A flexible conditioning roller device

Abstract

This invention discloses a flexible adjusting roller device, belonging to the technical field of film winding equipment. The device includes a roller body and a lever mechanism. The roller body is used to apply pressure to the release film roll to flatten its wrinkles and bulges. The lever mechanism includes a lever plate, bearings, and a rotating shaft. The lever plate and the rotating shaft achieve relative rotation through the bearings. The lever mechanism is mirror-symmetrically installed at both ends of the roller body, enabling relative rotation between the roller body and the lever mechanism. The ends of the two corresponding lever plates are fixedly connected to the piston rods of a low-friction cylinder mechanism. The control mechanism drives the piston rods to move linearly, causing the lever plates to swing around the axis of the rotating shaft in an arc trajectory, thereby driving the roller body to rotate relative to the rotation center on the lever mechanism. This allows the roller body to apply appropriate pressure to the release film roll, ensuring that the release film remains flat during winding and reducing the scrap rate caused by wrinkles and bulges.

Description

Technical Field

[0001] This invention relates to the field of film winding equipment technology, and more specifically, to a flexible adjusting roller device. Background Technology

[0002] In the lithium battery production process, the winding process of the separator film is crucial. Currently, common automatic winding equipment for lithium battery separator films requires manual loading of an empty roll with double-sided tape onto the winding shaft when the roll is almost full. The winding mechanism then automatically flips, and the adhesive roller presses the separator film onto the empty roll. A cutter quickly attaches the film to the empty roll to begin winding a new roll. However, as the equipment speed increases to 200m / min, numerous problems have emerged, severely impacting equipment stability and winding quality. Firstly, during the automatic tape attachment process, the tail length between the cutter's cutting point and the adhesive roller's pressing point is 150mm-200mm. This tail section is uncontrolled after cutting, easily folding and clumping, leading to… On the one hand, the film surface is prone to bulging and wrinkling; on the other hand, the winding tension of the release film is relatively small, and the bulges in the roll cannot be eliminated automatically. The bulges accumulate to form irregular hard ridges, causing the release film to shrink excessively in the width direction. In addition, during high-speed winding, the end face of the roll will also have misalignment of 10mm-30mm, which not only leads to the waste of finished film area in the slitting process, but may even prevent the entire roll of film from passing the CCD inspection of the slitting machine. Traditional mechanisms rely on the motor screw approach roller structure and only adjust a fixed distance for winding without assisting in smoothing the film surface. Once wrinkles appear, the entire roll of material cannot be eliminated from beginning to end, resulting in a significant increase in the number of meters of waste film material during winding.

[0003] Therefore, there is a need to provide a flexible adjusting roller device to solve the above technical problems. Summary of the Invention

[0004] The purpose of this invention is to provide a flexible adjusting roller device to solve the above-mentioned technical problems.

[0005] To achieve the above objectives, the present invention provides the following technical solution:

[0006] A flexible adjusting roller device, comprising

[0007] Rollers are used to apply pressure to the release film roll during the release film winding process to flatten its wrinkles and lumps;

[0008] A lever arm mechanism includes a lever arm plate, a bearing, and a rotating shaft. The middle section of the lever arm plate has a stepped bearing seat formed by a stepped through hole. The outer periphery of the bearing is installed close to the inner end face of the stepped bearing seat. One end of the rotating shaft has a limiting shoulder, which passes through the inner periphery of the bearing and abuts against the inner circumferential surface of the bearing. The other end of the rotating shaft is fixedly installed on the frame. The lever arm plate and the rotating shaft can rotate relative to each other through the bearing. The stepped bearing seat is the rotation center of the lever arm plate.

[0009] Two lever arms are provided, and the two lever arms are respectively mirror-symmetrically installed at both ends of the roller body. The top of each of the two corresponding lever arm plates is fixedly provided with a bearing seat. The bearing seat cooperates with the self-aligning ball bearings provided at both ends of the roller body, so that the roller body and the lever arm mechanism can rotate relative to each other. The ends of the two corresponding lever arm plates are connected to Y-type joints through shoulder hinge pins. The Y-type joints are fixedly connected to the piston rod of the low-friction cylinder mechanism. The low-friction cylinder mechanism is electrically connected to the control mechanism and drives the piston rod to move linearly. Through the Y-type joints, the shoulder hinge pins are pushed, causing the lever arm plates to swing around the axis of the rotation axis in an arc trajectory, thereby driving the roller body to rotate relative to the rotation center on the lever arm mechanism.

[0010] Furthermore, the low-friction cylinder mechanism is fixedly installed on the frame, and the low-friction cylinder mechanism is provided with an electric proportional valve electrically connected to the control mechanism to control the output thrust of the piston rod, thereby controlling the pressure of the roller on the release film roll.

[0011] Furthermore, the rotation center distance between the bearing seat and the lever arm plate is L1, and the rotation center distance between the shoulder hinge pin and the lever arm plate is L2, where L1=2L2, that is, the lever arm plate and the piston rod form a 1:2 lever ratio. When the piston rod outputs a thrust F, the pressure of the roller on the release film roll is F / 2.

[0012] Furthermore, the input end of the flexible adjusting roller device is provided with several conveying rollers and the output end is provided with a winding mechanism. The conveying rollers are used to convey the isolation film to the winding mechanism for collection. A cutting mechanism is provided between the winding mechanism and the flexible adjusting roller device for cutting the isolation film.

[0013] The winding mechanism includes a rotary support base, several cantilever arms, several transition rollers, and several winding shafts. The cantilever arms are radially distributed on the rotary support base and are on the same horizontal plane. The number of cantilever arms is equal to the total number of transition rollers and winding shafts. The transition rollers and winding shafts are alternately arranged at the ends of several cantilever arms and are rotatably connected to the cantilever arms. The winding shafts are electrically connected to a control mechanism. The control mechanism drives the winding shafts to rotate at a set speed to complete the winding operation. The rotary support base is connected to a drive assembly electrically connected to the control mechanism, which drives the rotary support base to rotate, thereby causing the cantilever arms to rotate around the rotation center of the rotary support base, and causing the transition rollers and winding shafts to alternately change positions.

[0014] If the take-up shaft at the current working position is located within the working angle domain β of the flexible adjusting roller device, i.e., |β|≤50°, the outer peripheral surface of the roller body is pressed against the film roll surface of the take-up shaft at the current working position. When the take-up shaft at the current working position moves out of the working angle domain β with the rotation of the cantilever, the roller body immediately disengages from contact. At the instant the new take-up shaft enters the working angle domain β, the cutting mechanism simultaneously cuts the release film. The roller body then contacts the new take-up shaft to continue the winding operation. The working angle domain β is the angle between the line connecting the axis of the roller body and the axis of the take-up shaft at the current working position and the horizontal line.

[0015] Furthermore, two correction rollers electrically connected to the control mechanism are provided directly above the conveying roller, and the axis of the correction roller is parallel to the axis of the corresponding conveying roller; the two correction rollers are respectively located at the ends of the conveying roller in the axial direction, and the control mechanism drives the correction roller to rotate and move up and down relative to the conveying roller.

[0016] Furthermore, the adjustment method of the flexible adjusting roller device includes the following steps:

[0017] S1. Initial pressure setting: Based on the material characteristics of the separator and the actual usage requirements, the constant output pressure P0 required by the flexible adjustment roller device is set. The control mechanism adjusts the output thrust of the piston rod according to the constant output pressure P0, so that the roller body of the flexible adjustment roller device applies the preset constant output pressure P0 to the separator roll.

[0018] S2. Radial Difference Monitoring of Material Roll: During the winding process, the diameter change of the release film roll at the current station winding shaft on the winding mechanism is monitored in real time using a laser diameter gauge, and the radial deviation ΔD is calculated, i.e., ΔD=D max -D min D max D is the maximum axial diameter of the release film roll on the current station's take-up shaft. minThe minimum axial diameter of the release film roll on the current station's take-up shaft;

[0019] S3. Adaptive Adjustment of Roller Stroke: When the radial deviation ΔD of the release film roll exceeds the threshold, it indicates that the release film roll has obvious unequal diameter. The control mechanism adjusts the adjustment based on the real-time measured D... max and D min The value is calculated to determine the required compensation displacement of the left and right ends of the roller body relative to the surface of the release film roll. The control mechanism drives the piston rod of the low-friction cylinder mechanism to extend and retract, independently adjusting the spatial position of the left and right ends of the roller body so that the roller body always contacts the surface of the release film roll with the constant output pressure P0.

[0020] Furthermore, it also includes a correction adjustment step: using an infrared sensor to measure in real time whether the isolation film is shifted on the conveyor roller, as well as the magnitude and direction of the shift. Based on the data fed back by the infrared sensor, the control mechanism determines whether there is a shift. If the shift of the isolation film is within a set threshold, the control mechanism continues to monitor without responding; if the shift of the isolation film exceeds the set threshold, the correction adjustment operation is initiated.

[0021] When the detected deviation of the isolation membrane exceeds a set threshold, the control mechanism corrects the deviation of the isolation membrane by adjusting the up-and-down movement and rotation speed of the two correction rollers, specifically:

[0022] When the separator film is detected to have shifted to one side, the control mechanism drives both of the alignment rollers to move downwards until the outer periphery of the alignment rollers is in close contact with the upper surface of the separator film to apply friction. The control mechanism dynamically adjusts the rotation speed of the two alignment rollers according to the direction and magnitude of the separator film's shift, so as to apply different friction forces to the two edges of the separator film. The alignment roller closer to the edge with a higher linear velocity exerts a greater friction force on the separator film than the alignment roller closer to the edge with a lower linear velocity. The infrared sensor continuously monitors the position of the separator film relative to the winding shaft until the shift caused by the inconsistent linear velocities of the two edges of the separator film is eliminated. The control mechanism then controls the alignment rollers to stop rotating and drives them away from the conveyor rollers to return to their initial positions.

[0023] Furthermore, the offset of the isolation membrane is set to Δx, and the initial rotational speed of the correction roller is v0, which is consistent with the preset conveying speed of the isolation membrane. The adjusted rotational speeds of the two correction rollers are set to v1 and v2, where v1 > v2, i.e., the rotational speed difference between the two correction rollers is Δv = v1 - v2. The offset of the isolation membrane, Δx, is directly proportional to the rotational speed difference Δv between the two correction rollers, and the following relationship can be obtained:

[0024]

[0025] In the formula, k' is a proportionality coefficient, which is determined according to the characteristics of the separator and has a value range of 0.1-1.0; the rotational speeds of the two correction rollers after adjustment are v1=v0+Δv / 2; v2=v0-Δv / 2.

[0026] Furthermore, the proportionality coefficient k' is determined based on the contact force N and the friction coefficient μ between the correction roller and the isolation membrane. The friction difference ΔF between the two correction rollers and the isolation membrane is μN(v1-v2). Since the offset of the isolation membrane relative to the conveying roller is caused by the difference in linear velocity between the two edges of the isolation membrane, the friction difference ΔF is proportional to the offset Δx. By experimentally determining the proportionality coefficient C between the friction difference ΔF and the offset Δx, it can be obtained that the friction difference ΔF and the offset Δx satisfy the following relationship: Δx=C×ΔF=C×μN(v1-v2)=C×μN×Δv, then k'=C×μN.

[0027] Furthermore, in step S3, the adjustment target of the control mechanism for adjusting the spatial position of the left and right ends of the roller is to dynamically adapt the surface contour of the roller to the current radial deviation shape of the release film roll while keeping the contact pressure of the roller on the release film roll constant at a preset constant output pressure P0.

[0028] In summary, compared with the prior art, the beneficial effects of the present invention are:

[0029] The flexible adjusting roller device of this invention achieves precise pressure control through a lever arm mechanism. The stepped bearing position in the middle section of the lever arm plate is tightly fitted with the bearing. The rotating shaft is axially positioned through a limiting shoulder to ensure the stability of the rotation center. Two mirror-symmetrical lever arm mechanisms enable the two ends of the roller to move synchronously, avoiding uneven loading. The self-aligning ball bearing compensates for roller installation errors. The shouldered hinge pin and Y-type joint convert the linear motion of the cylinder into the arc swing of the lever arm plate, ultimately driving the roller to apply pressure to the film roll. This ensures that uniform pressure is applied to the release film under different working conditions. By applying appropriate pressure to the film roll through the roller, the release film is ensured to remain flat during winding, reducing the scrap rate caused by wrinkles and protrusions. This device is used to solve the problems of wrinkling and poor edge alignment in the first 200 meters of automatic winding of release film rolls. Attached Figure Description

[0030] Figure 1 This is a schematic diagram of the flexible adjusting roller device of the present invention;

[0031] Figure 2 This is an exploded view of the flexible adjusting roller device of the present invention;

[0032] Figure 3This is a schematic diagram showing the positions of the flexible adjusting roller device, the winding mechanism, and the cutting mechanism of the present invention.

[0033] Among them, 1-flexible adjusting roller device, 11-roller body, 111-self-aligning ball bearing, 12-lever mechanism, 121-lever plate, 122-bearing, 123-rotating shaft, 124-stepped bearing seat, 125-limiting shoulder, 13-bearing seat, 14-shoulder hinge pin, 15-Y-type joint, 16-low friction cylinder mechanism, 2-isolation film, 3-transfer roller, 4-winding mechanism, 41-rotary support seat, 42-cantilever, 43-transition roller, 44-winding shaft, 5-cutting mechanism. Detailed Implementation

[0034] The specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. It should be understood that the specific embodiments given herein are for illustration and explanation only and are not intended to limit the present invention.

[0035] like Figures 1 to 3 As shown, a flexible adjusting roller device 1 includes...

[0036] Roller 11 is used to apply pressure to the release film roll during the winding process of the release film 2 to flatten its wrinkles and lumps;

[0037] The lever arm mechanism 12 includes a lever arm plate 121, a bearing 122, and a rotating shaft 123. The middle section of the lever arm plate 121 has a stepped bearing seat 124 formed by a stepped through hole. The outer periphery of the bearing 122 is installed close to the inner end face of the stepped bearing seat 124. One end of the rotating shaft 123 has a limiting shoulder 125, which passes through the inner periphery of the bearing 122 and abuts against the inner periphery surface of the bearing 122. The other end of the rotating shaft 123 is fixedly installed on the frame. The lever arm plate 121 and the rotating shaft 123 can rotate relative to each other through the bearing 122. The stepped bearing seat 124 is the rotation center of the lever arm plate 121.

[0038] Two lever arm mechanisms 12 are provided, and the two lever arm mechanisms 12 are respectively mirror-symmetrically installed at both ends of the roller body 11. The top ends of the corresponding two lever arm plates 121 are fixedly provided with bearing seats 13. The bearing seats 13 cooperate with the self-aligning ball bearings 111 provided at both ends of the roller body 11, so that the roller body 11 and the lever arm mechanism 12 can rotate relative to each other. The ends of the corresponding two lever arm plates 121 are connected to Y-type joints 15 through shoulder hinge pins 14. The Y-type joints 15 are fixedly connected to the piston rod of the low friction cylinder mechanism 16. The low friction cylinder mechanism 16 is electrically connected to the control mechanism and drives the piston rod to move linearly. Through the Y-type joints 15, the shoulder hinge pins 14 are pushed, causing the lever arm plates 121 to swing around the axis of the rotation shaft 123 in an arc trajectory, thereby driving the roller body 11 to rotate relative to the rotation center on the lever arm mechanism 12.

[0039] The flexible adjusting roller device 1 achieves precise pressure control through the lever arm mechanism 12. The stepped bearing position 124 in the middle section of the lever arm plate 121 is tightly fitted with the bearing 122. The rotating shaft 123 is axially positioned through the limiting shoulder 125 to ensure the stability of the rotation center. The two mirror-symmetrical lever arm mechanisms 12 enable the two ends of the roller body 11 to move synchronously to avoid uneven load. The self-aligning ball bearing 111 compensates for the installation error of the roller body 11. The shouldered hinge pin 14 and the Y-type joint 15 convert the linear motion of the cylinder into the arc swing of the lever arm plate 121, which ultimately drives the roller body 11 to apply pressure to the film roll, ensuring that uniform pressure can be applied to the separator film 2 under different working conditions. By applying appropriate pressure to the film roll through the roller body 11, the separator film 2 is kept flat during the winding process, reducing the scrap rate caused by wrinkles and protrusions.

[0040] In actual operation, the flexible adjusting roller device 1 can adapt to the release film 2 of different materials and thicknesses. For thinner or more sensitive film materials, the output thrust of the piston rod can be reduced, thereby reducing the pressure applied by the roller body 11 and ensuring that the film material is not damaged during the winding process. For thicker or harder film materials, the thrust can be increased to provide sufficient pressure and ensure the winding quality. This allows the flexible adjusting roller device 1 to maintain high efficiency in various production environments, significantly improving the versatility and economy of the equipment.

[0041] Furthermore, the low-friction cylinder mechanism 16 is fixedly mounted on the frame. The low-friction cylinder mechanism 16 is equipped with an electric proportional valve that is electrically connected to the control mechanism to control the output thrust of the piston rod, thereby controlling the pressure of the roller 11 on the release film roll.

[0042] It is equipped with an electric proportional valve that is electrically connected to the control mechanism to control the output thrust of the piston rod, thereby controlling the pressure of the roller 11 on the release film roll. Through the control of the electric proportional valve, the pressure can be dynamically adjusted according to different working conditions to ensure the winding quality.

[0043] Furthermore, the rotation center distance between the bearing seat 13 and the lever arm plate 121 is L1, and the rotation center distance between the shoulder hinge pin 14 and the lever arm plate 121 is L2, where L1=2L2, that is, the lever arm plate 121 and the piston rod form a 1:2 lever ratio. When the piston rod outputs a thrust F, the pressure of the roller body 11 on the release film roll is F / 2.

[0044] When the roller 11 requires pressure P, since the lever arm plate 121 and the piston rod form a 1:2 lever ratio, the piston rod only needs to output a thrust of P / 2, which greatly reduces energy consumption, reduces wear on mechanical parts, extends the service life of the equipment, and improves the accuracy and flexibility of pressure control. It can adapt to the isolation membrane 2 of different materials and thicknesses, significantly improves production efficiency and product quality, and has extremely high economic efficiency and wide applicability.

[0045] Furthermore, the input end of the flexible adjustment roller device 1 is provided with several conveying rollers 3 and the output end is provided with a winding mechanism 4. The conveying rollers 3 are used to convey the isolation film 2 to the winding mechanism 4 for collection. A cutting mechanism 5 is provided between the winding mechanism 4 and the flexible adjustment roller device 1 for cutting the isolation film 2.

[0046] The winding mechanism 4 includes a rotary support 41, several cantilever arms 42, several transition rollers 43, and several winding shafts 44. The cantilever arms 42 are radially distributed on the rotary support 41 and are on the same horizontal plane. The number of cantilever arms 42 is equal to the total number of transition rollers 43 and winding shafts 44. The transition rollers 43 and winding shafts 44 are alternately arranged at the ends of several cantilever arms 42 and are rotatably connected to the cantilever arms 42. The winding shafts 44 are electrically connected to the control mechanism. The control mechanism drives the winding shafts 44 to rotate at a set speed to complete the winding operation. The rotary support 41 is connected to a drive assembly electrically connected to the control mechanism, which drives the rotary support 41 to rotate, thereby causing the cantilever arms 42 to rotate around the rotation center of the rotary support 41, and causing the transition rollers 43 and winding shafts 44 to alternately change positions.

[0047] If the take-up shaft 44 of the current working position is located within the working position angle domain β of the flexible adjusting roller device 1, i.e., |β|≤50°, the outer circumferential surface of the roller body 11 is pressed against the film roll surface of the take-up shaft 44 of the current working position. When the take-up shaft 44 of the current working position moves out of the working position angle domain β with the rotation of the cantilever 42, the roller body 11 immediately disengages from the contact. At the instant the new take-up shaft 44 enters the working position angle domain β, the cutting mechanism 5 simultaneously cuts the release film 2. The roller body 11 then contacts the new take-up shaft 44 and continues the winding operation. The working position angle domain β is the angle between the line connecting the axis of the roller body 11 and the axis of the take-up shaft 44 of the current working position and the horizontal line.

[0048] After the release film 2 is introduced by the conveyor roller 3, it is wound up by the current station take-up shaft 44 in the take-up mechanism 4. The control mechanism synchronously drives the cantilever 42 to rotate continuously at low speed around the rotation center of the rotary support 41, which drives the transition roller 43 and the take-up shaft 44 to dynamically alternate their positions relative to the conveyor roller 3. As the cantilever 42 rotates, the original take-up shaft 44 gradually moves to the unloading position far away from the conveyor roller 3. The release film 2 always sticks tightly to the transition roller 43 to form a wrap angle. At the same time, the new take-up shaft 44 synchronously rotates to the preparatory position near the conveyor roller 3. When the take-up shaft 44 of the original take-up station reaches the set roll diameter, the cutting mechanism 5 cuts the film. The flexible adjusting roller device 1 presses against the surface of the new take-up shaft 44, continuously applying pressure to eliminate the wrinkles of the release film 2, and the next take-up cycle begins.

[0049] In the winding mechanism 4, the coordinated work of the rotary support 41, cantilever 42, transition roller 43, and winding shaft 44 achieves automation and high efficiency in the winding process. The continuous low-speed rotation of the rotary support 41 drives the cantilever 42 to rotate around its center of rotation, allowing the transition roller 43 and winding shaft 44 to alternate positions. This not only ensures the continuity of the winding process but also ensures that each winding shaft 44 can perform winding operations in the optimal position, improving winding efficiency and quality. Simultaneously, when one winding shaft 44 completes its winding task and moves to the unloading position, another new winding shaft 44 is already accurately positioned in the ready position. At this instant, the cutting mechanism 5 cuts the release film 2, and the roller 11 immediately adheres to the new winding shaft 44, starting the next winding cycle. The entire process is seamlessly connected, greatly improving production efficiency and reducing downtime caused by roll changes. Furthermore, the release film 2 always adheres tightly to the transition roller 43, forming a wrap angle, effectively preventing loosening and wrinkling of the film material during transmission, thus improving winding quality. In addition, the forced pressing operation of the flexible adjusting roller on the new take-up shaft 44 ensures a firm fit at the ends of the film material, reduces the scrap rate caused by unstable splicing, and solves the problems of wrinkling and poor edge alignment in the first 200 meters of the automatic take-up of the release film roll.

[0050] Furthermore, two correction rollers electrically connected to the control mechanism are provided directly above the conveyor roller 3. The axis of the correction roller is parallel to the axis of the corresponding conveyor roller 3. The two correction rollers are located at the ends of the conveyor roller 3 in the axial direction. The control mechanism drives the correction rollers to rotate and move up and down relative to the conveyor roller 3.

[0051] By dynamically adjusting the alignment rollers, the deviation of the isolation film 2 can be effectively corrected. When the isolation film 2 deviates, the two alignment rollers apply different frictional forces to the two edges of the isolation film 2 at different speeds to correct the deviation, ensuring that the isolation film 2 remains flat during the winding process. This effectively reduces wrinkles, loosening or damage caused by deviation, significantly reduces the scrap rate, improves production efficiency and product quality, and ensures the stability and reliability of the entire winding process.

[0052] The adjustment method of the flexible adjusting roller device 1 includes the following steps:

[0053] S1. Initial pressure setting: Based on the material characteristics of the separator film 2 and the actual usage requirements, the constant output pressure P0 required by the flexible adjustment roller device 1 is set. The control mechanism adjusts the output thrust of the piston rod according to the constant output pressure P0, so that the roller body 11 of the flexible adjustment roller device 1 applies the preset constant output pressure P0 to the separator film roll.

[0054] S2. Radial Difference Monitoring of Material Roll: During the winding process, the diameter change of the release film roll on the current station winding shaft of the winding mechanism 4 is monitored in real time using a laser diameter gauge, and the radial deviation ΔD is calculated, i.e., ΔD=D max-D min D max D is the maximum axial diameter of the release film roll on the current station's take-up shaft. min The minimum axial diameter of the release film roll on the current station's take-up shaft;

[0055] S3. Adaptive Adjustment of Roller Stroke: When the radial deviation ΔD of the release film roll exceeds the threshold, it indicates that the release film roll has obvious unequal diameter. The control mechanism adjusts the adjustment based on the real-time measured D... max and D min The value is calculated to determine the required compensation displacement of the left and right ends of the roller 11 relative to the surface of the release film roll. The control mechanism drives the piston rod of the low-friction cylinder mechanism 16 to extend and retract, independently adjusting the spatial position of the left and right ends of the roller 11 so that the roller 11 always contacts the surface of the release film roll with a constant output pressure P0.

[0056] The flexible adjusting roller device 1 can effectively flatten the wrinkles and lumps of the release film roll by setting a preset constant output pressure P0, ensuring that the release film 2 remains flat during the winding process. At the same time, the device monitors the radial deviation of the roll in real time and dynamically adjusts the compensation displacement of the roller body 11 according to the radial deviation, thereby effectively correcting the problem of uneven diameter of the roll, avoiding winding quality problems caused by uneven roll diameter, significantly improving winding quality, reducing scrap rate, enhancing the adaptability of the equipment to different materials and working conditions, reducing energy consumption and equipment wear, and improving production efficiency and economic benefits.

[0057] Furthermore, it also includes a correction adjustment step: using an infrared sensor to measure in real time whether the isolation membrane 2 is offset on the conveyor roller 3, as well as the magnitude and direction of the offset. Based on the data fed back by the infrared sensor, the control mechanism determines whether there is an offset. If the offset of the isolation membrane 2 is within the set threshold, the control mechanism continues to monitor without responding; if the offset of the isolation membrane 2 exceeds the set threshold, the correction adjustment operation is initiated.

[0058] When the detected offset of the isolation membrane 2 exceeds the set threshold, the control mechanism corrects the offset isolation membrane 2 by adjusting the up-and-down movement and rotation speed of the two correction rollers, specifically as follows:

[0059] When the isolation membrane 2 is found to have shifted to one side, the control mechanism drives both correction rollers to move downwards until the outer periphery of the correction rollers is in close contact with the upper surface of the isolation membrane 2 to apply friction to the isolation membrane 2. The control mechanism dynamically adjusts the rotation speed of the two correction rollers according to the direction and magnitude of the shift of the isolation membrane 2 to apply different friction forces to the two edges of the isolation membrane 2. The friction force of the correction roller closer to the edge of the isolation membrane 2 with a higher linear velocity is greater than that of the correction roller closer to the edge of the isolation membrane 2 with a lower linear velocity. The infrared sensor continuously monitors the position of the isolation membrane 2 relative to the winding shaft 44 until the shift caused by the inconsistent linear velocities of the two edges of the isolation membrane 2 is eliminated. The control mechanism then controls the correction rollers to stop rotating and drives them away from the conveyor roller 3 to return to their initial position.

[0060] The dynamic calculation of the correction coefficient K, based on real-time radial difference changes, makes pressure adjustment more precise and efficient. By adjusting the pressure, unevenness and waste of the separator film 2 during the winding process are avoided. The speed and up-down movement adjustment of the correction roller, combined with infrared sensor feedback, ensures that the dynamic adjustment of the separator film 2 is more flexible and accurate. Through differential speed control, the two edges of the separator film 2 are kept flat, effectively avoiding the problems of offset, wrinkles and unevenness that occur during the winding process. This enables the system to adaptively respond to changes in different materials and operating conditions, improving the stability and automation level of the equipment.

[0061] Furthermore, the offset of the isolation membrane 2 is set to Δx, and the initial rotational speed of the correction roller is set to v0, which is consistent with the preset conveying speed of the isolation membrane 2. The adjusted rotational speeds of the two correction rollers are set to v1 and v2, where v1 > v2, i.e., the rotational speed difference between the two correction rollers is Δv = v1 - v2. The offset of the isolation membrane 2, Δx, is directly proportional to the rotational speed difference Δv between the two correction rollers, and the following relationship can be obtained:

[0062]

[0063] In the formula, k' is the proportional coefficient, which is determined according to the characteristics of the separator 2, and its value ranges from 0.1 to 1.0; the rotational speeds of the two correction rollers after adjustment are v1=v0+Δv / 2; v2=v0-Δv / 2.

[0064] Furthermore, the proportionality coefficient k' is determined based on the contact force N between the correction roller and the isolation membrane 2 and the friction coefficient μ. The frictional difference ΔF between the two correction rollers and the isolation membrane 2 is μN(v1-v2). Since the offset of the isolation membrane 2 relative to the conveyor roller 3 is caused by the difference in linear velocity between the two edges of the isolation membrane 2, the frictional difference ΔF is proportional to the offset Δx. By experimentally determining the proportionality coefficient C between the frictional difference ΔF and the offset Δx, we can obtain the following relationship between the frictional difference ΔF and the offset Δx: Δx=C×ΔF=C×μN(v1-v2)=C×μN×Δv, then k'=CμN.

[0065] The proportionality coefficient C was determined experimentally. A known material of the separator membrane 2 was selected, and the experimental setup and operating conditions were kept consistent. Without applying a corrective force, the initial offset of the membrane belt was measured. An infrared sensor or laser rangefinder was used to accurately measure whether the membrane belt shifted during transport. By adjusting the rotational speed of the corrective roller, different speed differences ΔV were applied, and the applied speed difference was recorded each time. The frictional force difference ΔF applied to the membrane belt by the corrective roller was estimated by a force sensor or by calculating the torque. The offset ΔX of the membrane belt after each application of a different speed difference was measured. The measured offset ΔX and the corresponding frictional force difference ΔF were compared, and the proportionality coefficient C was obtained using regression analysis.

[0066] Furthermore, in step S3, the adjustment target of the control mechanism for adjusting the spatial position of the left and right ends of the roller 11 is to dynamically adapt the surface contour of the roller 11 to the current radial deviation shape of the separator film roll while keeping the contact pressure of the roller 11 on the separator film roll constant at the preset constant output pressure P0.

[0067] In areas where the diameter of the release film roll is small, the roller 11 extends more to maintain contact; in areas where the diameter of the release film roll is large, the roller 11 contracts more to avoid excessive pressure.

[0068] It should be understood that the above embodiments are one or more embodiments of the present invention. There are many other embodiments and variations based on the present invention. Any variations and modifications made by those skilled in the art without making pioneering innovations are within the protection scope of the present invention.

Claims

1. A flexible adjusting roller device, characterized in that: include Rollers are used to apply pressure to flatten the roll of release film material. A lever arm mechanism includes a lever arm plate, a bearing, and a rotating shaft. The middle section of the lever arm plate has a stepped bearing seat formed by a stepped through hole. The outer periphery of the bearing is installed close to the inner end face of the stepped bearing seat. One end of the rotating shaft has a limiting shoulder, which passes through the inner periphery of the bearing and abuts against the inner circumferential surface of the bearing. The other end of the rotating shaft is fixedly installed on the frame. The lever arm plate and the rotating shaft can rotate relative to each other through the bearing. The stepped bearing seat is the rotation center of the lever arm plate. The lever arm mechanism is provided in two parts, which are respectively mirror-symmetrically installed at both ends of the roller body. The top of each of the two corresponding lever arm plates is fixed with a bearing seat. The bearing seat cooperates with the self-aligning ball bearings provided at both ends of the roller body, so that the roller body and the lever arm mechanism can rotate relative to each other. The ends of each of the two corresponding lever arm plates are connected to a Y-type joint through a shoulder hinge pin. The Y-type joint is fixedly connected to the piston rod of the low friction cylinder mechanism. The low friction cylinder mechanism is electrically connected to the control mechanism and drives the piston rod to move linearly. The flexible adjusting roller device has several conveying rollers at its input end and a winding mechanism at its output end. The conveying rollers are used to convey the isolation film to the winding mechanism for collection. A cutting mechanism is provided between the winding mechanism and the flexible adjusting roller device for cutting the isolation film. The winding mechanism includes a rotary support base, several cantilever arms, several transition rollers, and several winding shafts. The cantilever arms are radially distributed on the rotary support base and are on the same horizontal plane. The number of cantilever arms is equal to the total number of transition rollers and winding shafts. The transition rollers and winding shafts are alternately arranged at the ends of several cantilever arms and are rotatably connected to the cantilever arms. The winding shafts are electrically connected to a control mechanism. The control mechanism drives the winding shafts to rotate at a set speed to complete the winding operation. The rotary support base is connected to a drive assembly electrically connected to the control mechanism, which drives the rotary support base to rotate, thereby causing the cantilever arms to rotate around the rotation center of the rotary support base, and causing the transition rollers and winding shafts to alternately change positions. If the take-up shaft at the current working position is located within the working angle domain β of the flexible adjusting roller device, i.e., |β|≤50°, the outer peripheral surface of the roller body is pressed against the film roll surface of the take-up shaft at the current working position. When the take-up shaft at the current working position moves out of the working angle domain β with the rotation of the cantilever, the roller body immediately disengages from contact. At the instant the new take-up shaft enters the working angle domain β, the cutting mechanism simultaneously cuts the release film. The roller body then contacts the new take-up shaft to continue the winding operation. The working angle domain β is the angle between the line connecting the axis of the roller body and the axis of the take-up shaft at the current working position and the horizontal line.

2. The flexible adjusting roller device according to claim 1, characterized in that: The low-friction cylinder mechanism is fixedly installed on the frame. The low-friction cylinder mechanism is equipped with an electric proportional valve that is electrically connected to the control mechanism to control the output thrust of the piston rod, thereby controlling the pressure of the roller on the release film roll.

3. The flexible adjusting roller device according to claim 1, characterized in that: The distance between the bearing seat and the rotation center of the lever plate is L1, and the distance between the shoulder hinge pin and the rotation center of the lever plate is L2, where L1=2L2, that is, the lever plate and the piston rod form a 1:2 lever ratio. When the piston rod outputs a thrust F, the pressure of the roller on the release film roll is F / 2.

4. The flexible adjusting roller device according to claim 1, characterized in that: Two correction rollers electrically connected to the control mechanism are provided directly above the conveying roller. The axis of the correction roller is parallel to the axis of the corresponding conveying roller. The two correction rollers are located at the ends of the conveying roller in the axial direction. The control mechanism drives the correction rollers to rotate and move up and down relative to the conveying roller.

5. The flexible adjusting roller device according to claim 4, characterized in that... The adjustment method of the flexible adjusting roller device includes the following steps: S1. Initial pressure setting: Based on the material characteristics of the separator and the actual usage requirements, the constant output pressure P0 required by the flexible adjustment roller device is set. The control mechanism adjusts the output thrust of the piston rod according to the constant output pressure P0, so that the roller body of the flexible adjustment roller device applies the preset constant output pressure P0 to the separator roll. S2. Radial Difference Monitoring of Material Roll: During the winding process, the diameter change of the release film roll at the current station winding shaft on the winding mechanism is monitored in real time using a laser diameter gauge, and the radial deviation ΔD is calculated, i.e., ΔD=D max -D min D max D is the maximum axial diameter of the release film roll on the current station's take-up shaft. min The minimum axial diameter of the release film roll on the current station's take-up shaft; S3. Adaptive Adjustment of Roller Stroke: When the radial deviation ΔD of the release film roll exceeds the threshold, it indicates that the release film roll has obvious unequal diameter. The control mechanism adjusts the adjustment based on the real-time measured D... max and D min The value is calculated to determine the required compensation displacement of the left and right ends of the roller body relative to the surface of the release film roll. The control mechanism drives the piston rod of the low-friction cylinder mechanism to extend and retract, independently adjusting the spatial position of the left and right ends of the roller body so that the roller body always contacts the surface of the release film roll with the constant output pressure P0.

6. The flexible adjusting roller device according to claim 5, characterized in that... It also includes a correction adjustment step: using an infrared sensor to measure in real time whether the isolation film is shifted on the conveyor roller, as well as the magnitude and direction of the shift. Based on the data fed back by the infrared sensor, the control mechanism determines whether there is a shift. If the shift of the isolation film is within a set threshold, the control mechanism continues to monitor without responding; if the shift of the isolation film exceeds the set threshold, the correction adjustment operation is initiated. When the detected deviation of the isolation membrane exceeds a set threshold, the control mechanism corrects the deviation of the isolation membrane by adjusting the up-and-down movement and rotation speed of the two correction rollers, specifically: When the separator film is detected to have shifted to one side, the control mechanism drives both of the alignment rollers to move downwards until the outer periphery of the alignment rollers is in close contact with the upper surface of the separator film to apply friction. The control mechanism dynamically adjusts the rotation speed of the two alignment rollers according to the direction and magnitude of the separator film's shift, so as to apply different friction forces to the two edges of the separator film. The alignment roller closer to the edge with a higher linear velocity exerts a greater friction force on the separator film than the alignment roller closer to the edge with a lower linear velocity. The infrared sensor continuously monitors the position of the separator film relative to the winding shaft until the shift caused by the inconsistent linear velocities of the two edges of the separator film is eliminated. The control mechanism then controls the alignment rollers to stop rotating and drives them away from the conveyor rollers to return to their initial positions.

7. The flexible adjusting roller device according to claim 6, characterized in that: The offset of the isolation membrane is set as Δx, and the initial rotational speed of the correction roller is v0, which is consistent with the preset conveying speed of the isolation membrane. The adjusted rotational speeds of the two correction rollers are set as v1 and v2, where v1 > v2. That is, the rotational speed difference between the two correction rollers is Δv = v1 - v2. The offset of the isolation membrane, Δx, is directly proportional to the rotational speed difference Δv between the two correction rollers, and the following relationship can be obtained: In the formula, k' is a proportionality coefficient, which is determined according to the characteristics of the separator and has a value range of 0.1-1.0; the rotational speeds of the two correction rollers after adjustment are v1=v0+Δv / 2; v2=v0-Δv / 2.

8. The flexible adjusting roller device according to claim 7, characterized in that: The proportionality coefficient k' is determined based on the contact force N and the friction coefficient μ between the correction roller and the isolation film. The friction difference ΔF between the two correction rollers and the isolation film is μN(v1-v2). Since the offset of the isolation film relative to the conveying roller is caused by the difference in linear velocity between the two edges of the isolation film, the friction difference ΔF is proportional to the offset Δx. By experimentally determining the proportionality coefficient C between the friction difference ΔF and the offset Δx, it can be obtained that the friction difference ΔF and the offset Δx satisfy the following relationship: Δx=C×ΔF=C×μN(v1-v2)=C×μN×Δv, then k'=C×μN.

9. The flexible adjusting roller device according to claim 5, characterized in that: The adjustment target of the control mechanism in step S3 for adjusting the spatial position of the left and right ends of the roller is to dynamically adapt the surface contour of the roller to the current radial deviation shape of the release film roll while keeping the contact pressure of the roller on the release film roll constant at a preset constant output pressure P0.

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