A device and method for detecting the cleanliness of aluminum powder on the surface of aluminum foil strips.

Abstract

This invention discloses a device and method for detecting the cleanliness of aluminum powder on the surface of aluminum foil strips. The detection device includes an unwinding device, an inlet guide roller, an aluminum powder collection device, an aluminum foil strip cleaning unit, an outlet guide roller, a winding device, and a conveyor belt. The detection method involves starting the detection after installing the tape roll, automatically replacing the tape when a set value is reached, and using a colorimeter to detect the L value of the tape to calculate the cleaning efficiency ΔL and determine whether the cleaning is qualified. This invention can adapt to different working conditions, improves the efficiency of detecting aluminum powder on the surface of aluminum foil strips, reduces numerical errors caused by improper operation, and breaks through the bottleneck of low efficiency and poor accuracy of traditional detection methods, providing an efficient and reliable cleanliness assessment solution for aluminum foil production lines.

Description

[Technical Field]

[0001] This invention relates to the field of aluminum processing, and in particular to a device and method for detecting the cleanliness of aluminum powder on the surface of aluminum foil strips. [Background Technology]

[0002] High and low voltage electronic aluminum foil is the raw material for aluminum electrolytic capacitors. It is made from high-purity aluminum with a purity of ≥99.99%. The aluminum is remelted in a melting and holding furnace, a certain amount of trace elements are added, and then cast into ingots with a length × width × thickness of approximately 6500mm × 1060mm × 365-520mm. The ingots are then processed into electronic aluminum foil through milling, homogenization treatment, hot rolling, cold rolling, foil rolling, cleaning, and finished product annealing. The aluminum foil is then etched and formed by downstream customers and then slit to make the anodes in aluminum electrolytic capacitors.

[0003] During the rolling process, aluminum foil easily accumulates aluminum powder and adheres to rolling oil (heavy oil) on its surface. A cleaning process is necessary to remove the surface aluminum powder and heavy oil. Improper adjustment of the cleaning process parameters can lead to incomplete cleaning and residual aluminum powder. Incompletely cleaned aluminum foil flowing to downstream etching plants will cause uneven corrosion on the electrochemical etching line due to the uneven current density caused by the residual aluminum powder. Therefore, it is necessary to establish a testing method to evaluate the effectiveness of aluminum powder cleaning and to determine the cleaning result.

[0004] Existing methods for detecting aluminum powder are cumbersome, typically employing chemical dissolution. This involves dissolving aluminum powder from the surface of aluminum foil and then analyzing the solution. However, this method is complex and causes significant damage to the aluminum foil surface, making it unsuitable for real-time detection during production. Patent CN106546512A, entitled "Qualitative and Quantitative Detection Method for Residual Aluminum Powder on the Surface of Aluminum Alloy Sheets and Strips," discloses a detection method comprising the following steps: 1) sampling the rolled aluminum alloy sheet or strip along the rolling direction; 2) qualitatively detecting the residual aluminum powder on the sample surface using a metallographic microscope; 3) quantitatively detecting the residual aluminum powder on the sample surface using ICP-OES; and 4) calculating the residual aluminum powder content on the sample surface. The technical problems with this method are: the chemical dissolution method is complex, requiring specialized chemical experimental equipment and personnel, and demanding a high-quality experimental environment; the use of chemical reagents may cause environmental pollution, and the detection time is long, failing to meet the needs of rapid detection on production lines. The patent with publication number CN108844902A, entitled "A qualitative and quantitative detection method for aluminum powder on the surface of aluminum plate, strip and foil", adopts a technical solution of manually using tape to pick up aluminum powder from aluminum plate, strip and foil. The operation process is relatively cumbersome and is limited by inconsistent operation, resulting in large data errors.

[0005] The above background information is provided only to aid in understanding the inventive concept and technical solution of this invention. It does not necessarily belong to the prior art of this patent application. In the absence of clear evidence that the above information was disclosed on the filing date of this patent application, the above background information should not be used to evaluate the novelty and inventiveness of this application. [Summary of the Invention]

[0006] The purpose of this invention is to provide a device and method for detecting the cleanliness of aluminum powder on the surface of aluminum foil strips, so as to solve the technical problems existing in the prior art.

[0007] Therefore, the present invention adopts the following technical solution:

[0008] A device for detecting the cleanliness of aluminum foil strip surface aluminum powder includes an unwinding device for holding unwashed aluminum foil strip rolls; an inlet guide roller connected to the unwinding device via a conveyor belt, the inlet guide roller having an aluminum powder collection device; an aluminum foil strip cleaning unit connected to the inlet guide roller via a conveyor belt for cleaning the aluminum foil strip; an outlet guide roller connected to the aluminum foil strip cleaning unit via a conveyor belt, the outlet guide roller having an aluminum powder collection device; a winding device connected to the outlet guide roller via a conveyor belt for rewinding the aluminum foil strip after aluminum powder collection; and a conveyor belt connecting the unwinding device, inlet guide roller, aluminum foil strip cleaning unit, outlet guide roller, and winding device to realize the transfer of aluminum foil strip between the components.

[0009] Furthermore, the aluminum powder collection device includes an aluminum powder collection structure, a tape recycling structure, a side cover plate, a top cover plate, and a bracket; the aluminum powder collection structure includes a pressure regulating structure, a tape fixing shaft, and a tape roll; the tape recycling structure includes a tape recycling shaft and a recycling drive module.

[0010] Furthermore, the bracket in the aluminum powder collection device connects the aluminum powder collection structure and the tape recycling structure. The top cover is located on the top of the tape recycling structure, and the side cover is located on the side of the aluminum powder collection structure. Both are connected to the bracket and can be opened. After opening the top cover, the old tape recycled by the tape recycling structure can be taken out. After opening the side cover, the pressure adjustment structure and the tape fixing shaft can be taken out.

[0011] Furthermore, the aluminum powder collection structure in the aluminum powder collection device has an opening at the bottom, a pressure regulating structure is installed above the opening, a tape fixing shaft is installed above the pressure regulating structure, and the tape roll is sleeved on the tape fixing shaft. The tape fixing shaft is detachable, with one end of the shaft fixed to the bracket through a slot structure, and the other end connected to the side cover plate through a slot structure.

[0012] Furthermore, the pressure adjustment structure in the aluminum powder collection structure includes a pressure adjustment shaft, a neodymium magnet for the pressure adjustment shaft, and a neodymium magnet for the side cover plate. The pressure adjustment shaft is detachable, with one end fixed to the bracket via a slot structure and the other end connected to the side cover plate via a slot structure. The neodymium magnet for the pressure adjustment shaft is fixed to the end of the pressure adjustment shaft, and the neodymium magnet for the side cover plate is embedded in the slot of the side cover plate. The two drive the pressure adjustment shaft downward through magnetic attraction, ensuring that the tape and the aluminum foil tape are in contact. The pressure on the pressure adjustment shaft can be adjusted by increasing or decreasing the number of neodymium magnets to adapt to different unit conveying speeds, unwinding tensions, and winding tensions.

[0013] Furthermore, the tape recycling structure in the aluminum powder collection device is located on one side of the aluminum powder collection structure. One end of the tape recycling shaft is fixed to the bracket through a slot structure, and the other end is connected to the recycling drive module, which is a detachable structure. The recycling drive module includes a motor and a sensor. The sensor monitors the number of meters the aluminum foil tape has traveled. When the tape has traveled to a predetermined number of meters, the motor drives the recycling shaft to recycle the used tape.

[0014] Furthermore, the aluminum foil strip has a thickness of 0.1-0.5mm; the tape roll includes a spool core and a special tape, with the special tape wound around the spool core; the spool core has a cylindrical structure and is hollow inside, and is fitted onto the tape fixing shaft during use; the special tape is made of double-layer frosted material, with a coarse frosted layer on the surface using frosted particles of Ra=6.0-6.5μm, and a fine frosted layer on the bottom layer using a smooth frosted structure of Ra=3.0-3.4μm; the tape substrate is a high-toughness PET film, and the adhesive is an acrylic pressure-sensitive adhesive; the special tape has black scale lines printed every 13-18cm on the back of the tape.

[0015] Furthermore, the sensor monitors the aluminum foil strip until it travels 70-90m, at which point the motor drives the recovery shaft to recover the used tape.

[0016] The present invention also provides a detection method using the aluminum foil strip surface aluminum powder cleanliness detection device described above, the method steps of which are as follows:

[0017] S1. Install the tape roll: Insert the tape roll with the new tape onto the tape fixing shaft in the aluminum powder collection device of the inlet guide roller and the outlet guide roller, pull out the tape section, let it pass around the pressure adjustment shaft, through the bottom opening of the aluminum powder collection structure, and connect the end to the tape recycling shaft. Adjust the pressure on the pressure adjustment shaft by increasing or decreasing the number of neodymium magnets to ensure that the tape is in close contact with the surface of the aluminum foil.

[0018] S2. Start the detection process: Set the conveyor speed, unwinding tension, winding tension, and tape replacement trigger threshold of the aluminum foil strip unit; turn on the unwinding device, and the aluminum foil strip enters the inlet guide roller via the conveyor belt, where the aluminum powder collection device collects surface aluminum powder from the tape roll; the aluminum foil strip enters the cleaning unit for surface cleaning, and then the aluminum powder collection device on the outlet guide roller collects residual aluminum powder again; the winding device simultaneously recovers the cleaned aluminum foil strip;

[0019] S3. Automated tape replacement: When the sensor detects that the aluminum foil tape has accumulated to the set value, the motor of the recycling drive module starts, and the recycling shaft winds up the used tape roll. The old tape can be taken out through the top cover after it is opened. After the special tape on the tape roll is used up, the old tape is taken out and a new tape roll is installed according to the steps described in S1.

[0020] S4. Quantitative analysis with a colorimeter: Cut the old tape removed from the inlet and outlet sections into segments according to the black scale lines on the back and paste them onto white paper, ensuring the surface is flat; use a calibrated colorimeter to detect the L value of the middle area of ​​the tape; the L value of the tape before cleaning is defined as L1, and the L value of the tape after cleaning is defined as L2; ​​calculate the cleaning efficiency ΔL = L2 - L1. If 25 ≥ ΔL ≥ 15, then the cleaning is deemed qualified.

[0021] Furthermore, in step S2, the conveying speed of the aluminum foil strip machine is set to 5-9 m / min, the unwinding tension to 15-25 N, the winding tension to 20-30 N, and the pressure adjustment tape replacement trigger threshold to 70-90 m.

[0022] The technical principle of this invention is as follows:

[0023] Double-layer frosted tape structure and function: The specially designed tape features a double-layer frosted design. The outer layer is a coarse frosted layer with a roughness Ra = 6.0-6.5μm, and the inner layer is a fine frosted layer with a roughness Ra = 3.0-3.4μm. The coarse frosted outer layer effectively peels away aluminum powder from the surface of the aluminum foil tape through friction, enhancing the mechanical adhesion to the aluminum powder and ensuring sufficient collection. The fine frosted inner layer ensures a tight bond between the tape and the white substrate, reducing glare interference during colorimeter detection. Together, they ensure sufficient aluminum powder collection and improve detection accuracy. When the aluminum foil tape comes into contact with the special tape during transport, aluminum powder adheres to the tape. As aluminum powder adheres, the tape gradually darkens, resulting in a decrease in the L value. The colorimeter quantifies the aluminum powder content by detecting changes in the L value of the tape, thus providing data support for assessing the cleanliness of the aluminum foil tape surface. During this process, factors such as the thickness of the aluminum foil tape and the unit speed affect the peeling and adhesion of aluminum powder. When the aluminum foil tape is too thin (less than 0.3 mm), it lacks rigidity and is prone to wrinkling, affecting the contact between the tape and the aluminum foil surface and resulting in uneven aluminum powder collection. If the thickness is too large (greater than 0.3 mm), the surface micro-roughness increases, and some aluminum powder becomes embedded and difficult to peel off. The unit speed also affects aluminum powder collection. Too low a speed (less than 7 m / min) results in insufficient aluminum powder peeling, while too high a speed (greater than 7 m / min) leads to aluminum powder splashing or tape abrasion, both of which result in poor collection and consequently affect the L-value detection results.

[0024] Pressure Regulation Mechanism: The neodymium magnets on the pressure regulating shaft and the side cover plate in the pressure regulating structure generate magnetic force. Because they are installed in the slot structure connecting the pressure regulating shaft and the side cover plate, the magnetic force drives the pressure regulating shaft to move towards the aluminum foil strip, that is, towards the bottom opening of the aluminum powder collection structure. This ensures that the tape is always in close contact with the surface of the aluminum foil strip. Regardless of any slight positional changes in the aluminum foil strip during transport due to factors such as unit conveying speed, unwinding tension, and coiling tension, the tape and aluminum foil strip surface are fully adhered, thus ensuring continuous and stable aluminum powder collection. Furthermore, by increasing or decreasing the number of neodymium magnets, the magnetic force can be changed, thereby adjusting the pressure on the pressure regulating shaft to adapt to the bonding pressure requirements under different working conditions.

[0025] Operational Monitoring Mechanism: Sensors in the tape recycling structure can monitor the length of the aluminum foil tape in real time. Its working principle is based on monitoring and calculating the number of rotations of the unwinding device. An encoder installed on the unwinding device converts the rotation information into an electrical signal, which is then processed and converted to determine the actual length of the aluminum foil tape. When the sensor detects that the aluminum foil tape has accumulated to a set value, it sends a signal to the motor in the recycling drive module. Upon receiving the signal, the motor starts, and its rotation is transmitted to the tape recycling shaft, causing it to rotate and thus recycle the used tape, which is now covered in aluminum powder. This mechanism, based on precise monitoring and automatic triggering, automates tape recycling, avoiding errors and inconveniences associated with manual judgment and operation.

[0026] Black graduations are printed on the back of the tape. These graduations mark the length of the inspection segments, facilitating accurate cutting of each segment during subsequent testing. This ensures uniform segment length, improving accuracy and standardization. This design, in conjunction with other process parameters, allows for accurate testing under various operating conditions, guaranteeing standardization and consistency in inspection.

[0027] The beneficial effects of this invention compared to the prior art include:

[0028] (1) Stability and ease of operation of tape fixation: Existing technology uses manual tape to pick up aluminum powder from aluminum foil tape. This invention uses an aluminum powder collection device to fix the tape roll, which can not only fix it firmly and support quick clamping, but also eliminate the need for manual collection, saving time and effort. It is not affected by changes in other process parameters and can always provide a stable tape fixation method for aluminum powder collection, ensuring the reliability of the detection process.

[0029] (2) Improved aluminum powder collection efficiency and detection accuracy: Existing technologies use traditional single-layer tapes with low aluminum powder capture efficiency and uniform surface roughness, which cannot simultaneously ensure aluminum powder peeling and detection stability. The special tape used in this invention has a double-layer frosted structure. The outer coarse frosting enhances the mechanical bonding of aluminum powder, while the inner fine frosting ensures tight adhesion and reduces reflective interference.

[0030] (3) Data Reliability and Process Optimization Support: The tape recycling structure can automatically trigger the motor-driven recycling shaft to recycle the used tape based on the number of meters of aluminum foil tape monitored by the sensor. This automates the tape replacement process, reduces manual intervention, and improves detection efficiency, whereas traditional detection devices require frequent manual inspection and tape replacement. A specially designed double-layer frosted tape and a colorimeter are used for quantitative analysis. The double-layer frosted structure of the specially designed tape and a suitable adhesive effectively collect aluminum powder. The black scale lines printed on the back of the tape facilitate segmented cutting and detection. The colorimeter quantitatively detects the L value and determines whether the cleaning is qualified by calculating the cleaning efficiency. Compared with some qualitative detection methods that rely on manual visual observation, the detection results are more accurate and reliable.

[0031] (4) Industrial adaptability and scalability: The pressure on the pressure regulating shaft can be adjusted by increasing or decreasing the number of neodymium magnets. It can adapt to different unit conveying speeds (5-9m / min), unwinding tension (15-25N) and winding tension (20-30N). It can ensure close contact between the tape and the aluminum foil surface under various working conditions and stably collect aluminum powder. Compared with some fixed structure aluminum powder collection devices, it has a wider range of applications.

[0032] (5) Precise control of process parameters: This invention clarifies the significant impact of five key process parameters—unit speed, unwinding tension, winding tension, running meters, and aluminum foil thickness—on the test results (ΔL value) and determines the optimal combination of process parameters. In actual operation, operators can strictly control the testing process based on these precise parameter standards. When parameters deviate from the optimal value, the cause can be quickly detected and analyzed, and adjustments can be made in a timely manner. For example, once a fluctuation in unit speed is detected, its impact on aluminum powder peeling and tape wear can be quickly determined, and corresponding adjustments can be made to ensure the accuracy and reliability of the test results. [Attached Image Description]

[0033] Figure 1 This is a schematic diagram of the structure and process of the aluminum foil strip surface aluminum powder cleanliness detection device;

[0034] Figure 2 This is a top view of the inlet and outlet guide roller structure;

[0035] Figure 3 This is a schematic diagram of the aluminum powder detection device;

[0036] Figure 4 This is a schematic diagram of a colorimeter testing tape.

[0037] The following are the labels in the diagram: 1. Unwinding device; 2. Aluminum powder collection device; 3. Inlet guide roller; 4. Aluminum foil strip cleaning unit; 5. Outlet guide roller; 6. Winding device; 7. Conveyor belt; 21. Pressure regulating shaft; 22. Side cover plate; 23. Recycling drive module; 24. Tape fixing shaft; 25. Tape recycling shaft; 26. Top cover plate; 27. Pressure regulating shaft neodymium magnet; 28. Side cover plate neodymium magnet; 29. ​​Support.

Detailed Implementation Methods

[0038] The present invention will now be described in further detail with reference to specific embodiments and the accompanying drawings. It should be emphasized that the following description is merely exemplary and is not intended to limit the scope or application of the present invention.

[0039] This invention discloses an aluminum foil strip surface aluminum powder cleanliness detection device, comprising: an unwinding device 1 for holding unwashed aluminum foil strip rolls; an inlet guide roller 3 connected to the unwinding device 1 via a conveyor belt 7, wherein an aluminum powder collection device 2 is mounted on the inlet guide roller 3; an aluminum foil strip cleaning unit 4 connected to the inlet guide roller 3 via the conveyor belt 7 for cleaning the aluminum foil strip; an outlet guide roller 5 connected to the aluminum foil strip cleaning unit 4 via the conveyor belt 7, wherein an aluminum powder collection device 2 is mounted on the outlet guide roller 5; and a rewinding device 6 connected to the outlet guide roller 5 via the conveyor belt 7 for rewinding the aluminum foil strip after aluminum powder collection. The conveyor belt 7 connects the unwinding device 1, the inlet guide roller 3, the aluminum foil strip cleaning unit 4, the outlet guide roller 5, and the rewinding device 6, enabling the transfer of the aluminum foil strip between the components. The aluminum foil strip thickness is 0.1-0.5 mm. A schematic diagram of the structure and process of the aluminum foil strip surface aluminum powder cleanliness detection device is shown below. Figure 1 See the top view diagram of the inlet and outlet guide rollers. Figure 2 A schematic diagram of the aluminum powder collection device 2 is shown below. Figure 3 .

[0040] The aluminum powder collection device 2 includes an aluminum powder collection structure, a tape recycling structure, a side cover plate 22, a top cover plate 26, and a bracket 29; the aluminum powder collection structure includes a pressure adjustment structure, a tape fixing shaft 24, and a tape roll; the tape recycling structure includes a tape recycling shaft 25 and a recycling drive module 23.

[0041] The bracket 29 in the aluminum powder collection device 2 connects the aluminum powder collection structure and the tape recycling structure. The top cover 26 is located on the top of the tape recycling structure, and the side cover 22 is located on the side of the aluminum powder collection structure. Both are connected to the bracket 29 and can be opened. After opening the top cover 26, the old tape recycled by the tape recycling structure can be taken out. After opening the side cover 22, the pressure adjustment structure and the tape fixing shaft 24 can be taken out.

[0042] The aluminum powder collection structure in the aluminum powder collection device 2 has an opening at the bottom. A pressure regulating structure is installed above the opening. A tape fixing shaft 24 is installed above the pressure regulating structure. The tape roll is sleeved on the tape fixing shaft 24. The tape fixing shaft 24 is detachable. One end of the shaft is fixed to the bracket 29 through a slot structure, and the other end is connected to the side cover plate 22 through a slot structure.

[0043] The pressure regulating structure in the aluminum powder collection structure includes a pressure regulating shaft 21, a pressure regulating shaft neodymium magnet 27, and a side cover plate neodymium magnet 28. The pressure regulating shaft 21 is detachable, with one end fixed to the bracket 29 via a slot structure and the other end connected to the side cover plate 22 via a slot structure. The pressure regulating shaft neodymium magnet 27 is fixed to the end of the pressure regulating shaft 21, and the side cover plate neodymium magnet 28 is embedded in the slot of the side cover plate 22. The two drive the pressure regulating shaft downward through magnetic attraction to ensure that the tape and the aluminum foil tape are in contact. The pressure on the pressure regulating shaft 21 can be adjusted by increasing or decreasing the number of neodymium magnets to adapt to different unit conveying speeds, unwinding tensions, and winding tensions.

[0044] The tape recycling structure in the aluminum powder collection device 2 is located on one side of the aluminum powder collection structure. One end of the tape recycling shaft 25 is fixed to the bracket 29 through a slot structure, and the other end is connected to the recycling drive module 23, which is a detachable structure. The recycling drive module 23 includes a motor and a sensor. The sensor monitors the number of meters the aluminum foil tape has traveled. When the tape has traveled to the predetermined number of meters, the motor drives the recycling shaft to recycle the used tape.

[0045] The tape roll includes a spool core and a special tape, with the special tape wound around the spool core. The spool core has a cylindrical structure and is hollow inside, and is fitted onto the tape fixing shaft 24 during use. The special tape is made of double-layer frosted material, with a coarse frosted layer on the surface using frosted particles with Ra=6.0-6.5μm, and a fine frosted layer using a smooth frosted structure with Ra=3.0-3.4μm. The tape substrate is a high-toughness PET film, and the adhesive is an acrylic pressure-sensitive adhesive. The special tape has black scale lines printed every 13-18cm on the back.

[0046] The sensor monitors the aluminum foil tape until it travels 70-90m, at which point the motor drives the recovery shaft to recover the used tape.

[0047] Example 1

[0048] A detection method using the aluminum foil strip surface aluminum powder cleanliness detection device described above, the method steps are as follows:

[0049] S1. Install the tape roll: Place the tape roll with the new tape wound onto the tape fixing shaft 24 in the aluminum powder collection device 2 of the inlet guide roller 3 and the outlet guide roller 5, pull out the tape section so that it passes around the pressure adjustment shaft 21, through the bottom opening of the aluminum powder collection structure, and the end is connected to the tape recycling shaft 25. Adjust the pressure on the pressure adjustment shaft 21 by increasing or decreasing the number of neodymium magnets to ensure that the tape is in close contact with the surface of the aluminum foil.

[0050] S2. Start the detection process: The aluminum foil strip thickness is 0.3mm; the conveying speed of the aluminum foil strip unit is set to 7m / min, the unwinding tension is 20N, the winding tension is 25N, and the tape replacement trigger threshold is to replace the tape after the aluminum foil strip has run for 80m. The integrated pressure sensor is activated for real-time monitoring; the unwinding device 1 is turned on, and the aluminum foil strip enters the inlet guide roller 3 via the conveyor belt 7. The aluminum powder is collected from the surface of the tape roll by the aluminum powder collection device 2; the aluminum foil strip enters the cleaning unit for surface cleaning, and then the residual aluminum powder is collected again by the aluminum powder collection device 2 on the outlet guide roller 5; the rewinding device 6 simultaneously recovers the cleaned aluminum foil strip;

[0051] S3. Automated tape replacement: When the sensor detects that the aluminum foil tape has accumulated to the set value, the motor of the recycling drive module 23 is started, and the recycling shaft winds up the used tape roll. The old tape can be taken out through the top cover 26 after it is opened. After the special tape on the tape roll is used up, the old tape is taken out and a new tape roll is installed according to the steps described in S1.

[0052] S4. Quantitative Analysis with a Colorimeter: Cut the old tape removed from the inlet and outlet sections into segments according to the black scale lines on the back and paste them onto white paper, ensuring the surface is flat. Use a calibrated colorimeter to measure the L value of the middle area of ​​the tape. The L value of the tape before cleaning is defined as L1, which is 62.4; the L value of the tape after cleaning is defined as L2, which is 81.9. Calculate the cleaning efficiency ΔL = L2 - L1, which is 19.5. If 25 ≥ ΔL ≥ 15, then the cleaning is considered qualified. See the schematic diagram of the colorimeter testing of the tape. Figure 4 .

[0053] Example 2

[0054] A detection method using the aluminum foil strip surface aluminum powder cleanliness detection device described above, the method steps are as follows:

[0055] S1. Install the tape roll: Place the tape roll with the new tape wound onto the tape fixing shaft 24 in the aluminum powder collection device 2 of the inlet guide roller 3 and the outlet guide roller 5, pull out the tape section so that it passes around the pressure adjustment shaft 21, through the bottom opening of the aluminum powder collection structure, and the end is connected to the tape recycling shaft 25. Adjust the pressure on the pressure adjustment shaft 21 by increasing or decreasing the number of neodymium magnets to ensure that the tape is in close contact with the surface of the aluminum foil.

[0056] S2. Start the detection process: The aluminum foil strip thickness is 0.2mm; the conveying speed of the aluminum foil strip unit is set to 3m / min, the unwinding tension is 20N, the winding tension is 30N, and the tape replacement trigger threshold is to replace the tape after the aluminum foil strip has run for 85m. The unwinding device 1 is turned on, and the aluminum foil strip enters the inlet guide roller 3 via the conveyor belt 7. The aluminum powder is collected from the surface of the tape roll by the aluminum powder collection device 2. The aluminum foil strip enters the cleaning unit for surface cleaning, and then the residual aluminum powder is collected again by the aluminum powder collection device 2 on the outlet guide roller 5. The rewinding device 6 simultaneously recovers the cleaned aluminum foil strip.

[0057] S3. Automated tape replacement: When the sensor detects that the aluminum foil tape has accumulated to the set value, the motor of the recycling drive module 23 is started, and the recycling shaft winds up the used tape roll. The old tape can be taken out through the top cover 26 after it is opened. After the special tape on the tape roll is used up, the old tape is taken out and a new tape roll is installed according to the steps described in S1.

[0058] S4. Quantitative analysis with a colorimeter: Cut the old tape removed from the inlet and outlet sections into segments according to the black scale lines on the back and paste them onto white paper, ensuring the surface is flat; use a calibrated colorimeter to measure the L value of the middle area of ​​the tape; the L value of the tape before cleaning is defined as L1, which is 64.5; the L value of the tape after cleaning is defined as L2, which is 82.6; calculate the cleaning efficiency ΔL = L2 - L1, which is 18.1; if 25 ≥ ΔL ≥ 15, then the cleaning is deemed qualified.

[0059] Example 3

[0060] A detection method using the aluminum foil strip surface aluminum powder cleanliness detection device described above, the method steps are as follows:

[0061] S1. Install the tape roll: Place the tape roll with the new tape wound onto the tape fixing shaft 24 in the aluminum powder collection device 2 of the inlet guide roller 3 and the outlet guide roller 5, pull out the tape section so that it passes around the pressure adjustment shaft 21, through the bottom opening of the aluminum powder collection structure, and the end is connected to the tape recycling shaft 25. Adjust the pressure on the pressure adjustment shaft 21 by increasing or decreasing the number of neodymium magnets to ensure that the tape is in close contact with the surface of the aluminum foil.

[0062] S2. Start the detection process: The aluminum foil strip thickness is 0.4mm; the conveying speed of the aluminum foil strip unit is set to 6m / min, the unwinding tension is 18N, the winding tension is 28N, and the tape replacement trigger threshold is to replace the tape after the aluminum foil strip has run for 75m. The integrated pressure sensor is activated for real-time monitoring; the unwinding device 1 is turned on, and the aluminum foil strip enters the inlet guide roller 3 via the conveyor belt 7. The aluminum powder is collected from the surface of the tape roll by the aluminum powder collection device 2; the aluminum foil strip enters the cleaning unit for surface cleaning, and then the residual aluminum powder is collected again by the aluminum powder collection device 2 on the outlet guide roller 5; the winding device 6 simultaneously recovers the cleaned aluminum foil strip.

[0063] S3. Automated tape replacement: When the sensor detects that the aluminum foil tape has accumulated to the set value, the motor of the recycling drive module 23 is started, and the recycling shaft reverses to wind up the used tape roll. The old tape can be taken out through the top opening of the bracket 29. After the special tape on the tape roll is used up, the old tape is taken out and a new tape roll is installed according to the steps described in S1.

[0064] S4. Quantitative analysis with a colorimeter: Cut the old tape removed from the inlet and outlet sections into segments according to the black scale lines on the back and paste them onto white paper, ensuring the surface is flat; use a calibrated colorimeter to measure the L value of the middle area of ​​the tape; the L value of the tape before cleaning is defined as L1, which is 61.8; the L value of the tape after cleaning is defined as L2, which is 78.7; calculate the cleaning efficiency ΔL = L2 - L1, which is 16.9; if 25 ≥ ΔL ≥ 15, then the cleaning is deemed qualified.

[0065] Single-factor experiment to screen key equipment parameters affecting the cleanliness detection effect (ΔL value) of aluminum powder:

[0066] (1) Single-factor experiment on unit operating speed:

[0067] Referring to the detection method of Example 1, with other equipment parameters kept constant, experiments were conducted at unit operating speeds of 3 m / min, 5 m / min, 7 m / min, 9 m / min, and 10 m / min. The cleanliness of the aluminum powder was tested according to the detection method of Example 1, and the results are shown in the table below:

[0068] Unit speed (m / min) ΔL value result 3 28.2 Unqualified 5 25.0 qualified 7 19.5 qualified 9 17.3 qualified 10 14.7 Unqualified

[0069] At speeds below the optimal range of 3-5 m / min (i.e., excessively low speeds), the aluminum foil tape's transport time between devices is too long. This causes the aluminum powder adhering to the tape to exceed its carrying capacity, resulting in patchy accumulation. Localized areas of the tape becoming excessively dark cause a sharp drop in the L1 value, leading the colorimeter to misread as having a high overall aluminum powder content, masking the true distribution and causing the ΔL value to exceed the acceptable range. This indicates that at excessively low speeds, the actual cleanliness of the aluminum powder on the aluminum foil tape surface cannot be adequately reflected.

[0070] At 7 m / min, the optimal speed is achieved, where the contact time and relative speed between the aluminum foil strip and the special adhesive tape reach a good balance. The special adhesive tape can fully rub against the surface of the aluminum foil strip within a suitable time, effectively peeling off the aluminum powder and adhering it to the tape. This achieves the best balance between aluminum powder peeling and collection, resulting in a maximum ΔL value within the acceptable range, which most accurately reflects the cleaning effect of the aluminum foil strip.

[0071] At speeds of 9-10 m / min, the contact time between the aluminum foil strip and the special adhesive tape is too short. The tape does not have enough time to fully bond with the aluminum powder, and some aluminum powder may be missed due to the high speed, failing to be collected by the tape. At the same time, high-speed movement may also increase friction between the tape and the aluminum foil strip, causing wear on the tape and affecting its ability to collect aluminum powder, thus leading to a decrease in the ΔL value.

[0072] (2) Single-factor experiment on unwinding tension:

[0073] Referring to the detection method of Example 1, with other equipment parameters kept constant, experiments were conducted at unwinding tensions of 10N, 15N, 20N, 25N, and 30N. The cleanliness of the aluminum powder was tested according to the detection method of Example 1, and the results are shown in the table below:

[0074] Unwinding tension (N) ΔL value result 10 14.1 Unqualified 15 17.2 qualified 20 19.5 qualified 25 17.8 qualified 30 14.5 Unqualified

[0075] When the unwinding tension increases from 10N to 20N, the ΔL value rises from 14.1 to 19.5; when it continues to increase to 30N, the ΔL value decreases to 14.5. This also shows a trend of first increasing and then decreasing.

[0076] When the unwinding tension is 10-15N, the tension is too low, causing the aluminum foil strip to be in a slack state during unwinding. This results in an uneven surface on the aluminum foil strip, preventing the special adhesive tape from making close contact with the surface. In this situation, the tape can only collect aluminum powder from certain areas, leading to uneven aluminum powder collection and an inability to accurately reflect the overall cleanliness of the aluminum foil strip, resulting in a low ΔL value.

[0077] 20N is the optimal value. At this value, the unwinding tension is moderate, the aluminum foil strip remains flat during unwinding, and the special tape can adhere tightly to the surface of the aluminum foil strip. During the conveying process, aluminum powder can be fully collected, so the aluminum powder collection effect is optimal, and therefore the ΔL value is the largest.

[0078] The unwinding tension should be 25-30N. Excessive tension will cause the aluminum foil strip to be overstretched and deformed. The deformed aluminum foil strip's surface microstructure changes, potentially affecting the adhesion between the aluminum powder and the tape, resulting in some aluminum powder not being collected by the tape. Furthermore, excessive tension may damage the surface of the aluminum foil strip, further affecting the collection and detection results of the aluminum powder, causing a decrease in the ΔL value.

[0079] (3) Single-factor experiment on winding tension:

[0080] Referring to the detection method of Example 1, with other equipment parameters kept constant, experiments were conducted at winding tensions of 15N, 20N, 25N, 30N, and 35N. The cleanliness of the aluminum powder was tested according to the detection method of Example 1, and the results are shown in the table below:

[0081] Winding tension (N) ΔL value result 15 14.3 Unqualified 20 17.5 qualified 25 19.5 qualified 30 17.1 qualified 35 14.9 Unqualified

[0082] When the winding tension increases from 15N to 25N, the ΔL value rises from 14.3 to 19.5; when it is further increased to 35N, the ΔL value drops to 14.9, showing a trend of first rising and then falling.

[0083] When the winding tension is between 15-20N, the winding tension is too low. The aluminum foil strip lacks sufficient tension during winding, and cannot pass stably through the various devices. This causes the aluminum foil strip to sway or loosen during transport, affecting the contact between the special adhesive tape and the aluminum foil strip surface, reducing the efficiency of aluminum powder peeling and collection, and thus causing the ΔL value to be lower than the acceptable level.

[0084] 25N is the optimal value. Under this tension, the aluminum foil strip remains stable during the winding process, and the special tape can adhere tightly to the surface of the aluminum foil strip. It can continuously and effectively collect aluminum powder throughout the entire conveying process, achieving full collection of aluminum powder, so the ΔL value is the largest.

[0085] When the winding tension is between 30-35N, excessive winding tension will cause the aluminum foil strip to be overstretched, resulting in significant surface stress. On the one hand, this stress may cause the aluminum powder to adhere more tightly to the surface of the aluminum foil strip, making it difficult for the tape to peel off. On the other hand, excessive tension may also damage the surface of the aluminum foil strip, disrupting the distribution of the aluminum powder and affecting the tape's ability to collect the aluminum powder, thus reducing the ΔL value.

[0086] (4) Run the single-factor experiment on meter count:

[0087] Referring to the detection method of Example 1, with other equipment parameters kept constant, experiments were conducted at running distances of 60m, 70m, 80m, 90m, and 100m. The cleanliness of the aluminum powder was tested according to the detection method of Example 1, and the results are shown in the table below:

[0088] Distance traveled (m) ΔL value result 60 14.4 Unqualified 70 17.0 qualified 80 19.5 qualified 90 25.0 qualified 100 27.8 Unqualified

[0089] When the running distance is 60-70m, the contact length between the special tape and the aluminum foil surface is limited, and the amount of aluminum powder collected is insufficient to fully reflect the cleanliness of the aluminum foil surface. Because the distribution of aluminum powder on the aluminum foil surface may be uneven, a shorter running distance may result in unrepresentative aluminum powder samples, leading to a lower ΔL value.

[0090] 80m represents the optimal value. At this operating length, the specially designed tape has sufficient contact length with the aluminum foil surface, allowing for the collection of a sufficient amount of aluminum powder samples. This enables the test results to more accurately reflect the overall cleanliness of the aluminum foil. Simultaneously, within this length, the tape's adsorption capacity and collection effect are both at their best, resulting in the maximum ΔL value.

[0091] When the running distance is 90-100m, the special tape will gradually reach adsorption saturation after collecting a certain amount of aluminum powder. At this point, even if it continues to be in contact with the aluminum foil tape, it will be impossible to collect any more aluminum powder. Moreover, the excessive running distance may cause aluminum powder to overlap or accumulate on the tape, interfering with the colorimeter's accurate detection of the tape's L value, thus resulting in an excessively high ΔL value.

[0092] (5) Single-factor experiment on aluminum foil thickness:

[0093] Referring to the detection method of Example 1, with other equipment parameters remaining unchanged, experiments were conducted with aluminum foil strip thicknesses of 0.1 mm, 0.2 mm, 0.3 mm, 0.4 mm, and 0.5 mm, respectively. The cleanliness of the aluminum powder was tested according to the detection method of Example 1, and the results are shown in the table below:

[0094] Aluminum foil tape thickness (mm) ΔL value result 0.1 15.5 qualified 0.2 17.1 qualified 0.3 19.5 qualified 0.4 17.4 qualified 0.5 15.6 qualified

[0095] When the thickness of the aluminum foil strip increases from 0.1 mm to 0.3 mm, the ΔL value rises from 15.5 to 18.8; when it increases to 0.5 mm, the ΔL value decreases to 15.6, showing a trend of first rising and then falling.

[0096] When the aluminum foil tape thickness is 0.1-0.2mm, it is too thin and lacks rigidity, making it prone to stretching and deformation during transport, resulting in wrinkles. These wrinkles prevent the special adhesive tape from making tight contact with the aluminum foil tape surface, allowing only partial collection of aluminum powder from the wrinkled areas. This uneven collection of aluminum powder fails to accurately reflect the cleanliness of the aluminum foil tape, resulting in a low ΔL value.

[0097] 0.3mm is the optimal value. At this thickness, the aluminum foil strip is of moderate thickness, possessing sufficient rigidity to ensure flatness during transport, without being too thick and hindering the peeling and collection of aluminum powder. The special adhesive tape can fully contact the surface of the aluminum foil strip, achieving effective peeling and collection of aluminum powder, resulting in the best detection effect, and therefore the maximum ΔL value.

[0098] When the aluminum foil strip thickness is 0.4-0.5 mm, excessive thickness increases the surface roughness, potentially embedding some aluminum powder deep within the foil strip. The specialized adhesive tape struggles to completely remove this embedded powder. Furthermore, excessively thick aluminum foil strips exhibit excessive rigidity, affecting their adhesion to the adhesive tape. This results in insufficient contact between the tape and the foil strip surface, further reducing aluminum powder collection efficiency and causing a decrease in the ΔL value.

[0099] In the process of testing the cleanliness of aluminum powder on the surface of aluminum foil strips, five process parameters—machine speed, unwinding tension, winding tension, running meters, and aluminum foil strip thickness—all have a significant impact on the test results (ΔL value). Each parameter has an optimal value. The optimal combination of process parameters is: machine speed: 7 m / min; unwinding tension: 20 N; winding tension: 25 N; running meters: 80 m; aluminum foil strip thickness: 0.3 mm. When the parameters are below or above their optimal values, the test results will deteriorate for various reasons. Therefore, in practical applications, these process parameters need to be strictly controlled to keep them within their optimal range to ensure the accuracy and reliability of the test results.

[0100] The aluminum foil strip surface aluminum powder cleanliness detection device of the present invention has a reasonable structural design, and all components work together to achieve effective detection of aluminum foil strip cleanliness. The overall layout consists of an unwinding device 1, an inlet guide roller 3, an aluminum foil strip cleaning unit 4, an outlet guide roller 5, a winding device 6, and a conveyor belt 7, forming a complete aluminum foil strip conveying and detection process, ensuring that the aluminum foil strip can smoothly pass through each stage for cleanliness detection.

[0101] The embodiments verified the effectiveness of the detection method. Under different unit conveyor speeds, unwinding tensions, coiling tensions, aluminum foil thicknesses, and tape replacement trigger threshold settings, the cleanliness of the aluminum foil tape could be accurately detected. The operation steps are clear and straightforward, making it easy to operate and implement. This detection method can accurately detect the cleanliness of the aluminum foil tape under different parameter combinations.

[0102] The above description, in conjunction with specific / preferred embodiments, provides a further detailed explanation of the present invention and should not be construed as limiting the specific implementation of the invention to these descriptions. It should be understood that various changes, substitutions, and modifications can be made without departing from the spirit and scope of the invention. Furthermore, the scope of the invention is not limited to the specific embodiments of the processes, machines, manufactures, compositions of matter, methods, and steps described in the specification. From the disclosure of this invention, those skilled in the art will readily utilize existing or future processes, machines, manufactures, compositions of matter, methods, or steps that substantially perform the same function or achieve the same results as the corresponding embodiments described herein. Therefore, the appended claims are intended to encompass such processes, machines, manufactures, compositions of matter, methods, or steps.

Claims

1. An apparatus for detecting surface aluminum powder cleanliness of an aluminum foil tape, characterized by comprising: The device comprises a unwinding device for placing unwashed aluminum foil strip; an inlet deflector roller connected with the unwinding device through a conveying belt, the inlet deflector roller is provided with an aluminum powder collecting device; an aluminum foil strip cleaning unit connected with the inlet deflector roller through a conveying belt, the aluminum foil strip cleaning unit is used for cleaning the aluminum foil strip; an outlet deflector roller connected with the aluminum foil strip cleaning unit through a conveying belt; the outlet deflector roller is provided with an aluminum powder collecting device; A winding device connected with the outlet deflector roller through a conveying belt, the winding device is used for winding the aluminum foil strip after the aluminum powder is collected; The conveying belt is used for connecting the unwinding device, the inlet deflector roller, the aluminum foil strip cleaning unit, the outlet deflector roller and the winding device, and conveying the aluminum foil strip between the components; The thickness of the aluminum foil strip is 0.1-0.5mm; The adhesive tape roll in the aluminum powder collecting device comprises a reel core and a special adhesive tape, the special adhesive tape is wound on the reel core; The reel core is in a cylindrical structure and is hollow, and is sleeved on the adhesive tape fixing shaft during use; The special adhesive tape is made of double-layer frosted glass, the surface layer is a coarse frosted layer, the frosted particles of which are Ra=6.0-6.5μm, the bottom layer is a fine frosted layer, the smooth frosted structure of which is Ra=3.0-3.4μm; the adhesive tape base material is a high-toughness PET film, and the adhesive is an acrylic pressure-sensitive adhesive; The special adhesive tape is printed with black scale lines on the back of the adhesive tape every 13-18cm.

2. The aluminum foil tape surface aluminum powder cleanliness detection device according to claim 1, characterized by, The aluminum powder collecting device comprises an aluminum powder collecting structure, an adhesive tape recycling structure, a side cover, a top cover and a support; the aluminum powder collecting structure comprises a pressure adjusting structure, an adhesive tape fixing shaft and an adhesive tape roll; the adhesive tape recycling structure comprises an adhesive tape recycling shaft and a recycling drive module.

3. The aluminum foil tape surface aluminum powder cleanliness detection device according to claim 1, characterized by, The support of the aluminum powder collecting device connects the aluminum powder collecting structure and the adhesive tape recycling structure, the top cover is located at the top of the adhesive tape recycling structure, the side cover is located at the side of the aluminum powder collecting structure, and both are connected with the support and can be opened; the old adhesive tape recycled by the adhesive tape recycling structure can be taken out after the top cover is opened, and the pressure adjusting structure and the adhesive tape fixing shaft can be taken out after the side cover is opened.

4. The aluminum foil tape surface aluminum powder cleanliness detection device according to claim 1, characterized by, The bottom of the aluminum powder collecting structure of the aluminum powder collecting device is provided with an opening, the pressure adjusting structure is installed above the opening, the adhesive tape fixing shaft is installed above the pressure adjusting structure, and the adhesive tape roll is sleeved on the adhesive tape fixing shaft; the adhesive tape fixing shaft is detachable, one end of the shaft is fixed with the support through a clamping groove structure, and the other end is connected with the side cover through a clamping groove structure.

5. The apparatus for detecting cleanliness of a surface of an aluminum foil tape according to claim 2, characterized by The pressure adjusting structure in the aluminum powder collecting structure comprises a pressure adjusting shaft, a pressure adjusting shaft neodymium magnet and a side cover neodymium magnet; the pressure adjusting shaft is detachable, one end of the shaft is fixed with the support through a clamping groove structure, and the other end is connected with the side cover through a clamping groove structure; the pressure adjusting shaft neodymium magnet is fixed at the end of the pressure adjusting shaft, and the side cover neodymium magnet is embedded in the clamping groove of the side cover; the two drive the pressure adjusting shaft to press down through magnetic force, ensure that the adhesive tape contacts with the aluminum foil strip, and the pressure on the pressure adjusting shaft can be adjusted by increasing or decreasing the number of neodymium magnets, so as to adapt to different conveying speeds, unwinding tension and winding tension of the unit.

6. The aluminum foil tape surface aluminum powder cleanliness detection device according to claim 1, characterized by, The adhesive tape recovery structure in the aluminum powder collecting device is located on one side of the aluminum powder collecting structure, one end of the adhesive tape recovery shaft is fixed with the support through the clamping groove structure, and the other end is connected with the recovery drive module, which is a detachable structure; the recovery drive module includes a motor and a sensor, the sensor monitors the running meters of the aluminum foil tape, and when the aluminum foil tape runs to the predetermined meters, the motor drives the recovery shaft to recover the used adhesive tape.

7. The apparatus for detecting the cleanliness of the surface of an aluminum foil tape according to claim 6, wherein The sensor monitors the running meters of the aluminum foil tape, and when the aluminum foil tape runs to 70-90m, the motor drives the recovery shaft to recover the used adhesive tape.

8. A detection method using the aluminum foil tape surface aluminum powder cleanliness detection device according to any one of claims 1-7, the method steps are as follows: S1. Install the adhesive tape roll: wrap the new adhesive tape roll into the adhesive tape fixing shaft in the aluminum powder collecting device of the entrance deflector roller and the exit deflector roller, pull out the adhesive tape section, make it pass through the bottom opening of the aluminum powder collecting structure, and connect the end to the adhesive tape recovery shaft, adjust the pressure on the pressure adjusting shaft by increasing or decreasing the number of neodymium magnets, and ensure that the adhesive tape is in close contact with the surface of the aluminum foil tape; S2. Start the detection process: set the aluminum foil tape machine group conveying speed, unwinding tension and winding tension, and adhesive tape replacement trigger threshold; start the unwinding device, the aluminum foil tape enters the entrance deflector roller through the conveying belt, and the surface aluminum powder is collected by the adhesive tape roll of the aluminum powder collecting device; the aluminum foil tape enters the cleaning unit for surface cleaning, and then the residual aluminum powder is collected again by the aluminum powder collecting device of the exit deflector roller; the winding device synchronously recovers the cleaned aluminum foil tape; S3. Automatic adhesive tape replacement: when the sensor detects that the aluminum foil tape has run to the set value, the recovery drive module motor starts, the recovery shaft winds the used adhesive tape roll, and the old adhesive tape can be taken out through the opened top cover; after the special adhesive tape on the adhesive tape roll is used up, the old adhesive tape is taken out, and a new adhesive tape roll is installed according to the steps described in S1; S4. Quantitative analysis by color difference meter: cut the old adhesive tape taken from the entrance section and the exit section according to the black scale line behind it, and paste it on the white paper to ensure the surface is flat; use the calibrated color difference meter to detect the L value of the middle region of the adhesive tape; the L value of the adhesive tape before cleaning is L1, and the L value of the adhesive tape after cleaning is L2; calculate the cleaning efficiency AL=L2-L1, if 25≥AL≥15, it is determined that the cleaning is qualified.

9. The detection method of the aluminum foil tape surface aluminum powder cleanliness detection device according to claim 8, characterized in that, The set aluminum foil tape machine group conveying speed in step S2 is 5-9m / min, the unwinding tension is 15-25N, the winding tension is 20-30N, and the pressure adjusting adhesive tape replacement trigger threshold is 70-90m.

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