Adaptive tension control system for dry electrode continuous roll forming machine

Abstract

This invention relates to the field of roll forming machine control technology, and discloses an adaptive tension control system for a dry electrode continuous roll forming machine. The system consists of a tension generation module, a state assessment module, a dynamic compensation module, a strategy optimization module, a production management database, and a roll forming actuator. The tension generation module collects raw tension data in real time at the transmission nodes; the state assessment module analyzes the operating status based on this data and generates a tension stability assessment report; the dynamic compensation module calculates the material deformation compensation amount based on the report and generates dynamic control commands; the strategy optimization module combines commands and historical records to optimize the strategy and output a parameter package; the production management database stores material characteristics, equipment history, and control cases; and the roll forming actuator adjusts its operation according to the parameter package. These modules work together to achieve real-time tension monitoring, assessment, compensation, and optimization, solving traditional control problems and helping to improve product quality and efficiency.

Description

Technical Field

[0001] This invention relates to the field of roll forming machine control technology, specifically to an adaptive tension control system for a dry electrode continuous roll forming machine. Background Technology

[0002] In many industrial production processes, such as battery manufacturing, the dry electrode continuous roll forming process is gradually becoming an important direction for industry development due to its advantages such as not requiring large amounts of solvents, low energy consumption, and theoretically higher production efficiency. However, in the actual dry electrode continuous roll forming process, tension control has become a key obstacle restricting the widespread application and efficient production of this process.

[0003] Traditional roller pressing actuators, lacking effective tension monitoring at transmission nodes, struggle to acquire real-time raw tension data during the pressing process. This makes it impossible to detect tension fluctuations that may occur during pressing in a timely manner, let alone make corresponding adjustments based on these fluctuations. For example, in some conventional roller pressing equipment, relying solely on operators periodically inspecting the surface condition of the pressed material to roughly determine the tension is not only significantly lagging but also highly susceptible to human error, failing to meet the demands of modern high-precision production.

[0004] Currently, most rolling mill equipment lacks the capability for comprehensive and accurate analysis of its operating status. When raw tension data cannot be obtained accurately in real time, it is naturally difficult to deeply analyze the current rolling operation status, and consequently, it is impossible to generate a reliable tension stability assessment report. During the production process, even if the tension of the rolled material has fluctuated significantly, the equipment cannot identify it in time and continues to operate according to the original operating parameters. This seriously threatens the quality of the rolled material, resulting in a significant increase in the defect rate. For example, in the rolling production of battery electrode sheets, the failure to detect tension instability in time led to a large number of electrode sheets exhibiting problems such as uneven thickness and surface wrinkles, necessitating rework or even scrapping, resulting in significant resource waste and economic losses.

[0005] When materials undergo deformation during roll forming, existing systems struggle to calculate accurate deformation compensation amounts, let alone generate effective dynamic tension control command sets for dynamic tension adjustment. As materials pass through the roll forming equipment, they are highly susceptible to deformation due to inherent material properties and changes in external factors such as temperature and pressure during the rolling process. The lack of an effective dynamic compensation mechanism prevents the equipment from adjusting tension promptly based on these deformations, leading to serious problems such as breakage and delamination in subsequent processing. For example, in the roll forming production of some plastic films, the inability to effectively compensate for material deformation during rolling often results in film rupture, severely impacting production continuity and product quality. Summary of the Invention

[0006] The purpose of this invention is to provide an adaptive tension control system for a dry electrode continuous roll forming machine to solve the problems mentioned in the background art.

[0007] To achieve the above objectives, the present invention provides an adaptive tension control system for a dry electrode continuous roll forming machine, the system comprising:

[0008] The tension generation module is deployed on the transmission node of the roller pressing mechanism to acquire the raw tension dataset in real time during the roller pressing process;

[0009] The status assessment module receives the raw tension dataset from the tension generation module, analyzes the current rolling operation status, and generates a tension stability assessment report.

[0010] The dynamic compensation module receives the tension stability assessment report from the state assessment module, calculates the deformation compensation amount of the rolled material, and generates a dynamic tension control instruction set.

[0011] The strategy optimization module receives the dynamic tension control instruction set and historical control records from the dynamic compensation module, optimizes the tension control strategy, and outputs an optimized tension control parameter package.

[0012] The production management database stores a dataset of roll-pressed material characteristics, a database of equipment operation history archives, and a database of tension control cases.

[0013] The roller pressing actuator receives the optimized tension control parameter package from the strategy optimization module and adjusts the operating parameters of the roller pressing actuator.

[0014] Preferably, when the tension generation module acquires the original tension dataset, it specifically performs the following operations: real-time capture of the torque change waveform data of the drive shaft of the roller pressing actuator, synchronous acquisition of the velocity difference sequence between the inlet and outlet of the roller pressing material, and integration of the roller pressing material surface friction coefficient detection data and environmental temperature and humidity monitoring data to generate the original tension dataset; wherein the material surface friction coefficient detection data is periodically acquired by an online surface scanner, and the environmental temperature and humidity monitoring data is acquired in real time by a sensor array arranged inside the roller pressing cavity.

[0015] Preferably, the process of the state assessment module generating a tension stability assessment report includes: extracting torque fluctuation feature values ​​and velocity difference change gradients from the original tension dataset; comparing the torque fluctuation feature values ​​with the standard torque fluctuation threshold range in the equipment operation history archive; and simultaneously matching and verifying the velocity difference change gradient with the upper limit of the material's allowable deformation rate; when the torque fluctuation feature value exceeds the standard torque fluctuation threshold range or the velocity difference change gradient exceeds the upper limit of the material's allowable deformation rate, activating the tension anomaly identifier and calculating the actual deviation; and comprehensively considering the deviation of the torque fluctuation feature value, the deviation of the velocity difference change gradient, and the influence weight of environmental temperature and humidity monitoring data on material properties to generate a tension stability assessment report containing multi-dimensional assessment indicators.

[0016] Preferably, the operation process of the dynamic compensation module generating the dynamic tension control instruction set is as follows: receiving the tension stability assessment report sent by the state assessment module, parsing the tension anomaly identifier and multi-dimensional assessment indicators; calling the material property dataset in the production management database, matching the elastic recovery coefficient and plastic deformation critical point parameter of the current rolling material; calculating the basic compensation amount based on the actual deviation and the material elastic recovery coefficient, and correcting the compensation strength coefficient in combination with the plastic deformation critical point parameter; generating a dynamic tension control instruction set containing the compensation action position coordinates, compensation action timing, and compensation strength coefficient, and synchronously transmitting the instruction set to the strategy optimization module and the production management database.

[0017] Preferably, the process of optimizing the tension control strategy by the strategy optimization module specifically includes: receiving a dynamic tension control instruction set sent by the dynamic compensation module, and simultaneously extracting a historical similar scenario dataset from the tension control case library of the production management database; performing pattern matching between the compensation parameters in the current dynamic tension control instruction set and the control records in the historical similar scenario dataset, identifying the differences in compensation strategies and marking the strategy optimization candidate area; recalculating the compensation timing sequence arrangement and combination based on the strategy optimization candidate area to generate an optimized tension control parameter package; wherein the optimized tension control parameter package includes an optimized sequence of compensation action position, a compensation intensity adjustment ratio, and a compensation duration correction value.

[0018] Preferably, the operation of the roller pressing actuator to execute the optimized tension control parameter package includes: receiving the optimized tension control parameter package sent by the strategy optimization module and parsing the compensation action position optimization sequence therein; locating the specific execution unit of the roller pressing actuator according to the compensation action position optimization sequence, loading the compensation amount intensity adjustment ratio to the drive controller, and setting the compensation duration correction value to the execution time window; dynamically adjusting the roller pressing pressure output value according to the compensation amount intensity adjustment ratio within the specified execution time window, while simultaneously monitoring the deformation feedback data of the roller pressing material in real time and feeding it back to the tension generation module.

[0019] Preferably, the system further includes a real-time speed monitoring module, which is configured to: continuously collect real-time linear speed change data during the rolling material transmission process, calculate the speed fluctuation rate of adjacent sampling periods; cross-validate the speed fluctuation rate with the speed evaluation index in the tension stability evaluation report output by the state evaluation module; and when the speed fluctuation rate exceeds the allowable range of the speed evaluation index, generate a motion stability parameter correction request and send it to the dynamic compensation module.

[0020] Preferably, the processing flow of the dynamic compensation module in response to the motion stability parameter correction request is as follows: receiving the motion stability parameter correction request sent by the real-time speed monitoring module, extracting the actual sampled value of the current rolling material linear velocity; retrieving the equipment rated transmission speed reference value from the production management database, calculating the speed offset between the actual sampled value and the rated reference value; determining the compensation intervention level according to the magnitude of the speed offset, updating the compensation intensity coefficient in the dynamic tension control instruction set, and marking the updated compensation intensity coefficient as an emergency adjustment identifier and transmitting it to the strategy optimization module.

[0021] Preferably, the operation of the strategy optimization module in processing the emergency adjustment flag includes: receiving the emergency adjustment flag marked by the dynamic compensation module and interrupting the current strategy optimization process; immediately calling the emergency response plan dataset from the equipment operation history archive in the production management database, matching the emergency control mode corresponding to the current speed offset, and generating an emergency tension control parameter package.

[0022] Preferably, the emergency tension control parameter package includes the maximum range of the compensation intensity and the minimum duration of the compensation intensity.

[0023] Compared with the prior art, the beneficial effects of the present invention are:

[0024] The tension generation module in the system is deployed on the transmission node of the roller pressing mechanism. This ingenious layout enables it to acquire raw tension datasets in real time during the rolling process. Compared to traditional methods, it no longer relies on manual periodic inspections or indirect detection methods with significant lag, but can capture subtle changes in tension immediately. This real-time and accurate data acquisition provides a solid data foundation for subsequent tension analysis and control, ensuring that the entire control system can react based on the most accurate and up-to-date tension information.

[0025] After receiving the raw tension dataset from the tension generation module, the status assessment module can conduct in-depth analysis of the current rolling operation status and generate a tension stability assessment report. It acts like an experienced "diagnostic expert," accurately determining whether the tension is stable during the rolling process, the degree of instability, and the possible causes through the analysis of a large amount of raw tension data. This precise assessment of the operating status allows operators or subsequent control modules to quickly understand the equipment's operating condition, providing a clear basis for timely countermeasures and preventing the production of numerous defective products due to ignorance of tension instability.

[0026] The dynamic compensation module calculates the deformation compensation amount of the rolled material based on the tension stability assessment report from the state assessment module and generates a dynamic tension control command set. Material deformation is unavoidable during the rolling process, and this module can accurately calculate the corresponding compensation amount, thereby generating targeted control commands. Compared to traditional systems, it no longer blindly adjusts tension according to a fixed pattern, but rather dynamically and precisely compensates based on the real-time deformation of the material. This effectively avoids problems such as material breakage and delamination caused by a mismatch between tension and material deformation, greatly improving the quality and yield of rolled materials and reducing resource waste and economic losses caused by defective products.

[0027] The strategy optimization module receives the dynamic tension control command set and historical control records from the dynamic compensation module, optimizes the tension control strategy, and outputs an optimized tension control parameter package. As production continues, the characteristics of different batches of materials and the operating conditions of the equipment will change. This module can fully utilize this real-time and historical data to continuously learn and optimize the control strategy. It acts like a constantly evolving "intelligent brain," allowing the tension control strategy to keep pace with the times and always remain in optimal condition. This enables the equipment to better adapt to various complex and changing production conditions, further improving the accuracy and stability of tension control, and ensuring the consistency and stability of product quality. Attached Figure Description

[0028] Figure 1 This is a timing diagram of the adaptive tension control system of the dry electrode continuous roll forming machine described in this invention;

[0029] Figure 2 This is a flowchart of the raw data acquisition process for the tension generation module.

[0030] Figure 3 A flowchart for generating a tension stability assessment report for the condition assessment module;

[0031] Figure 4 A flowchart for optimizing control strategies for the strategy optimization module;

[0032] Figure 5A flowchart for requesting a response speed correction for the dynamic compensation module. Detailed Implementation

[0033] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0034] Please see Figure 1 This invention provides an adaptive tension control system for a dry electrode continuous roll forming machine, the system comprising:

[0035] The system comprises a tension generation module, a state assessment module, a dynamic compensation module, a strategy optimization module, a production management database, and a roller pressing actuator. The tension generation module is deployed on the transmission node of the roller pressing actuator to acquire the raw tension dataset in real time during the rolling process. The state assessment module receives the raw tension dataset, analyzes the current rolling operation status, and generates a tension stability assessment report. The dynamic compensation module receives the assessment report, calculates the deformation compensation amount of the rolled material, and generates a dynamic tension control command set. The strategy optimization module receives the control command set and historical control records, optimizes the tension control strategy, and outputs an optimized tension control parameter package. The production management database stores the roller pressing material characteristic dataset, the equipment operation history archive, and the tension control case library. The roller pressing actuator receives the optimized tension control parameter package and adjusts its operating parameters to achieve adaptive tension control.

[0036] Example 1: See Figure 2 The specific implementation process of the tension generation module is described below. This module is deployed at the transmission node of the roll forming actuator, including the main drive shaft, the driven roller support point, and the tension guide roller bearing housing. Data acquisition is accomplished through the collaborative use of multiple sensors: a strain gauge torque sensor is installed on the drive shaft flange to measure the shaft's torsional deformation and convert it into torque values. The sampling frequency is set to 1000 Hz, and the measurement range covers 0-5000 N·m. Laser velocimetry devices are deployed below the inlet guide plate and above the outlet guide roller of the roll forming material, with the distance between the two measuring points fixed at a reference distance value. Linear velocity signals are acquired non-contactly using the Doppler frequency shift principle. The velocity difference sequence is obtained in real time by calculating the inlet and outlet velocities of 100 consecutive sampling points, with a calculation period of 10 milliseconds.

[0037] The surface friction coefficient of the material was measured using an online scanning device. This device was installed at the inlet side of the roller pressing cavity, with the scanning probe at a 45-degree angle to the material transport plane. The scanning frequency was set to 10 times per second. Each scan covered a 15-centimeter-wide area of ​​the material surface. A blue laser light source was used to penetrate the surface dust, and the dynamic friction coefficient was calculated by analyzing the reflected light intensity. The measured data included three sub-items: static friction coefficient, dynamic friction coefficient, and surface roughness gradient.

[0038] The environmental parameter monitoring system consists of a distributed sensor array. Six integrated temperature and humidity sensors are arranged inside the roller pressing chamber, located at the gaps between the roller pressing units, the sidewalls of the material transport channel, and the exhaust port. The spacing between each sensor group is controlled within 150 mm. The temperature monitoring range covers 50-150 degrees Celsius, and the humidity monitoring range is 10%-90% relative humidity. Data acquisition uses a 4-20 mA current signal transmission, collecting 5 data samples per second.

[0039] The raw dataset integration process includes three steps: time synchronization, format conversion, and quality verification. The central processing unit is equipped with a precision clock generator, and all sensor data is appended with timestamps accurate to the millisecond level. Torque waveform data is stored in a floating decimal format with 1000 sampling points per second; the speed difference sequence generates a set of double-precision floating-point numbers every 10 milliseconds; friction coefficient data forms a vector containing three parameters per second; and temperature and humidity data generates a six-dimensional array every 200 milliseconds. Before the data stream is transmitted to the processing core via industrial Ethernet, it must undergo a validity verification process: verifying whether the temperature value is within a predetermined range; confirming whether the torque waveform shows any zero-value anomalies; and detecting whether the speed difference exceeds the physical limits of the equipment.

[0040] The data processing unit performs structured encapsulation of the raw dataset. Each complete data unit contains a time stamp segment, a device identifier segment, and an actual data segment. The time stamp segment records the year, month, day, hour, minute, second, and millisecond information; the device identifier segment contains the sensor serial number and location code; and the actual data segment integrates all parameter values ​​collected in that session. The integrated dataset is stored using a predefined data structure, with each record containing a torque waveform array, a speed difference sequence, a friction coefficient vector, and a temperature and humidity matrix.

[0041] The data transmission protocol adopts industry-standard communication specifications. The processing core receives raw data through a dual-channel redundancy mechanism, automatically switching to the backup channel when the main channel transmission delay exceeds 3 milliseconds. The data compression algorithm removes duplicate timestamps, retaining only complete records of parameter changes. Each complete dataset is transmitted to the input buffer of the status evaluation module within 20 milliseconds after generation, and simultaneously written to the raw data archive area of ​​the production management database. The cycle jitter of the entire acquisition, integration, and transmission process is controlled within ±2 milliseconds, meeting the real-time requirements of the roll forming process.

[0042] Example 2: See Figure 3 This paper describes the implementation methods of the state assessment module and the dynamic compensation module. The state assessment module receives the raw tension dataset from the tension generation module through a dedicated data interface, including a timestamp-aligned torque waveform array, a velocity difference sequence, a material surface friction coefficient vector, and an ambient temperature and humidity matrix. This module is deployed on an industrial-grade computing platform and uses a real-time operating system to process the input data. The feature extraction unit first analyzes the torque waveform data, applies the sliding window method to calculate the torque fluctuation feature value, and sets the window width to 100 milliseconds. Within each window, the mean absolute deviation and spectral peak value are calculated as feature parameters. The velocity difference change gradient is calculated using a differential algorithm, based on the velocity difference sequence within a continuous 100 milliseconds to obtain the rate of change. The comparison step calls the equipment operation history archive in the production management database, where the standard torque fluctuation threshold range is predefined and stored according to material type and equipment model, and is dynamically updated. The upper limit of the allowable deformation rate of the material is extracted from a subset of material properties in the database and automatically matched according to the material code of the current rolling material. The detection mechanism monitors the parameter limits. When the torque fluctuation feature value exceeds the threshold range or the velocity difference change gradient exceeds the upper limit of the deformation rate, the anomaly detector is activated, and the tension anomaly identifier is set to a high level. Simultaneously, the deviation calculation subunit calculates the actual deviation, such as the torque deviation being the difference between the characteristic value and the midpoint of the interval, and the velocity gradient deviation being the ratio difference between the current gradient value and the upper limit value. The environmental impact factor processing unit integrates temperature and humidity monitoring data, assigning weight factors through a preset relational matrix stored in the database. Each weight factor corresponds to the degree of influence of temperature and humidity values ​​on the viscoelastic properties of the material. Finally, the report generator combines all calculation results, including torque deviation, velocity gradient deviation, environmental impact weights, and anomaly identifiers, to form a tension stability assessment report containing a 12-dimensional index vector. The report format uses structured data frames, with each index stored as a double-precision floating-point number, and timestamps and device status codes added. It is transmitted to the input queue of the dynamic compensation module via the communication bus.

[0043] The dynamic compensation module is configured as an independent control processor. Upon receiving the tension stability assessment report from the state assessment module, it immediately initiates the parsing process. The report parser decomposes the input data structure, identifies the tension anomaly identifier state, and extracts multi-dimensional assessment index values. The material parameter retrieval engine queries the production management database based on the unique identifier of the current rolled material to accurately obtain the elastic recovery coefficient and plastic deformation critical point parameters. These parameters originate from the material property dataset in the database. The elastic recovery coefficient is stored as a dimensionless value, and the plastic deformation critical point parameters include the stress yield point and strain limit value. The compensation calculation logic is based on the actual deviation. The basic compensation amount is solved using numerical algorithms to analyze the response characteristics of the elastic recovery coefficient to the deviation. For example, the torque deviation is multiplied by the reciprocal of the elastic recovery coefficient as the initial compensation value. The compensation strength correction mechanism further processes the calculation, adjusting the compensation strength coefficient according to the plastic deformation critical point parameters, and applying a nonlinear function to limit the compensation value to a range that avoids permanent material deformation. The instruction generator integrates the calculation results to generate a dynamic tension control instruction set. The instruction set contains three-dimensional spatial coordinate data, corresponding to the compensation point positions on the roller pressing actuator. The compensation action timing is defined as a microsecond-level time series, representing the trigger and stop times of the compensation action. The compensation intensity coefficient is standardized as a floating-point number within the range of 0-1. The instruction set is encapsulated in JSON format, with a unique transaction ID and timestamp tag. The transmission unit synchronously distributes the instruction set to the strategy optimization module and its input interface, and writes it into the tension control case library of the production management database. The entire process takes less than 50 milliseconds, and data integrity is guaranteed through a checksum mechanism. High-speed data bus communication is used between system modules to ensure seamless connection between state assessment and dynamic compensation, meeting the real-time response requirements of the roller pressing process. This implementation covers the entire processing flow, does not rely on external hypothetical effect verification, but achieves precise control through pre-set algorithms and database interaction.

[0044] Example 3: See Figure 4The implementation methods of the strategy optimization module and the roller pressing mechanism are described below. The strategy optimization module receives a dynamic tension control instruction set from the dynamic compensation module via a high-speed data channel. This instruction set contains structured data such as the coordinates of the compensation action position, the timing of the compensation amount, and the compensation intensity coefficient. Simultaneously, the module activates the database access interface to retrieve historical similar scenario datasets from the tension control case library in the production management database. The data matching engine sets a similarity threshold of 85%, and the retrieval algorithm is based on multi-dimensional feature space distance calculation. Features include material type encoding, environmental temperature and humidity vectors, original tension fluctuation amplitude patterns, and the temporal distribution of compensation intensity. The pattern recognition unit applies a dynamic time warping algorithm to compare the current dynamic tension control instruction set with the control records in the retrieved historical similar scenario dataset. This algorithm processes parameter sequences with different time scales, finding the optimal alignment mapping by accumulating the minimum distance path. The difference analysis module identifies compensation parameter deviation points, including position coordinate offsets, temporal phase differences, and intensity ratio differences. The strategy optimization candidate region is delineated based on clustering analysis results, specifically by marking parameter coordinate regions that deviate from the historical optimization strategy threshold in the high-dimensional parameter space. The optimization calculation was implemented using a genetic algorithm, with a population size of 100 chromosomes, each chromosome encoding a candidate compensation time sequence permutation scheme. The fitness function was defined as a comprehensive evaluation index of the achievement of the compensation goal and the stability of historical strategies. The strategy stability factor Ψ considered the pattern difference between the current compensation scheme and historically successful schemes.

[0045]

[0046] Explanation of formula symbols: Strategy stability factor, a dimensionless evaluation index; : Optimize the total number of feature parameters in the candidate region, with values ​​taking positive integers; Current plan number Each feature vector has dimensions that match the parameter space. Historical Case No. Each feature vector represents data of the same dimension. Euclidean norm operator; Numerical stability constant, taken as a fixed value. .

[0047] The maximum number of iterations during optimization is set to 50. Iteration terminates when the fitness growth stagnation threshold is met (an improvement of less than 0.1% for 5 consecutive generations) or the maximum number of generations is reached, and the optimal set of decoded chromosome parameters is output. The generated optimization tension control parameter package is encapsulated in binary data and specifically includes:

[0048] Compensation action location optimization sequence: contains a coordinate list of the execution unit topology, with each element representing the spatial location as three sets of floating-point numbers; Compensation intensity adjustment ratio: expressed as a percentage matrix relative to the original compensation intensity, with an accuracy of 0.1%; Compensation duration correction value: an array of time adjustment factors in milliseconds.

[0049] The parameter packet is transmitted to the control node of the roller pressing actuator via redundant industrial Ethernet. The actuator's instruction parsing unit decomposes the data packet, and the address mapper locates the specific execution unit based on the spatial coordinates in the position optimization sequence, with the positioning error controlled within ±0.1mm. The compensation driver loads the intensity adjustment ratio data to the multi-stage drive controller, which integrates the ratio value into the closed-loop PID control loop and outputs a calibration signal to the servo valve group. The timing controller receives the duration correction value and generates a time window schedule for the compensation action, with a system clock synchronization error of less than 10ms. Within the specified execution time window, the pressure execution unit dynamically adjusts the hydraulic output of the roller pressing power unit according to the intensity adjustment ratio, with a pressure adjustment resolution of 0.05% of the full range. The deformation monitoring unit integrates a laser triangular displacement sensor array, which collects material deformation feedback data in the roller pressing area in real time at a sampling frequency of 5kHz. This data stream is appended with a precise time stamp and transmitted back to the raw data input interface of the tension generation module via a dedicated channel, completing the closed-loop control system loop. The data logger synchronously stores complete execution process parameters, including the actual applied pressure curve, deformation response waveform, and timing deviation log. All operation time nodes are strictly synchronized with the main control system clock, with the time base source being a high-precision crystal oscillator. The real-time monitoring interface for the execution status displays the activation status of the position sequence, the progress of the intensity ratio activation, and the remaining duration of the time window.

[0050] Example 4: See Figure 5 The collaborative implementation process of the real-time speed monitoring module and the dynamic compensation module is described. The real-time speed monitoring module deploys detection points at key nodes along the material transport path, with a photoelectric encoder measurement unit installed every 200 mm. The unit itself includes an incremental photoelectric encoder and signal conditioning circuitry. The encoder resolution is 5000 pulses / revolution, directly coupled to the shaft end of the transport guide roller. The signal acquisition card records pulse sequences at a sampling frequency of 1000 Hz and converts the raw signal into linear velocity data using quadruple frequency decoding technology. Adjacent sampling periods are fixed at 20 milliseconds. The speed fluctuation rate calculation unit processes the data using the following logic: storing the linear velocity values ​​of the previous ten sampling periods to form a reference queue, and comparing the latest sampled value with the median of this queue to calculate the relative deviation rate. The calculation results are synchronously transmitted to the output interface of the state assessment module for cross-validation. The cross-validation process accesses the speed assessment index field in the tension stability assessment report. This field contains material-specific speed tolerance parameters, typical values ​​of which are shown in Table 1.

[0051] Table 1: Speed ​​stability verification parameter table.

[0052] Material type code Maximum allowed volatility Tolerance time window Temperature compensation factor ELE-05 3.5% 150ms 0.8 ELE-12 2.8% 200ms 1.2 POL-07 4.2% 120ms 0.6

[0053] When the actual velocity fluctuation rate of the current material type ELE-12 exceeds the 2.8% threshold three consecutive times (e.g., at sampling points T+320ms, T+340ms, and T+360ms), the request generator is triggered. This component creates a structured motion stability parameter correction request data packet containing the following elements: timestamp label, an outlier index list, actual velocity profile data, and a copy of the tension assessment report for the corresponding interval. The data packet uses a lightweight binary format and is transmitted to the priority processing port of the dynamic compensation module within 5 milliseconds via the real-time communication bus.

[0054] The dynamic compensation module has a dedicated request processing channel. Upon receiving a motion stability parameter correction request, it initiates a three-level response mechanism. The parsing engine decomposes the data packet content and extracts the actual sampled values ​​of linear velocity within the abnormal time period (e.g., [48.2, 47.8, 46.5] m / min). The database access agent automatically queries the equipment parameter partition of the production management database to obtain the current production line's rated transmission speed baseline value (50.0 m / min). The offset calculator executes a relative percentage algorithm: it calculates the absolute deviation of each sampling point from the baseline value ([1.8, 2.2, 3.5]), divides it by the baseline value to obtain the percentage offset sequence ([3.6%, 4.4%, 7.0%]).

[0055] The compensation intervention level decision tree operates according to preset hierarchical rules: Level-1 mode is activated when the maximum offset is below 5%; Level-2 mode is activated in the 5%-8% range; and Level-3 emergency mode is activated when it exceeds 8%. In the current example, a maximum offset of 7.0% triggers a Level-2 response, and the corresponding compensation intensity coefficient increment is adjusted to 1.8 times the baseline value. The instruction set updater uses memory hot-swap technology to dynamically modify the intensity coefficient field in the currently executed dynamic tension control instruction set: the original compensation intensity coefficient of 0.75 is updated to 1.35. The updated data packet is appended with a red alert identifier code (code #FF0000), which forces the strategy optimization module to interrupt the normal processing flow. The complete update operation is completed within a 20-millisecond cycle, and an operation log is synchronously written to the production management database. The log entries include the original instruction set hash value, the modification time, and the operator's system identifier.

[0056] During anomaly handling, the status monitoring mechanism continues to operate, displaying a real-time parameter panel on the system's human-machine interface: the upper left area scrolls and refreshes the real-time linear velocity curve, with the current value highlighted in red; the right panel displays the latest calculated offset statistics, including the average (4.33%), maximum (7.0%), and number of exceedances (3); the bottom status bar flashes the "COMP_L2ACTIVE" running status code. All modification operations are subject to the permission verification mechanism, and only control accounts with priority 3 or higher can execute hot updates of the instruction set. At the same time, the system maintains a backup cache of the original data, and automatically triggers the data archiving process after the request is processed, storing the complete event sequence, including the original velocity data, a copy of the correction request, and the updated instruction set, in the historical anomaly case library. This case library is indexed by material type and supports multi-dimensional retrieval by time range, offset level, and intervention mode. The entire implementation process is synchronized by a hardware-level real-time clock, with the time deviation of each node controlled within ±2 milliseconds. The system watchdog timer checks the process status every 50 milliseconds to ensure that critical tasks are completed on time.

[0057] Example 5: Operation Mechanism of the Adaptive Tension Control System in Emergency Situations. When the strategy optimization module receives an emergency adjustment flag (red alert code #FF0000) from the dynamic compensation module, the internal process scheduler immediately sends a thread interruption command to the strategy optimization main thread. This command activates the context protection mechanism: saving the current genetic algorithm population state to a non-volatile buffer, freezing the data stream at the optimization parameter output port, and releasing computing resources for emergency response. The contingency plan management unit then accesses the equipment operation history archive in the production management database. This archive has an independent emergency response plan data partition, and the partition index structure adopts a speed offset hierarchical coding system (integer variables, each 5% offset is a level). For example, when a 12% speed offset is detected, the system automatically matches a level three emergency code. The contingency plan retrieval engine accelerates data reading based on memory-mapped file technology, completing the loading of the target contingency plan set within 40 milliseconds.

[0058] The contingency plan dataset is stored in a tree structure, with each plan node containing a control mode feature vector, equipment constraint boundary conditions, and execution benefit evaluation indicators. The emergency mode matcher uses an improved nearest neighbor classification algorithm to process the feature vectors: calculating the multidimensional spatial distance between the current operating parameters and the plan feature vectors, and handling nonlinear relationships through radial basis function kernel transformation. During the algorithm search process, schemes that violate equipment mechanical constraints (such as pressure output values ​​exceeding hydraulic system limits) are eliminated in real time. The final optimal control mode includes the topological distribution of compensation application points, the definition of the intensity application curve waveform, and time constraint rules.

[0059] The generation of the emergency tension control parameter package follows strict time-series standards. The package data includes a predefined range of maximum compensation strength, with upper and lower limits derived from destructive testing calibration results in the materials laboratory; for example, the upper limit of a certain type of dry electrode material is 120 MPa. The parameter definitions employ a three-segment structure: initial action strength (60% of the calibrated upper limit), peak sustained strength (85% of the calibrated upper limit), and decay gradient (decreasing by 10% of the calibrated upper limit per second). The time parameter module sets a minimum action duration threshold, determined based on the equipment's dynamic response characteristics: the hydraulic actuator's action delay time is superimposed with the control signal transmission delay, setting the minimum effective intervention period to 15 milliseconds. The parameter package format uses simplified binary encoding, with a header containing a version identifier and checksum. The main body is divided into an equipment control section (execution unit address list, strength action curve number) and a process protection section (duration scale, material condition monitoring requirements).

[0060] The data transmission mechanism initiates the highest priority communication channel. The physical layer uses a dedicated fiber optic link for transmission, and a bandwidth reservation strategy ensures data transmission latency is less than 2 milliseconds. The protocol stack applies an emergency data frame encapsulation format: skipping the regular handshake process, omitting the transport layer acknowledgment mechanism, and adding three retransmissions to each data frame as a guarantee. During execution, the system automatically disables non-critical data logging functions, retaining only basic operational logs, thus shortening the control cycle by 30%.

[0061] The operation of the roller press actuator after receiving the emergency parameter package is strictly time-sequential. The time window controller divides the operation into three phases: parameter package parsing and equipment preheating are completed within the first 5 milliseconds; during the main execution phase, the hydraulic proportional valve opening is adjusted according to the preset strength action curve, while the displacement sensor array monitors the roll gap change at a frequency of 10 kHz; the final phase outputs pressure according to gradient decay. The dynamic compensation module synchronously initiates protective monitoring: when the material deformation is detected to be approaching the plastic critical point (calculated based on the real-time stress-strain relationship), the compensation strength pre-decay mechanism is triggered. All execution data is transmitted to the emergency event database of the production management database through an independent feedback loop, forming a closed-loop recording system. After the emergency operation ends, the event recovery unit automatically assesses the system status and performs resource recovery operations, including: restoring the frozen optimization thread context, clearing the temporary data cache, resetting the communication channel priority, and finally returning system control to the regular strategy optimization process. The standard time for the entire emergency response process from identification to execution completion is 80 milliseconds, and the time node accuracy is guaranteed by a nanosecond-level clock synchronization network. During execution, the human-machine interface switches to emergency monitoring mode, displaying key parameters such as pressure output curves, material deformation rates, and remaining processing time. Operators have only priority viewing permissions and are prohibited from manually interfering with the control command flow. The system's built-in abnormal termination mechanism continuously monitors the equipment's operating boundary parameters. When it detects overtravel of the actuator or abnormal sudden change in hydraulic pressure, it immediately triggers a safety shutdown sequence.

[0062] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0063] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An adaptive tension control system for a dry electrode continuous roll forming machine, characterized in that, include: The tension generation module is deployed on the transmission node of the roller pressing mechanism to acquire the raw tension dataset in real time during the roller pressing process; The status assessment module receives the raw tension dataset from the tension generation module, analyzes the current rolling operation status, and generates a tension stability assessment report. The dynamic compensation module receives the tension stability assessment report from the state assessment module, calculates the deformation compensation amount of the rolled material, and generates a dynamic tension control instruction set. The strategy optimization module receives the dynamic tension control instruction set and historical control records from the dynamic compensation module, optimizes the tension control strategy, and outputs an optimized tension control parameter package. The production management database stores a dataset of roll-pressed material characteristics, a database of equipment operation history archives, and a database of tension control cases. The roller pressing actuator receives the optimized tension control parameter package from the strategy optimization module and adjusts the operating parameters of the roller pressing actuator. When the tension generation module acquires the original tension dataset, it specifically performs the following operations: real-time capture of the torque change waveform data of the drive shaft of the roller pressing actuator, synchronous acquisition of the velocity difference sequence between the inlet and outlet of the roller pressing material, and integration of the roller pressing material surface friction coefficient detection data and environmental temperature and humidity monitoring data to generate the original tension dataset; wherein the material surface friction coefficient detection data is periodically acquired by an online surface scanner, and the environmental temperature and humidity monitoring data is acquired in real time by a sensor array arranged inside the roller pressing cavity; The process of generating a tension stability assessment report by the state assessment module includes: extracting torque fluctuation feature values ​​and velocity difference change gradients from the original tension dataset; comparing the torque fluctuation feature values ​​with the standard torque fluctuation threshold range in the equipment operation history archive; and simultaneously matching and verifying the velocity difference change gradient with the upper limit of the material's allowable deformation rate. When the torque fluctuation feature value exceeds the standard torque fluctuation threshold range or the velocity difference change gradient exceeds the upper limit of the material's allowable deformation rate, the tension anomaly identifier is activated and the actual deviation is calculated. By combining the deviation of the characteristic value of the comprehensive torque fluctuation, the deviation of the gradient of the speed difference change, and the influence weight of the environmental temperature and humidity monitoring data on the material properties, a tension stability assessment report containing multi-dimensional evaluation indicators is generated.

2. The adaptive tension control system of the dry electrode continuous roll forming machine according to claim 1, characterized in that, The operation process of the dynamic compensation module in generating the dynamic tension control instruction set is as follows: receiving the tension stability assessment report sent by the state assessment module, and parsing the tension anomaly identifier and multi-dimensional assessment indicators in it; The material property dataset in the production management database is called to match the elastic recovery coefficient and plastic deformation critical point parameters of the current rolling material; The basic compensation amount is calculated based on the actual deviation and the material's elastic recovery coefficient. The compensation strength coefficient is then corrected by combining the plastic deformation critical point parameter. A dynamic tension control instruction set containing the coordinates of the compensation action position, the timing of the compensation action, and the compensation strength coefficient is generated and synchronously transmitted to the strategy optimization module and the production management database.

3. The adaptive tension control system of the dry electrode continuous roll forming machine according to claim 2, characterized in that, The process of optimizing the tension control strategy by the strategy optimization module specifically includes: receiving a set of dynamic tension control instructions sent by the dynamic compensation module, and simultaneously extracting a historical similar scenario dataset from the tension control case library in the production management database; performing pattern matching between the compensation parameters in the current dynamic tension control instruction set and the control records in the historical similar scenario dataset, identifying differences in compensation strategies and marking candidate regions for strategy optimization; recalculating the compensation timing sequence based on the candidate regions for strategy optimization to generate an optimized tension control parameter package; wherein the optimized tension control parameter package includes an optimized sequence of compensation action positions, a compensation intensity adjustment ratio, and a compensation duration correction value.

4. The adaptive tension control system of the dry electrode continuous roll forming machine according to claim 3, characterized in that, The operation of the roller pressing actuator to execute the optimized tension control parameter package includes: receiving the optimized tension control parameter package sent by the strategy optimization module and parsing the compensation action position optimization sequence therein; locating the specific execution unit of the roller pressing actuator according to the compensation action position optimization sequence, loading the compensation amount intensity adjustment ratio to the drive controller, and setting the compensation duration correction value to the execution time window; dynamically adjusting the roller pressing pressure output value according to the compensation amount intensity adjustment ratio within the specified execution time window, while simultaneously monitoring the deformation feedback data of the roller pressing material in real time and feeding it back to the tension generation module.

5. The adaptive tension control system of the dry electrode continuous roll forming machine according to claim 1, characterized in that, The system also includes a real-time speed monitoring module, which is configured to: continuously collect real-time linear speed change data during the material rolling process, calculate the speed fluctuation rate of adjacent sampling periods; cross-validate the speed fluctuation rate with the speed evaluation index in the tension stability evaluation report output by the state evaluation module; and generate a motion stability parameter correction request and send it to the dynamic compensation module when the speed fluctuation rate exceeds the allowable range of the speed evaluation index.

6. The adaptive tension control system of the dry electrode continuous roll forming machine according to claim 5, characterized in that, The processing flow of the dynamic compensation module in response to the motion stability parameter correction request is as follows: receive the motion stability parameter correction request sent by the real-time speed monitoring module, and extract the actual sampled value of the current rolling material linear velocity; The system retrieves the rated transmission speed reference value of the equipment from the production management database, calculates the speed deviation between the actual sampled value and the rated reference value, determines the compensation intervention level based on the speed deviation, updates the compensation intensity coefficient in the dynamic tension control instruction set, and marks the updated compensation intensity coefficient as an emergency adjustment identifier before transmitting it to the strategy optimization module.

7. The adaptive tension control system of the dry electrode continuous roll forming machine according to claim 6, characterized in that, The operation of the strategy optimization module in processing the emergency adjustment flag includes: receiving the emergency adjustment flag marked by the dynamic compensation module and interrupting the current strategy optimization process; immediately calling the emergency response plan dataset from the equipment operation history archive in the production management database, matching the emergency control mode corresponding to the current speed offset, and generating an emergency tension control parameter package.

8. The adaptive tension control system of the dry electrode continuous roll forming machine according to claim 7, characterized in that, The emergency tension control parameter package includes the maximum range of the compensation intensity and the minimum duration of the compensation intensity.

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