating direction.

[0064] The controller is also used to control the rear frame to start scanning along the scanning trajectory of the first frame at the same scanning speed and the same starting position when the actual position is greater than or equal to the sum of the pre-stored position and the distance between the front and rear frames, so as to achieve synchronous measurement.

[0065] Preferably, the controller is further configured to, in multi-frame synchronous mode, if the rear frame is waiting at the zero boundary position, and the longitudinal coordinate value of the rear frame is greater than the sum of the longitudinal coordinate of the front frame and the upper threshold, control the rear frame to abandon the current motion cycle and wait for the next cycle motion signal from the front frame before continuing to move. It should be noted that the upper threshold is 1 cm.

[0066] Preferably, the controller is further configured to, in length measurement mode, abandon modifying the distance between the front and rear frames when the absolute value of the difference between the measured distance between the two fixed color marks and the distance calibrated in length measurement mode is less than a preset value. It should be noted that the preset value is 5mm.

[0067] Preferably, the zero boundary is set on the outside of the substrate;

[0068] Each shelf density measuring instrument is set with the same scanning speed, reversal time and scanning width, and the reversal time is set to more than 1 second, and the timing period of the reversal time timer is 1 ms;

[0069] N≥5, and the N-frame surface density measuring instrument includes the detection of substrate surface density, single-sided wet film, single-sided dry film, double-sided wet film, and double-sided dry film.

[0070] Preferably, the original front and rear frame spacing L = L1 + L2 - L3 + L4, where L1 represents the spacing between the two color marks on the front frame, L2 represents the spacing between this frame and the front frame, L3 represents the spacing between the two color marks on the rear frame, and L4 represents the corrected front and rear frame spacing.

[0071] After each dynamic distance correction, the distance between the front and rear frames is obtained according to L1+Ld-L3+L4, where Ld represents the dynamic measurement of the two fixed color mark values.

[0072] Preferably, during synchronous operation, the stopping position of the rear frame measuring instrument in a single cycle of forward scanning is determined by the scanning width; the stopping position in reverse scanning is determined by the stored position of the front frame thickness gauge from the edge of the substrate.

[0073] This system consists of a main station and various measuring instruments, connected via Ethernet. Figure 3 As shown, the master station does not participate in motion control, but only obtains the surface density measurement values ​​of each measuring instrument via Ethernet to calculate the net coating surface density.

[0074] The measuring instruments are connected by a CAN bus and I / O signal lines. The CAN bus baud rate of 500k to 1Mbps is used for data transmission with high real-time requirements: the spacing information of the two color marks on the first instrument, the scanning status of the measuring head (normal scan pass or reset pass, etc.), and the application layer protocol is CANOpen; the I / O signal lines transmit the front instrument color mark signal and the front instrument forward scan status signal with the highest real-time requirements.

[0075] The encoder in the coating direction is used to record the belt transport position information, and the front and rear frame measuring instruments interactively measure and encode the coordinate information of the belt transport direction.

[0076] Both the IO signals and encoder signals are high-frequency pulse signals. To prevent interference from the complex electromagnetic environment on site and avoid losing critical information, all signals are transmitted via optical fiber. Each scanner is equipped with an optical transceiver to achieve photoelectric signal conversion.

[0077] In this embodiment, multi-unit synchronous measurement (scan trajectory co-position measurement) is essentially servo motion control. The multi-unit measuring instruments are divided into several dual-unit units. For example, a multi-unit scanning measurement system consisting of five areal density measuring instruments is divided into four dual-unit units (front unit and rear unit). Each dual unit uses its own independent length measuring sensor and edge measuring color mark sensor.

[0078] Each measuring instrument scanning frame is equipped with two color mark sensors: a fixed-position color mark sensor and a measuring head color mark sensor, such as... Figure 4 As shown.

[0079] In this embodiment, the specific steps for the above system are as follows:

[0080] Marking: Apply high-temperature tape to the front of the first device in the direction of the conveyor belt, applying it to both sides and ensuring that the positions of the front and back sides are consistent as much as possible. The application direction should be the scanning direction, and the tape should be perpendicular to the foil as much as possible. The length of the tape on each side should be greater than or equal to the width of the foil.

[0081] Set color mark mode: Set all color marks (including moving and fixed color marks) on each measuring instrument, and set the light illumination mode to "suspended light", "foil off", and "high temperature tape on".

[0082] Determine the position of each color mark: Position each measuring instrument at approximately the same location as the fixed color mark. The purpose is to ensure that the moving color mark and the fixed color mark of each measuring instrument measure signals from the same location.

[0083] Reset the ordinate of the belt transport direction and start belt transport.

[0084] L1 = X-coordinate of a fixed color mark during operation - X-coordinate of a moving color mark during sensing

[0085] L2 = X-coordinate of 2 fixed color mark sensors during operation - X-coordinate of 1 fixed color mark sensor during operation

[0086] L3 = X-coordinate of 2 fixed color mark sensors during operation - X-coordinate of 2 moving color mark sensors during operation

[0087] Specifically, such as Figure 5 As shown.

[0088] In this embodiment, when synchronous measurement is required for normal operation, the first scan is initiated after the coating line speed stabilizes. During the first scan of the front frame, the rear frame will determine its current position. If the current position is greater than the set zero boundary, it will automatically move to the set zero boundary and wait. During synchronization, the zero boundary and full boundary of each frame are dynamically changing. The zero boundary is determined based on the substrate edge and the set edge-to-edge distance; the position coordinates are equal to the substrate edge coordinates minus the set edge-to-edge distance. The full boundary position is the zero boundary plus the scan width, such as... Figure 6 As shown, the distance between the rear frame measuring instrument's reverse scanning stop position and the electrode plate remains consistent with the position when the first frame starts scanning. Each time the front frame starts a forward scan, the rear frame equipment needs to record the position of the coating length measuring encoder at that moment. The scanning of the rear frame equipment is controlled by the recorded position and the calibrated distance between the two frames. For example... Figure 7 The diagram shown is a flowchart of the synchronous measurement process. It should be noted that the first instrument is the first areal density measuring instrument.

[0089] In this embodiment, under synchronous measurement mode, if the back frame does not receive a synchronization signal for more than 10 seconds, it will automatically switch to standby mode, in which any operation can be performed; when the back frame device is in a normal motion control state, it will perform scanning action according to the synchronization signal after receiving the synchronization signal.

[0090] In synchronous measurement mode, the rear frame's motion reset cycle should be performed according to the front frame's motion reset trajectory, and then the rear frame and front frame scanning trajectories should be completed.

[0091] The front frame measuring instrument scans the open interval according to the zero boundary and full boundary settings, and the rear frame measuring instrument first automatically returns to the zero boundary position to wait for startup.

[0092] Each time the front-mounted measuring instrument performs a forward scan, it must measure the position data of the zero boundary distance from the substrate edge (edge ​​measurement) and transmit this position data to the rear-mounted measuring instrument, which then saves it to a designated data storage area. This data needs to be updated and transmitted in each cycle.

[0093] During synchronous operation, the stop position (full boundary) of the forward scan of the rear frame measuring instrument in a single cycle is determined by the scan width; the stop position of the reverse scan is determined by the stored position of the front frame thickness gauge from the edge of the substrate. In other words, the reverse stop position of the rear frame measuring instrument is also the start position of the next forward scan, so that the distance from the start position to the electrode is consistent with that of the front frame.

[0094] When performing dynamic distance correction, the reference distance value should be the distance between two fixed color marks measured in length measurement calibration mode. This distance can be corrected manually or automatically in length measurement mode.

[0095] The beneficial effects of the above technical solution are: it simplifies the multi-frame synchronous system into multiple independent dual-frame systems, eliminating the need for additional synchronous controllers and simplifying control. Besides the necessary longitudinal coordinate data transmission, the dual frames also exchange information such as color mark sensor status, color mark position spacing, measuring instrument scanning status, and measuring instrument surface density measurement values. Depending on real-time requirements and data volume, different transmission media such as fiber optics, CAN bus, and Ethernet are used for data transmission, which is more conducive to the accuracy of synchronous control. Each measuring instrument is equipped with two color mark sensors: a fixed color mark and a moving color mark for the measuring head. This eliminates the influence of changes in the fixed position distance between the two frames caused by electrode tension fluctuations, enabling length calibration. By periodically marking the electrode with marks that can be recognized by the color mark sensors, the tape travel distance between the two frames is determined, providing compensation values ​​for synchronous measurement. Using the moving color mark of the measuring head, the relative position of the measuring head and the electrode tape (zero boundary and full boundary) is determined, thereby determining the starting position of the measuring head and achieving overlap of the movement trajectory with the front frame.

[0096] This invention provides a system for simultaneous measurement using multiple areal density measuring instruments, and further includes:

[0097] The main station is used to send status signals to the control board of each areal density measuring instrument. When the control board receives the status signal, it turns off the automatic start mode.

[0098] The relationship determination module is used to determine the control interaction relationship between the master station and each density surface measuring instrument, and to determine whether there is a control signal with a control interaction failure number greater than or equal to a set value. If so, it is determined that there is a control interaction failure relationship for the corresponding density surface measuring instrument.

[0099] The control chart determination module is used to determine the actuator based on the control signal in the corresponding density surface measuring instrument and the other controllable signals matched with the actuator, and to further interactively mine to obtain an initial control chart, wherein the initial control chart includes the controlled effective coefficient of each other controllable signal;

[0100] A secondary interactive mining process is performed on the initial control graph to obtain an extended control graph, wherein the extended control graph contains the controlled effective coefficients of each extended functional device based on the corresponding remaining controllable signals;

[0101] The replacement module is used to provide replacement reminders based on the replacement probability of the execution function device according to the initial control diagram and the extended control diagram, respectively.

[0102] In this embodiment, the status signal refers to whether the control board needs to switch modes. The mode switch is to the off mode and the start mode. In addition to the control board controlling the operation of the measuring instrument, the master station also needs to obtain control and verify whether the measuring instrument is operating normally, so as to ensure the accuracy of the measurement.

[0103] In this embodiment, the control interaction relationship includes: a valid control interaction relationship and a invalid control interaction relationship.

[0104] In this embodiment, the set value is 3, and the number of times the control signal is sent is generally 10. If the number of control interaction failures is 5, which is greater than 3, it is determined that there is a control interaction failure relationship with the corresponding density surface measuring instrument. It should be noted that the control signal is to control the surface density measuring instrument to operate according to the corresponding signal. The control signals corresponding to the execution function devices involved in the surface density measuring instrument may be different or the same. For example, the control signals of device 1 are: signal 11 and signal 12, and the control signals of device 2 are: signal 21 and signal 11.

[0105] In this embodiment, taking device 1 as an example, if the issued control signal is signal 12, then the remaining control signals are signal 11. At this point, after performing a first-level interactive mining on signal 11, it is found that device 2 is also controlled by signal 11. The calculation method for the controlled effective coefficient of signal 11 is as follows:

[0106]

[0107] Where X11 is the controlled effective coefficient of signal 11; n1 represents the actuator involved in signal 11; M i1 N represents the number of successful control tests performed on the i1th functional device using signal 11; i1 This represents the total number of control tests performed on the i1th functional device using signal 11; β i1 Let represent the device weight of the i1th functional device, and Nz i1 This represents the total number of control tests performed on the i1th functional device using all control signals.

[0108] In this embodiment, the second-level interactive mining refers to determining the controlled effectiveness coefficient of the extended function device in each of the remaining controllable signals in the initial control diagram based on the execution function device (extended function device) involved in each of the remaining controllable signals. That is, it is: the number of times the corresponding extended function device passes the test for the corresponding remaining controllable signal / the total number of times the corresponding extended function device is tested for the corresponding remaining controllable signal.

[0109] In this embodiment, the replacement probability of the functional device is 1 - A1 × control success rate of the control signal - A2 × average value of the controlled effective coefficients based on the initial control chart - A3 × average value of the controlled effective coefficients based on the extended control chart, where A1, A2, and A3 are set constants, namely 0.6, 0.3, and 0.1, respectively.

[0110] The beneficial effects of the above technical solution are: by determining the control interaction failure relationship, the initial control diagram and extended control diagram of the functional device are determined, and the replacement probability is determined comprehensively from two aspects, thus ensuring the reliability of the judgment.

[0111] This invention provides a system for simultaneous measurement using multiple areal density measuring instruments, and further includes:

[0112] The drawing module is used to receive the distance measured by the laser rangefinder when the substrate passes by, simultaneously measure the distance to the surface of the substrate, and draw the surface along the distribution of the coating direction to obtain the first distance surface of the substrate;

[0113] The locking module is used to project the first distance surface and the calibration distance surface of the laser rangefinder sensor into a standard coordinate system, and lock the abnormal points in the first distance surface in combination with the shape of the substrate.

[0114] If the number of abnormal points is 0, then the distance measured to the substrate surface remains unchanged;

[0115] If the number of abnormal points is 1, then the abnormal point is adjusted once by 0.1 mm.

[0116] Otherwise, determine the normal vector of the sub-face that forms a triangle with any three points in the first distance plane, and find the first normal vector R1 corresponding to the smallest face from all sub-faces, where at least one of the three points is an outlier.

[0117] The face construction module is used to filter out the three normal points that are closest to the abnormal points of the smallest face and the abnormal points of the second smaller face and form a triangle, and to form the corresponding first reference triangle and second reference triangle.

[0118] Angle determination module is used to determine the first angle J1 between the first reference triangle and the first normal vector R1 and the second angle J2 between the second reference triangle and the first normal vector R1. At the same time, based on the two-dimensional plane formed by the normal vectors of the first and second reference triangles, the third angle J3 with the horizontal plane is obtained.

[0119] The unit determination module is used to determine the unit adjustment distance if the directions of the first included angle J1 and the second included angle J2 are consistent, based on the absolute difference between the first vertical distance from the abnormal point of the minimum face to the first reference face and the second vertical distance to the second reference face, and the absolute difference between the included angles J1 and J2.

[0120] Otherwise, the unit adjustment distance is obtained by summing the first vertical distance from the anomaly point of the minimum face to the first reference face and the second vertical distance to the second reference face, the sum of the angles between the first included angle J1 and the second included angle J2, and combining the third included angle J3.

[0121] The optical module is adjusted to determine the actual position of each abnormal point by adjusting the distance between the abnormal point and the three nearest normal points, based on the concavity ratio of each abnormal point and the unit adjustment distance.

[0122] In this embodiment, the number of laser ranging sensors is 10 or more, providing a numerical basis for forming a triangle. The smallest face refers to the face with the smallest area among all sub-faces, and the second smallest face is the face with the second smallest area.

[0123] In this embodiment, the first distance plane refers to the distance plane of the substrate drawn by the distance between the laser range sensor and the substrate surface.

[0124] In this embodiment, the calibration distance surface of the laser rangefinder refers to the distribution surface set by the laser rangefinder based on the coating direction.

[0125] In this embodiment, the standard coordinate system is pre-defined and is a three-dimensional coordinate system.

[0126] In this embodiment, the substrate is generally planar. If there are protruding or recessed points in the first distance surface that deviate significantly from the planar shape, they are considered abnormal points. It should be noted that significant deviation refers to a distance of 2mm from the protruding or recessed point.

[0127] In this embodiment, "consistent direction" means that the first included angle J1 and the second included angle J2 are both between 0 and 180°, or between 180° and 360°. It should be noted that the included angles are obtained sequentially in a clockwise direction.

[0128] The inconsistency in direction refers to the fact that the first included angle J1 is between 0 and 180°, and the second included angle J2 is between 180° and 360°.

[0129] In this embodiment, when the directions are consistent, the unit adjustment distance Ld is calculated. yz :

[0130]

[0131] Where |Lc1―Lc2| represents the absolute difference between the first vertical distance Lc1 and the second vertical distance Lc2.

[0132] It should be noted that, This reflects the proportion of the difference between the first included angle J1 and the second included angle J2 to the total straight angle; the greater the angle difference, the larger this proportion. When the directions are consistent, the angle difference can reflect the degree of deviation of the abnormal point. In 0.1mm + |Lc1―Lc2|, 0.1mm is the basic adjustment amount.

[0133] In this embodiment, when the directions are inconsistent, the unit adjustment distance Ld is calculated. byz :

[0134]

[0135] Where Lave represents the average distance measured to normal points in the first and second reference triangular faces.

[0136] It should be noted that, It reflects the proportion of the overall angle difference to the full circle angle. The 0.1mm×sinJ3 adds a fine-tuning term. |Lc1+Lc2―2×Lave| measures the difference between the distance from the abnormal point to the reference surface and the average distance of the normal point. Overall, it meets the requirement of adjusting the distance based on the comprehensive calculation of angle and distance.

[0137] In this embodiment, the value of the depression ratio is between 0 and 1. The abnormal point is determined based on the height of each of the three most recent normal points. If it is lower than the corresponding normal point, it is considered a depression; if it is higher than the corresponding normal point, it is considered a convexity. At this time, the depression ratio is counted, which is the number of times it is in a depression state / 3.

[0138] In this embodiment, if the depression ratio is 1, then according to max(Ld) yz Ld byz Adjust the unit upwards;

[0139] If the concavity ratio is 2 / 3, then according to (Ld) yz +Ld byz Adjust the unit upwards by ) / 2;

[0140] If the concavity ratio is 1 / 3, then according to min(Ld) yz ,Ld byz Adjust the unit downwards;

[0141] If the concavity ratio is 0, then according to max(Ld) yz Ld byz Adjust the unit downwards.

[0142] The beneficial effects of the above technical solution are: by locking out anomalies through the first distance plane and the calibration distance plane, when there are anomalies, the number of anomalies is at least 2. The normal vector of the smallest plane is used as the cutting point, and the angle is obtained by constructing the normal vector based on the reference triangle face of the two anomalies. The unit adjustment distance is obtained in the case of consistent and inconsistent directions, so as to achieve reasonable adjustment of the distance and ensure the accuracy of actual position acquisition.

[0143] This invention provides a method for simultaneous measurement using multiple areal density measuring instruments, such as... Figure 2 As shown, it includes:

[0144] Step 1: In length measurement mode, start the coating machine normally. Mark the front frame with a marker pen and record the encoder information of the marker moving to the front frame measuring head color mark, the front frame fixed color mark, the rear frame fixed color mark, and the rear frame measuring head color mark. Calibrate the distance between the two color marks on the front frame, the distance between the front and rear frames, and the distance between the two color marks on the rear frame. There are N frames of surface density measuring instruments, and each frame of surface density measuring instrument is equipped with a fixed position color mark sensor and a measuring head color mark sensor. The N measuring instruments are arranged into N-1 dual-frame units.

[0145] Step 2: Use the spacing between the two color marks on the front frame and the two color marks on the rear frame to calibrate the spacing between the front and rear frames, and then control the coating machine to start working;

[0146] Step 3: The substrate position information is obtained by measuring the substrate surface based on the first displacement sensor set on the areal density measuring instrument. At the same time, the edge distance of the substrate is obtained by measuring the substrate edge based on the second displacement sensor set on the areal density measuring instrument. The zero boundary position of the rear frame is automatically adjusted according to the substrate position information and the edge distance.

[0147] Step 4: As the substrate passes by, the actual position of the substrate in the coating direction is obtained by measuring the distance to the substrate surface using a laser rangefinder.

[0148] Step 5: When the actual position is greater than or equal to the sum of the pre-stored position and the distance between the front and rear frames, control the rear frame to start scanning along the scanning trajectory of the first frame at the same scanning speed and the same starting position to achieve synchronous measurement.

[0149] The beneficial effects of the above technical solution are as follows: By constructing a synchronous scanning measurement system with multiple dual-frame measuring instruments, the control method is simple, and the transmitted data and status information are abundant. Each measuring instrument uses two color mark sensors, making full use of the position coordinate information of the electrode strip length direction and the transverse scanning direction of the measuring head, which facilitates the synchronization of the trajectory. The hardware connection for data transmission is reliable. In particular, the transmission of high-frequency signals such as encoder high-speed pulses and color mark status is carried out via optical fiber, avoiding interference in complex electromagnetic environments. The synchronous measurement trajectory error between multiple frames is less than 3mm.

[0150] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this invention and their equivalents, this invention also intends to include these modifications and variations.

Claims

1. A system for simultaneous measurement using multiple areal density measuring instruments, characterized in that, include: N areal density measuring instruments are provided, and each areal density measuring instrument is equipped with a fixed position color mark sensor and a measuring head color mark sensor. The scanning structure of the N areal density measuring instruments is divided into N-1 dual-frame units. The length encoder is used in length measurement mode to mark the positions of the front frame, the front frame surface density measuring instrument measuring head color mark sensor, the front frame surface density measuring instrument fixed position color mark sensor, the rear frame surface density measuring instrument fixed position color mark sensor, and the rear frame surface density measuring instrument measuring head color mark sensor when the machine is turned on normally. The encoder information is used to calibrate the distances between the front frame surface density measuring instrument measuring head color mark sensor and the front frame surface density measuring instrument fixed position color mark sensor, the front frame surface density measuring instrument fixed position color mark sensor and the rear frame fixed position color mark sensor, and the rear frame surface density measuring instrument measuring head color mark sensor and the rear frame surface density measuring instrument fixed position color mark sensor. The controller is used to calibrate the distance between the color mark sensor of the front frame surface density measuring instrument and the fixed position color mark sensor of the front frame surface density measuring instrument, the distance between the fixed position color mark sensor of the front frame surface density measuring instrument and the fixed position color mark sensor of the rear frame surface density measuring instrument, and the distance between the color mark sensor of the rear frame surface density measuring instrument and the fixed position color mark sensor of the rear frame surface density measuring instrument, and to control the coating machine to start working. The first displacement sensor is set on the areal density measuring instrument to measure the substrate surface to obtain substrate position information. At the same time, based on the second displacement sensor set on the areal density measuring instrument, the substrate edge is measured to obtain the edge distance. Based on the substrate position information and the edge distance, the zero boundary position of the rear frame is automatically adjusted. Laser rangefinders are mounted on the rear frame of the dual-frame unit and distributed along the coating direction. They are used to measure the distance to the substrate surface as the substrate passes by, thereby obtaining the actual position of the substrate in the coating direction. The controller is also used to control the rear frame to start scanning along the scanning trajectory of the first frame at the same scanning speed and the same starting position when the actual position is greater than or equal to the sum of the pre-stored position and the distance between the front and rear frames, so as to achieve synchronous measurement; The original front and rear frame spacing L = L1 + L2 - L3 + L4, where L1 represents the spacing between the two color marks on the front frame, L2 represents the spacing between this frame and the front frame, L3 represents the spacing between the two color marks on the rear frame, and L4 represents the corrected front and rear frame spacing.

2. The system for simultaneous measurement by multiple areal density measuring instruments according to claim 1, characterized in that, The controller is also configured to, in the case of a multi-frame synchronous mode, if the rear frame is waiting at the zero boundary position, at this time, the rear frame obtains a longitudinal coordinate value that is greater than the sum of the longitudinal coordinate of the front frame and the upper threshold, and controls the rear frame to abandon the current motion cycle and wait for the next cycle motion signal of the front frame before continuing to move.

3. The system for simultaneous measurement by multiple areal density measuring instruments according to claim 1, characterized in that, The controller is also used to, in length measurement mode, abandon modifying the distance between the front and rear frames when the absolute value of the difference between the distance between the two fixed-position color mark sensors and the distance calibrated in length measurement mode is less than a preset value.

4. The system for simultaneous measurement by multiple areal density measuring instruments according to claim 1, characterized in that, The zero boundary is set on the outside of the substrate; Each shelf density measuring instrument is set with the same scanning speed, reversal time and scanning width, and the reversal time is set to more than 1 second, and the timing period of the reversal time timer is 1 ms; Furthermore, the N-frame surface density measuring instrument includes the detection of substrate surface density, single-sided wet film, single-sided dry film, double-sided wet film, and double-sided dry film.

5. The system for simultaneous measurement by multiple areal density measuring instruments according to claim 1, characterized in that, During synchronous operation, the stopping position of the rear frame measuring instrument in a single cycle of forward scanning is determined by the scanning width; the stopping position in reverse scanning is determined by the stored position of the front frame thickness gauge from the edge of the substrate.

6. The system for simultaneous measurement by multiple areal density measuring instruments according to claim 1, characterized in that, Also includes: The main station is used to send status signals to the control board of each areal density measuring instrument. When the control board receives the status signal, it turns off the automatic start mode. The relationship determination module is used to determine the control interaction relationship between the master station and each density surface measuring instrument, and to determine whether there is a control signal with a control interaction failure number greater than or equal to a set value. If so, it is determined that there is a control interaction failure relationship for the corresponding density surface measuring instrument. The control chart determination module is used to determine the actuator based on the control signal in the corresponding density surface measuring instrument and the other controllable signals matched with the actuator, and to further interactively mine to obtain an initial control chart, wherein the initial control chart includes the controlled effective coefficient of each other controllable signal; A secondary interactive mining process is performed on the initial control graph to obtain an extended control graph, wherein the extended control graph contains the controlled effective coefficients of each extended functional device based on the corresponding remaining controllable signals; The replacement module is used to provide replacement reminders based on the replacement probability of the execution function device according to the initial control diagram and the extended control diagram, respectively.

7. The system for simultaneous measurement by multiple areal density measuring instruments according to claim 1, characterized in that, Also includes: The drawing module is used to receive the distance measured by the laser rangefinder when the substrate passes by, simultaneously measure the distance to the surface of the substrate, and draw the surface along the distribution of the coating direction to obtain the first distance surface of the substrate; The locking module is used to project the first distance surface and the calibration distance surface of the laser rangefinder sensor into a standard coordinate system, and lock the abnormal points in the first distance surface in combination with the shape of the substrate. If the number of abnormal points is 0, then the distance measured to the substrate surface remains unchanged; If the number of abnormal points is 1, then the abnormal point is adjusted once by 0.1 mm. Otherwise, determine the normal vector of the sub-face that forms a triangle with any three points in the first distance plane, and find the first normal vector R1 corresponding to the smallest face from all sub-faces, where at least one of the three points is an outlier. The face construction module is used to filter out the three normal points that are closest to the abnormal points of the smallest face and the abnormal points of the second smaller face and form a triangle, and to form the corresponding first reference triangle and second reference triangle. Angle determination module is used to determine the first angle J1 between the first reference triangle and the first normal vector R1 and the second angle J2 between the second reference triangle and the first normal vector R1. At the same time, based on the two-dimensional plane formed by the normal vectors of the first and second reference triangles, the third angle J3 with the horizontal plane is obtained. The unit determination module is used to determine the unit adjustment distance if the directions of the first included angle J1 and the second included angle J2 are consistent, based on the absolute difference between the first vertical distance from the abnormal point of the minimum face to the first reference face and the second vertical distance to the second reference face, and the absolute difference between the included angles J1 and J2. Otherwise, the unit adjustment distance is obtained by summing the first vertical distance from the anomaly point of the minimum face to the first reference face and the second vertical distance to the second reference face, the sum of the angles between the first included angle J1 and the second included angle J2, and combining the third included angle J3. The optical module is adjusted to determine the actual position of each abnormal point by adjusting the distance between the abnormal point and the three nearest normal points, based on the concavity ratio of each abnormal point and the unit adjustment distance.

8. A method for simultaneous measurement using multiple areal density measuring instruments, characterized in that, include: Step 1: In length measurement mode, start the coating machine normally. Mark the front frame with a marker pen and record the encoder information of the positions of the markers when they move to the color mark sensor of the front frame surface density measuring instrument, the fixed position color mark sensor of the front frame surface density measuring instrument, the fixed position color mark sensor of the rear frame surface density measuring instrument, and the color mark sensor of the rear frame surface density measuring instrument. Calibrate the distances between the color mark sensor of the front frame surface density measuring instrument and the fixed position color mark sensor of the front frame surface density measuring instrument, the fixed position color mark sensor of the front frame surface density measuring instrument and the fixed position color mark sensor of the rear frame surface density measuring instrument, and the color mark sensor of the rear frame surface density measuring instrument and the fixed position color mark sensor of the rear frame surface density measuring instrument. There are N frames of surface density measuring instruments, and each frame surface density measuring instrument is equipped with a fixed position color mark sensor and a measuring head color mark sensor. The N frames of surface density measuring instruments are configured into N-1 dual-frame units. Step 2: Use the distances between the color mark sensor of the front frame surface density measuring instrument and the fixed position color mark sensor of the front frame surface density measuring instrument, the distances between the fixed position color mark sensor of the front frame surface density measuring instrument and the fixed position color mark sensor of the rear frame surface density measuring instrument, and the distances between the color mark sensor of the rear frame surface density measuring instrument and the fixed position color mark sensor of the rear frame surface density measuring instrument to calibrate the distances between the color mark sensors of the front frame surface density measuring instrument and the rear frame surface density measuring instrument, and then control the coating machine to start working; Step 3: The substrate position information is obtained by measuring the substrate surface based on the first displacement sensor set on the areal density measuring instrument. At the same time, the edge distance of the substrate is obtained by measuring the substrate edge based on the second displacement sensor set on the areal density measuring instrument. The zero boundary position of the rear frame is automatically adjusted according to the substrate position information and the edge distance. Step 4: As the substrate passes by, the actual position of the substrate in the coating direction is obtained by measuring the distance to the substrate surface using a laser rangefinder. Step 5: When the actual position is greater than or equal to the sum of the pre-stored position and the distance between the front and rear frames, control the rear frame to start scanning along the scanning trajectory of the first frame at the same scanning speed and the same starting position to achieve synchronous measurement; The original front and rear frame spacing L = L1 + L2 - L3 + L4, where L1 represents the spacing between the two color marks on the front frame, L2 represents the spacing between this frame and the front frame, L3 represents the spacing between the two color marks on the rear frame, and L4 represents the corrected front and rear frame spacing.

Images