A continuous roll forming method for stainless steel corrugated backboard

Abstract

The application belongs to the field of photovoltaic module manufacturing, and provides a continuous roll forming method of stainless steel corrugated backboard, which comprises the following steps: the stainless steel plate is unfolded and broadcast through an oil pressure automatic material feeding frame, so that the stainless steel plate enters a forming process; the front end of the stainless steel plate is cut by a manual front cutting machine, so as to adjust the initial state of the plate entering a subsequent process; the cut stainless steel plate is guided to a forming roller by a feeding guide plate, the forming roller adopts a multi-section roller structure, the stainless steel plate sequentially passes through each section of the roller, and each section of the roller continuously rolls the stainless steel plate, so that the stainless steel plate is processed into a corrugated plate with multiple groups of wave crest structures; in the rolling process, the wave pitch and wave height structure parameters of the corrugated plate are accurately controlled by adjusting the rolling path and the profile design of the roller; after the corrugated plate is roll formed, the plate is cut according to a preset size by using a hydraulic cutting module, and the required stainless steel corrugated backboard is obtained.

Description

Technical Field

[0001] This invention belongs to the field of photovoltaic module manufacturing, and specifically relates to a continuous roll forming method for stainless steel corrugated backsheets. Background Technology

[0002] In the photovoltaic module manufacturing industry, stainless steel corrugated backsheets, due to their high strength and corrosion resistance, have become a key component for improving the module's resistance to wind pressure deformation. Traditional stainless steel corrugated backsheet forming processes mainly rely on stamping or bending technologies.

[0003] When traditional stamping / bending processes use single stamping or segmented bending, stainless steel sheets are prone to cracking due to local stress concentration. Furthermore, the peak structure parameters (such as wave pitch and wave height) after forming are difficult to control precisely and require manual adjustment. This results in low material utilization (approximately 60%-70%), which cannot meet the requirements for consistent backsheet strength in the mass production of photovoltaic modules.

[0004] Existing roll forming equipment is mostly designed for ordinary metal sheets, using a single-segment roller for one-time forming. It can only process simple waveform structures and cannot achieve continuous forming of multiple wave peaks. Furthermore, it lacks a dynamic adjustment mechanism for the roll forming path and roller profile, making it difficult to meet the high-precision forming requirements of 0.5mm to 0.7mm thick stainless steel sheets. In particular, there are significant technical bottlenecks in the coordinated control of wave pitch and wave height parameters.

[0005] How to achieve high-strength forming of stainless steel corrugated back panels through continuous roll forming without adding extra reinforcing ribs, while solving problems such as stress concentration cracking, inaccurate parameter control, and low production efficiency in traditional processes, has become a technical challenge that urgently needs to be solved in this field. Summary of the Invention

[0006] This application provides a continuous roll forming method for stainless steel corrugated back panels, which aims to achieve high-strength forming of stainless steel corrugated back panels through continuous roll forming without adding additional reinforcing ribs, while solving problems such as stress concentration cracking, inaccurate parameter control, and low production efficiency in traditional processes.

[0007] In a first aspect, this application provides a continuous roll forming method for stainless steel corrugated backing plates, applied to the electrical control box of a continuous roll forming equipment. The continuous roll forming equipment further includes a hydraulic automatic feeding rack, a manual front shear, a feeding guide plate, forming rolls, a hydraulic cutting module, and a hydraulic pump station. The electrical control box has a built-in intelligent algorithm module that optimizes the roll forming path and roll profile design parameters based on historical production data and real-time monitoring parameters through a machine learning model. This is achieved by collecting forming data of stainless steel corrugated backing plates with different thicknesses, wave pitches, and wave heights from historical production. The method includes:

[0008] The stainless steel sheet is unfolded and fed by a hydraulic automatic feeding rack, allowing it to enter the forming process; the front end of the stainless steel sheet is trimmed by a manual front shear to adjust the initial state of the sheet for subsequent processes.

[0009] The cut stainless steel sheet is guided to the forming roller by the feed guide plate. The forming roller adopts a multi-segment roller structure. The stainless steel sheet passes through each segment of roller in sequence. Each segment of roller continuously rolls the stainless steel sheet, so that the stainless steel sheet is processed into a corrugated sheet with multiple sets of crests. During the rolling process, the wave pitch and wave height structural parameters of the corrugated sheet can be precisely controlled by adjusting the rolling path and the contour design of the roller. The thickness of the stainless steel sheet can be adjusted to 0.5mm to 0.7mm according to the application requirements.

[0010] After the corrugated sheet is roll-formed, the sheet is cut according to the preset size using a hydraulic cutting module to obtain the required stainless steel corrugated back plate. The hydraulic pump station provides power for the rolling action of the forming rolls and the cutting action of the hydraulic cutting module. The system also includes: establishing a mapping relationship between rolling parameters and forming quality using a machine learning model; and generating the optimal rolling path and roller profile adjustment scheme through an intelligent algorithm module based on the material of the current stainless steel sheet and the target product parameters.

[0011] In some embodiments, the step of unfolding and feeding the stainless steel sheet through the hydraulic automatic feeding rack to allow the stainless steel sheet to enter the forming process includes: monitoring the feeding tension of the stainless steel sheet in real time through the tension control mechanism of the hydraulic automatic feeding rack; when an abnormal tension is detected, automatically adjusting the feeding speed of the feeding rack and the coil support force through the hydraulic system, so that the stainless steel sheet is unfolded flat with constant tension and enters the subsequent process at a uniform speed, avoiding wrinkles or stretching deformation of the sheet due to uneven tension.

[0012] In some embodiments, the method of using a manual front shear to cut the front end of the stainless steel sheet to adjust the initial state of the sheet entering the subsequent process includes: determining the cutting position by using the positioning ruler of the manual front shear, cutting the irregular part or rough edge of the front end of the stainless steel sheet, so that the front end of the sheet forms a flat cut perpendicular to the length direction of the sheet, and ensuring that the width of the cut sheet is consistent with the width of the guide channel of the feed guide plate.

[0013] In some embodiments, guiding the cut stainless steel sheet to the forming roll via the feed guide plate includes: the feed guide plate is provided with an adjustable guide groove, and the distance between the limiting plates on both sides of the guide groove is adjusted according to the actual width of the stainless steel sheet, so that the sheet is smoothly conveyed along the center line of the guide groove to the roll pressing inlet of the forming roll, avoiding the sheet from shifting or tilting during the conveying process and ensuring the accuracy of the roll pressing position.

[0014] In some embodiments, the stainless steel sheet passes through various rollers in sequence, with each roller continuously rolling the stainless steel sheet to process it into a corrugated sheet with multiple sets of wave crests. This includes: the multiple rollers of the forming roll are arranged in a preset rolling sequence; the front rollers pre-press the stainless steel sheet to form an initial wave crest profile; the rear rollers perform precision pressing and shaping on the sheet, gradually increasing the wave crest height and correcting the wave crest spacing. Through the continuous progressive rolling of the multiple rollers, the deformation of a single rolling is reduced, and cracking or wrinkling of the sheet due to stress concentration is avoided.

[0015] In some embodiments, during the rolling process, the precise control of the wave pitch and wave height structural parameters of the corrugated sheet is achieved by adjusting the rolling path and the contour design of the rollers. This includes: the electrical control box pre-stores multiple sets of roller contour parameters and rolling path schemes; according to the design requirements of the target corrugated sheet, the corresponding parameter scheme is called and control commands are sent to the drive system of the forming roller; the lateral position or rotation angle of each section of roller is adjusted by a servo motor; the rolling path is corrected in real time; and the wave pitch and wave height errors of the finally formed corrugated sheet are controlled within a preset range.

[0016] In some embodiments, adjusting the thickness of the stainless steel sheet to 0.5mm to 0.7mm according to usage requirements includes: adjusting the vertical distance between adjacent rollers according to the target thickness parameter using the roller gap adjustment device of the forming roller; simultaneously detecting the sheet thickness in real time using a thickness sensor during the rolling process; and automatically fine-tuning the roller gap by the electrical control box when the detected value deviates from 0.5mm to 0.7mm so that the thickness of the formed corrugated sheet meets the usage requirements.

[0017] In some embodiments, the step of cutting the corrugated sheet into a desired stainless steel corrugated back plate using a hydraulic cutting module according to a preset size after roll forming includes: the hydraulic cutting module is equipped with a photoelectric sensor to detect the conveying length of the roll-formed sheet in real time; when the sheet is conveyed to a preset cutting position, the electrical control box sends a cutting command to the hydraulic pump station, which hydraulically drives the cutting blade to press down quickly to cut the sheet; during the cutting process, the positioning clamp of the hydraulic cutting module simultaneously clamps the sheet to prevent displacement of the sheet during cutting and ensure a smooth cut without burrs.

[0018] In some embodiments, the hydraulic pump station provides power for the rolling action of the forming roll and the cutting action of the hydraulic cutting module, including: the hydraulic pump station is equipped with a pressure sensor and a flow regulating valve, and automatically adjusts the output pressure and flow according to the rolling stage of the forming roll and the cutting requirements of the hydraulic cutting module; it provides lower pressure in the pre-pressing stage to ensure smooth deformation of the sheet metal, increases pressure in the fine pressing stage to ensure the formation of the wave crest structure, and instantly increases pressure in the cutting stage to achieve rapid cutting, thereby improving the stability of equipment operation and forming accuracy through dynamic pressure control.

[0019] This invention relates to the manufacturing process of stainless steel corrugated backsheets for photovoltaic modules, specifically a method for achieving high-precision forming of stainless steel sheets through continuous rolling pressing with multiple rollers, belonging to the field of metal sheet forming and processing technology (specifically involving continuous rolling forming equipment and control methods).

[0020] By employing continuous, progressive rolling with multiple rollers (pre-pressing at the front and fine pressing at the rear), the large deformation in a single process is decomposed into multiple smaller deformations, significantly reducing stress concentration during the stainless steel sheet forming process. This lowers the risk of cracking compared to traditional stamping processes and increases the yield rate. Utilizing preset roller profile parameters and rolling path schemes in the control box, combined with real-time adjustment of roller position and angle by a servo motor, the wave pitch and wave height errors are controlled within ±0.5mm, and the sheet thickness can be precisely adjusted within the range of 0.5mm to 0.7mm, meeting the customized production needs of photovoltaic modules with different strength requirements. The use of a hydraulic automatic feeding rack, feeding guide plate, and hydraulic cutting device creates a fully automated production line, significantly reducing production costs. The backsheet strength is improved without the need for additional reinforcing ribs, making it suitable for mass production of high-strength photovoltaic modules, especially suitable for module production in coastal high-wind-pressure and high-corrosion environments, effectively extending the service life of photovoltaic modules.

[0021] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and do not limit this application. Attached Figure Description

[0022] To more clearly illustrate the technical solutions of the embodiments of this application, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0023] Figure 1 This is a schematic flowchart of the steps of a continuous roll forming method for a stainless steel corrugated back plate according to an embodiment of this application;

[0024] Figure 2 This is a schematic diagram of a continuous roll forming apparatus provided in one embodiment of this application;

[0025] Figure 3 This is a schematic block diagram of the structure of an electrical control box provided in one embodiment of this application.

[0026] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and do not limit this application. Detailed Implementation

[0027] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0028] The flowchart shown in the attached diagram is for illustrative purposes only and does not necessarily include all content and operations / steps, nor does it necessarily have to be performed in the order described. For example, some operations / steps can be broken down, combined, or partially merged, so the actual execution order may change depending on the actual situation.

[0029] It should be understood that, in order to clearly describe the technical solutions of the embodiments of the present invention, the terms "first" and "second" are used in the embodiments of the present invention to distinguish identical or similar items with essentially the same function and effect. Those skilled in the art will understand that the terms "first" and "second" do not limit the quantity or execution order, and the terms "first" and "second" are not necessarily different.

[0030] It should be understood that the terminology used in this specification is for the purpose of describing particular embodiments only and is not intended to limit the scope of the application. As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms unless the context clearly indicates otherwise.

[0031] It should also be understood that the term “and / or” as used in this application specification and the appended claims means any combination of one or more of the associated listed items and all possible combinations, and includes such combinations.

[0032] The following detailed description of some embodiments of this application is provided in conjunction with the accompanying drawings. Unless otherwise specified, the following embodiments and features can be combined with each other.

[0033] In the photovoltaic module manufacturing industry, stainless steel corrugated backsheets, due to their high strength and corrosion resistance, have become a key component for improving the module's resistance to wind pressure deformation. Traditional stainless steel corrugated backsheet forming processes mainly rely on stamping or bending technologies.

[0034] When traditional stamping / bending processes use single stamping or segmented bending, stainless steel sheets are prone to cracking due to local stress concentration. Furthermore, the peak structure parameters (such as wave pitch and wave height) after forming are difficult to control precisely and require manual adjustment. This results in low material utilization (approximately 60%-70%), which cannot meet the requirements for consistent backsheet strength in the mass production of photovoltaic modules.

[0035] Existing roll forming equipment is mostly designed for ordinary metal sheets, using a single-segment roller for one-time forming. It can only process simple waveform structures and cannot achieve continuous forming of multiple wave peaks. Furthermore, it lacks a dynamic adjustment mechanism for the roll forming path and roller profile, making it difficult to meet the high-precision forming requirements of 0.5mm to 0.7mm thick stainless steel sheets. In particular, there are significant technical bottlenecks in the coordinated control of wave pitch and wave height parameters.

[0036] How to achieve high-strength forming of stainless steel corrugated back panels through continuous roll forming without adding extra reinforcing ribs, while solving problems such as stress concentration cracking, inaccurate parameter control, and low production efficiency in traditional processes, has become a technical challenge that urgently needs to be solved in this field.

[0037] To resolve the above issues, please refer to [link / reference]. Figure 1 , Figure 1 This is a schematic flowchart of a continuous roll forming method for a stainless steel corrugated back plate according to an embodiment of this application. This continuous roll forming method for the stainless steel corrugated back plate can be performed by, for example... Figure 2 The control box of the continuous roll forming equipment shown is implemented. The continuous roll forming equipment also includes a hydraulic automatic feeding rack, a manual front shear, a feeding guide plate, forming rolls, a hydraulic cutting module and a hydraulic pump station. The control box has a built-in intelligent algorithm module to optimize the roll path and roll profile design parameters based on historical production data and real-time monitoring parameters through machine learning models. It collects forming data of stainless steel corrugated back plates with different thicknesses, pitches and heights from historical production.

[0038] Specifically, such as Figure 1 As shown, the continuous roll forming method for the provided stainless steel corrugated back plate includes steps S101 to S103. Details are as follows:

[0039] Step S101. Unfold and feed the stainless steel sheet using a hydraulic automatic feeding rack to allow it to enter the forming process; use a manual front shear to trim the front end of the stainless steel sheet to adjust its initial state for subsequent processes.

[0040] Specifically, the stainless steel coil is smoothly unwound by a hydraulic automatic feeding rack, and the front end of the sheet is corrected by a manual front shear to provide qualified feeding conditions for subsequent processes.

[0041] The feeding control of the hydraulic automatic feeding rack is achieved by using a hydraulically driven roller structure in the main body of the feeding rack. The roll material is fitted onto the roller, and the feeding tension of the sheet material is monitored in real time through a tension control mechanism (including a pressure sensor and a speed encoder).

[0042] When the sensor detects tension fluctuations exceeding a preset threshold (e.g., ±5N / mm) 2 When the material is in operation, the electrical control box sends a command to the hydraulic system to adjust the rotation speed of the unloading roller (range: 0.5~2m / min) and the clamping force of the roll support arm (range: 50~200N) through the proportional valve. This ensures that the sheet is unfolded flat with constant tension (target value: 80±5N / mm²) and avoids wrinkles (wrinkle occurrence rate ≤0.3%) or tensile deformation (elongation controlled within 1%) caused by uneven tension.

[0043] The manual front shear is equipped with a high-precision positioning scale (graduation accuracy ±0.1mm). The vertical distance between the scale and the shear blade can be adjusted via a screw to accommodate different cutting length requirements. The operator aligns the front end of the sheet material with the zero position of the scale and drives the shear blade (hardness HRC55~60) via the handle to cut the sheet material, removing irregular parts at the front end (such as burrs or rolled edges), ensuring a cut flatness error ≤0.2mm and a perpendicularity error ≤0.5° to the length of the sheet material. After cutting, the sheet material width is confirmed by checking the scale to ensure it matches the guide channel width of the feed guide plate (error ±0.5mm), preventing subsequent conveying jams due to width deviations.

[0044] Step S102. The cut stainless steel sheet is guided to the forming roller by the feeding guide plate. The forming roller adopts a multi-segment roller structure. The stainless steel sheet passes through each segment of roller in sequence. Each segment of roller continuously rolls the stainless steel sheet to process it into a corrugated sheet with multiple sets of wave crests. During the rolling process, the wave pitch and wave height structural parameters of the corrugated sheet are precisely controlled by adjusting the rolling path and the contour design of the roller. The thickness of the stainless steel sheet is adjusted to 0.5mm to 0.7mm according to the usage requirements.

[0045] Specifically, the sheet material is precisely conveyed to the forming rolls through an adjustable feed guide plate, and the corrugated structure is formed by progressive rolling of multiple rollers, while the wave pitch, wave height and thickness parameters are dynamically controlled.

[0046] The feeding guide plate is designed with a U-shaped groove structure. The spacing between the two side limit plates is adjusted via a servo motor-driven screw and nut mechanism (adjustment range: 300~1200mm, accuracy ±0.1mm). The inner side of the limit plates is covered with a PTFE wear-resistant layer (friction coefficient ≤0.15). The operator inputs the target width value into the control box interface based on the actual width of the sheet material (detected in real-time by a laser width measuring instrument, accuracy ±0.2mm). The system automatically adjusts the limit plates to the corresponding positions, ensuring that the deviation between the sheet material centerline and the guide groove centerline is ≤1mm, guaranteeing no offset during conveying (offset occurrence rate ≤0.1%).

[0047] Multi-segment rolling process of forming rolls: Roller structure design: The forming roll consists of 5 to 8 roll groups (such as 3 groups of pre-pressing sections and 5 groups of fine pressing sections). The profile of the front roll is a shallow waveform (wave height 5 to 10 mm, wave pitch 30 to 50 mm), and the profile of the rear roll is the target waveform (wave height 15 to 30 mm, wave pitch 50 to 100 mm). The distance between adjacent roll groups can be adjusted by guide rails (adjustment accuracy ±0.5 mm).

[0048] The progressive roll forming process includes: Pre-pressing stage: The front rollers initially shape the sheet material at a low linear speed (10~15m / min) and a small reduction (single reduction ≤ 20% of the sheet thickness), forming a preliminary wave shape. Simultaneously, anti-slip textures on the roller surface (texture depth 0.3mm, spacing 2mm) prevent slippage. Fine pressing stage: The linear speed of the rear rollers gradually increases to 20m / min, and the reduction increases to the target value. The lateral position of the rollers is adjusted by a servo motor (accuracy ±0.05mm) to correct the wave pitch. The wave height is controlled by changing rollers with different profiles or adjusting the roller tilt angle (adjustment range 0~5°). Ultimately, the wave pitch error is ≤ ±0.5mm, and the wave height error is ≤ ±1mm.

[0049] Precise thickness control is achieved through a roller assembly equipped with a gap adjustment device (ball screw + worm gear mechanism, adjustment accuracy ±0.01mm). An initial gap is preset based on the target thickness (0.5~0.7mm, accuracy ±0.02mm). As the sheet material passes through the rollers, a β-ray thickness sensor (accuracy ±0.01mm) installed at the roller exit detects the thickness in real time. When the detected value deviates from the preset value by more than ±0.03mm, the control box automatically fine-tunes the roller gap, forming a closed-loop control system.

[0050] Step S103. After the corrugated sheet is roll-formed, the sheet is cut according to the preset size using a hydraulic cutting module to obtain the required stainless steel corrugated back plate; wherein, the hydraulic pump station provides power for the rolling action of the forming roll and the cutting action of the hydraulic cutting module; it also includes: using a machine learning model to establish a mapping relationship between rolling parameters and forming quality; and generating the optimal rolling path and roller profile adjustment scheme through an intelligent algorithm module based on the material of the current stainless steel sheet and the target product parameters.

[0051] The formed corrugated sheet is cut to a fixed length using a hydraulic cutting module, and the hydraulic pump station provides dynamic pressure support for the rolling and cutting actions.

[0052] The hydraulic cutting module performs fixed-length cutting: The cutting module integrates a photoelectric sensor (detection accuracy ±1mm), installed above the conveyor rail, to monitor the conveying length of the sheet material in real time (with the front end after cutting in step S101 as the reference zero point). When the sheet material is conveyed to the preset cutting position (error ±2mm), the electrical control box sends a cutting command to the hydraulic pump station. The hydraulic system drives the cutting blade (edge ​​roughness Ra≤0.8μm) to press down at a speed of 50mm / s. Simultaneously, the positioning clamp (pneumatic clamping, clamping force 500~1000N) clamps both sides of the sheet material, ensuring no displacement during cutting (displacement ≤0.1mm). The cutting blade adopts a detachable design, allowing for different edge angles to be changed according to the sheet material thickness (30° edge angle for 0.5mm thickness, 45° edge angle for 0.7mm thickness). The burr height of the cut is ≤0.1mm, and the flatness error is ≤0.3mm.

[0053] Dynamic pressure control of the hydraulic pump station: The pump station is equipped with a plunger pump (flow range 5~50L / min) and a proportional pressure valve (control accuracy ±1%FS). It automatically switches pressure modes according to different process requirements: Pre-pressing stage: Output pressure 6~8MPa, ensuring smooth deformation of the sheet metal and avoiding surface scratches caused by excessive pressure (scratch incidence ≤0.2%). Fine pressing stage: Pressure is increased to 10~15MPa, ensuring full corrugation and uniform stress distribution between the rollers and the sheet metal (deviation ≤5%). Cutting stage: Instantaneous output of 20MPa high pressure allows the blade to quickly cut the sheet metal, with a cutting time ≤0.2 seconds, reducing sheet metal deformation. A pressure sensor (accuracy ±0.5%FS) provides real-time feedback on system pressure. When pressure fluctuations exceed ±5%, the electrical control box automatically adjusts the proportional valve opening to ensure equipment operational stability.

[0054] By using the built-in intelligent algorithm module in the electrical control box, the rolling parameters are optimized based on historical data and machine learning, achieving intelligent and precise control and reducing trial and error costs.

[0055] Data Acquisition and Storage: The system collects data in real time across 30+ dimensions, including: Sheet metal parameters: material (304 / 316L), thickness (0.5-0.7mm), yield strength (200-300MPa); Process parameters: roller pressure (6-20MPa), roller speed (10-25m / min), roller gap (0.4-0.8mm); Quality data: wave crest defect rate (cracking / wrinkling), dimensional deviation (wave pitch / wave height / thickness), production efficiency (pieces / hour). Historical data is stored in an SQL database, supporting retrieval by time / product model / defect type, with a data retention period of 3 years.

[0056] The machine learning model is constructed using the Gradient Boosting Tree algorithm. The input layer consists of the material, thickness, and target wave pitch / height of the sheet metal. The output layer consists of adjustment parameters such as the lateral displacement, angle, and gap of each roller segment. The model training process is as follows: Data preprocessing: Defect rate data is one-hot encoded and continuous variables are normalized to [0,1]. Cross-validation: Five-fold cross-validation is used to evaluate the model's generalization ability. The objective function is the root mean square error (RMSE), requiring a wave pitch prediction RMSE ≤ 0.6mm and a wave height prediction RMSE ≤ 1.2mm. Model update: The latest 1000 production data entries are automatically imported weekly for incremental training. Retraining is triggered when the online prediction error exceeds a preset threshold three times consecutively.

[0057] Real-time intelligent control allows operators to input target parameters (such as material 304, thickness 0.6mm, wave pitch 80mm, wave height 20mm). The intelligent algorithm module generates the optimal adjustment scheme within 2 seconds, including: the angle of each roller in the pre-pressing section (5° for the first section, 7° for the second section, and 9° for the third section); the lateral spacing of the rollers in the fine pressing section (79.5mm for the fourth section, 80.2mm for the fifth section, and 80.0mm for the sixth section); and the roller gap compensation value (0.61mm, considering a material springback rate of 3%).

[0058] After the solution is confirmed by the operator (manual fine-tuning is supported), it is sent to the drive system. Compared with traditional manual trial and error, the parameter debugging time is shortened from 30 minutes to 5 minutes, and the first-piece pass rate of new products is improved.

[0059] In some embodiments, the step of unfolding and feeding the stainless steel sheet through the hydraulic automatic feeding rack to allow the stainless steel sheet to enter the forming process includes: monitoring the feeding tension of the stainless steel sheet in real time through the tension control mechanism of the hydraulic automatic feeding rack; when an abnormal tension is detected, automatically adjusting the feeding speed of the feeding rack and the coil support force through the hydraulic system, so that the stainless steel sheet is unfolded flat with constant tension and enters the subsequent process at a uniform speed, avoiding wrinkles or stretching deformation of the sheet due to uneven tension.

[0060] The tension control mechanism of the hydraulic automatic feeding rack enables closed-loop tension control during the feeding process of stainless steel sheets, ensuring that the sheets are conveyed flat with constant tension and avoiding wrinkles or stretching deformation caused by tension fluctuations.

[0061] Tension control mechanism hardware configuration: The tension control mechanism integrates a high-precision pressure sensor (range 0~200N / mm). 2 The pressure sensor is installed at the connection end between the roll support arm and the roller of the feeding rack to monitor the lateral tension of the sheet material during feeding in real time; the speed encoder is coaxially installed on the drive shaft of the feeding roller to collect the roller rotation speed in real time.

[0062] Tension anomaly detection and feedback: The electrical control box has a preset tension threshold range (target value 80 N / mm). 2 Allowable fluctuation ±5N / mm 2 When the pressure sensor reading exceeds the threshold, it is determined to be an abnormal tension (such as excessive tension causing the sheet to stretch and deform, or insufficient tension causing wrinkles). The system transmits tension data to the electrical control box in real time via the Modbus bus, triggering an automatic adjustment program.

[0063] The hydraulic system features a dynamic adjustment mechanism: the feeding roller is driven by a hydraulic motor (5kW power, speed range 0~30rpm), with the roller speed linearly related to the feeding speed (1rpm corresponds to a feeding speed of 0.2m / min). When the tension is too high, the control box sends a command to the hydraulic proportional valve to reduce the hydraulic motor's oil supply flow, causing the roller speed to decrease (adjustment accuracy 0.1rpm), thus slowing down the feeding speed. When the tension is too low, the oil supply flow is increased to raise the speed. The coil support arm is equipped with a hydraulic telescopic rod (stroke 0~100mm, thrust range 50~200N). Based on the tension deviation fed back by the pressure sensor, the support arm synchronously adjusts the clamping force on the coil: increasing the clamping force when the tension is insufficient (adjustment step 10N each time), and decreasing the clamping force when the tension is too high, ensuring that the tension fluctuation during the sheet feeding process is controlled within ±3N / mm. 2 Within.

[0064] A visual inspection camera (1280×720 resolution, 30fps) is installed at the material unloading rack exit to capture real-time images of the board surface. An image recognition algorithm detects wrinkles (an alarm is triggered when a wrinkle width ≥ 2mm). If wrinkles are detected three times consecutively, the system automatically stops and prompts for manual intervention to prevent defective boards from entering subsequent processes.

[0065] In some embodiments, the method of using a manual front shear to cut the front end of the stainless steel sheet to adjust the initial state of the sheet entering the subsequent process includes: determining the cutting position by using the positioning ruler of the manual front shear, cutting the irregular part or rough edge of the front end of the stainless steel sheet, so that the front end of the sheet forms a flat cut perpendicular to the length direction of the sheet, and ensuring that the width of the cut sheet is consistent with the width of the guide channel of the feed guide plate.

[0066] The positioning ruler of the manual front shear is used to accurately determine the cutting position, cut off the irregular part of the front end of the board, and form a flat and vertical cut. This ensures that the width of the board after cutting matches the feed guide plate, providing conditions for stable feeding.

[0067] The manual front shear body is a gantry frame, and the shear blade is made of high-hardness alloy steel (hardness HRC58~62). The blade edge is mirror-finished (roughness Ra≤0.4μm) to ensure a smooth, burr-free cut. The positioning scale is fixed to the worktable in front of the shear blade, with a scale accuracy of 0.1mm, and the zero point of the scale is vertically aligned with the shear blade edge.

[0068] The operator places the front end of the sheet material on the worktable and pushes it so that the front end exceeds the preset length of the shear blade (set according to process requirements, such as 50mm). The cutting position is confirmed by the scale markings. An adjustable positioning baffle is installed below the scale, which moves laterally via a screw and nut mechanism (1mm pitch, 0.1mm adjustment accuracy) to adapt to the alignment requirements of different sheet widths, ensuring that the edge of the sheet material is parallel to the scale markings (parallelism error ≤0.2°).

[0069] During cutting, the operator presses down on the handles with both hands, driving the shear blades vertically downwards via a linkage mechanism (stroke 50mm, pressing speed 20mm / s). The gap between the shear blades and the worktable is precisely adjusted using a shim set (gap value equal to the board thickness, error ±0.05mm) to prevent tearing of the board due to excessive gap. After cutting, a right-angle ruler (accuracy 0.1mm) is used to check the perpendicularity of the cut to the length direction of the board, requiring a perpendicularity error ≤0.5°. The width of the board is measured using a vernier caliper (accuracy 0.02mm) and compared with the width of the feed guide channel, with an allowable error of ±0.5mm. If the error exceeds this, a second cutting is performed.

[0070] The manual front shears are equipped with an infrared hand guard that automatically locks the handle when a hand enters the working area of ​​the shear blade to prevent accidental operation. Cutting waste is collected and recycled through a collection trough under the worktable, with the waste length controlled between 50 and 100 mm to avoid waste.

[0071] In some embodiments, guiding the cut stainless steel sheet to the forming roll via the feed guide plate includes: the feed guide plate is provided with an adjustable guide groove, and the distance between the limiting plates on both sides of the guide groove is adjusted according to the actual width of the stainless steel sheet, so that the sheet is smoothly conveyed along the center line of the guide groove to the roll pressing inlet of the forming roll, avoiding the sheet from shifting or tilting during the conveying process and ensuring the accuracy of the roll pressing position.

[0072] The adjustable guide groove of the feed guide plate adapts and guides the cut sheet material to fit the width, ensuring that the sheet material enters the forming roll smoothly along the center line and avoiding conveying deviation that affects the rolling accuracy.

[0073] Feed guide plate structure and adjustment system: The feed guide plate has a "T" shaped structure. The main frame is made of aluminum alloy profile. The limit plates on both sides are driven by a servo motor (power 100W, positioning accuracy ±0.05mm) to move laterally via a screw and nut mechanism (pitch 5mm, lead accuracy ±0.02mm / m). Anti-slip rubber strips (hardness Shore A 70, coefficient of friction ≥0.3) are pasted on the inner side of the limit plates to prevent the plate from sliding.

[0074] After the sheet material is cut, it first passes through a laser width measuring instrument (measuring range 0~1500mm, accuracy ±0.2mm). The width measuring instrument is installed above the inlet of the feed guide plate, and collects the sheet width data in real time and transmits it to the electrical control box. The electrical control box automatically calculates the movement distance of the limit plate according to the preset guide groove width (target value = sheet width + 2mm, with a 1mm gap reserved on one side) and sends the command to the servo motor. The adjustment time is ≤5 seconds.

[0075] Two sets of alignment sensors (infrared through-beam type, detection accuracy ±0.5mm) are installed at the bottom of the guide groove, located at 1 / 4 and 3 / 4 positions along the width of the material, respectively. When the sensor signals triggered by the edge of the material are inconsistent, it is determined to be an offset (allowable deviation ≤1mm). If the offset exceeds the threshold, the electrical control box sends a command to the correction cylinder of the feed guide plate (stroke 50mm, response time ≤0.1 seconds), which finely adjusts the position of the material through the lateral push plate to ensure that the center line of the material coincides with the center line of the guide groove (deviation ≤0.5mm). The contact surface between the limiting plate and the material is coated with a molybdenum disulfide lubricating coating (thickness 5~10μm), with a lubrication cycle of 8 hours / time. It is sprayed periodically by an automatic lubrication device (volume distributor, oil output 0.1mL / time) to reduce the conveying friction resistance (friction resistance ≤5N / m) and avoid scratches on the surface of the material due to excessive friction.

[0076] In some embodiments, the stainless steel sheet passes through various rollers in sequence, with each roller continuously rolling the stainless steel sheet to process it into a corrugated sheet with multiple sets of wave crests. This includes: the multiple rollers of the forming roll are arranged in a preset rolling sequence; the front rollers pre-press the stainless steel sheet to form an initial wave crest profile; the rear rollers perform precision pressing and shaping on the sheet, gradually increasing the wave crest height and correcting the wave crest spacing. Through the continuous progressive rolling of the multiple rollers, the deformation of a single rolling is reduced, and cracking or wrinkling of the sheet due to stress concentration is avoided.

[0077] The multi-segment rollers of the forming roll gradually form a corrugated structure through progressive rolling pressing of pre-pressing and fine pressing, reducing the deformation of a single roll to reduce stress concentration and achieve high-precision control of peak parameters.

[0078] The forming roll consists of 7 roller groups connected in series (3 pre-pressing rollers + 4 precision pressing rollers). Each roller group includes an upper roller and a lower roller (both with a diameter of 200mm and a surface hardness of HRC60~65). The pre-pressing roller has a shallow trapezoidal wave profile (wave height 8mm, wave pitch 40mm, apex angle 120°), and the precision pressing roller has a target arc-shaped wave profile (wave height 25mm, wave pitch 80mm, arc radius 15mm). The spacing between adjacent roller groups can be adjusted by a guide rail slider mechanism (adjustment range 50~150mm, accuracy ±0.5mm).

[0079] During the pre-compression stage, the roller linear speed is controlled at 12~15m / min, and the single compression amount is 15%~20% of the plate thickness (e.g., 0.12mm for a 0.6mm thick plate). The upper roller applies a pressure of 6~8MPa (monitored in real time by a pressure sensor with an accuracy of ±0.5MPa). The first pre-compression roller forms the initial wave crest profile (wave height 5mm), the second section raises it to 8mm, and the third section corrects the wave pitch to 45mm. After each section of roller compression, the initial wave crest shape is detected by a laser profile scanner (accuracy ±0.3mm). If the wave height deviation exceeds ±1mm, the compression amount of the next roller is automatically adjusted.

[0080] During the fine pressing stage, the roller linear speed is gradually increased to 20 m / min, the pressing amount increases to 0.05~0.1 mm per stroke, and the upper roller pressure is increased to 10~15 MPa. In the fourth stage of fine pressing, the wave height is increased to 15 mm, in the fifth stage to 20 mm, in the sixth stage to 25 mm, and in the seventh stage, the wave pitch is corrected to the target value (error ±0.5 mm) by laterally moving the roller (servo motor driven, displacement accuracy ±0.05 mm). During the fine pressing process, a temperature sensor (accuracy ±1℃) on the roller surface monitors the roller temperature rise in real time. When the temperature exceeds 60℃, the circulating cooling water system (flow rate 5 L / min) is activated to prevent oxidation of the board surface due to roller overheating.

[0081] Strain gauge sensors (1με resolution) are installed at the exit of each roller section to detect the strain distribution on the plate surface. When the local strain exceeds 80% of the yield strength of stainless steel (i.e., ≥240MPa, yield strength of 304 stainless steel is 300MPa), the control box automatically reduces the pressing speed of subsequent rollers (by 10%) to release stress in stages. After precision pressing, the corrugated structure is scanned by a machine vision system (accuracy ±0.2mm) to detect the peak height, wave pitch, and surface cracks (crack length ≥1mm is considered unqualified), and the cracking rate is controlled below 0.5%.

[0082] In some embodiments, during the rolling process, the precise control of the wave pitch and wave height structural parameters of the corrugated sheet is achieved by adjusting the rolling path and the contour design of the rollers. This includes: the electrical control box pre-stores multiple sets of roller contour parameters and rolling path schemes; according to the design requirements of the target corrugated sheet, the corresponding parameter scheme is called and control commands are sent to the drive system of the forming roller; the lateral position or rotation angle of each section of roller is adjusted by a servo motor; the rolling path is corrected in real time; and the wave pitch and wave height errors of the finally formed corrugated sheet are controlled within a preset range.

[0083] By using the pre-stored roller parameters and rolling path scheme in the electrical control box, and combining the servo motor to dynamically adjust the roller position / angle, the precise control of the corrugated board's wave pitch and wave height can be achieved, keeping the error within the preset range.

[0084] The control box has a built-in database storing over 200 sets of roller profile parameters (including wave height 10-30mm, wave pitch 40-120mm, roller curvature R10-R30mm, etc.) and rolling path schemes (categorized by plate thickness 0.5mm / 0.6mm / 0.7mm). Each scheme includes the lateral displacement of each roller segment (±5mm, accuracy ±0.05mm), rotation angle (0-8°, accuracy ±0.1°), and linear speed matching relationship (10-25m / min, step size 0.5m / min). Operators input the target wave pitch (e.g., 80mm), wave height (e.g., 20mm), and plate thickness (e.g., 0.6mm) through the HMI interface, and the system automatically matches the optimal historical scheme or generates an initial scheme.

[0085] The upper roller of each roller section is driven by a servo motor (2kW power, 24-bit encoder resolution) to drive a transverse lead screw slide (stroke ±20mm, positioning accuracy ±0.02mm) to achieve fine adjustment of the roller's transverse position, which is used to correct the wave pitch (wave pitch = center distance between adjacent wave crests, positively correlated with the transverse spacing of the rollers); the lower roller is equipped with an angle adjustment mechanism (worm gear drive, angle accuracy ±0.05°), which adjusts the wave height by changing the roller tilt angle (the larger the angle, the more the wave height increases by 0.5mm / °).

[0086] During the rolling process, a 3D laser profilometer (scanning frequency 100Hz, accuracy ±0.2mm) installed at the exit of the forming roll collects the wave crest morphology data of the corrugated sheet in real time and transmits it to the electrical control box for comparison with the target parameters. When the wave pitch error > ±0.8mm or the wave height error > ±1.2mm, the system triggers automatic correction: Wave pitch deviation: The lateral spacing of the two sets of rollers in the rear section is adjusted synchronously by the servo motor (single adjustment amount ≤0.3mm), and corrected to the target value in 2-3 steps; Wave height deviation: The tilt angle of the corresponding precision pressing section roller is adjusted (single adjustment ≤0.5°), combined with fine adjustment of the pressing amount (±0.03mm), and the correction is completed within one sheet length cycle. Finally, the wave pitch error ≤ ±0.5mm and the wave height error ≤ ±1mm, meeting the high-precision assembly requirements of photovoltaic module backsheets.

[0087] In some embodiments, adjusting the thickness of the stainless steel sheet to 0.5mm to 0.7mm according to usage requirements includes: adjusting the vertical distance between adjacent rollers according to the target thickness parameter using the roller gap adjustment device of the forming roller; simultaneously detecting the sheet thickness in real time using a thickness sensor during the rolling process; and automatically fine-tuning the roller gap by the electrical control box when the detected value deviates from 0.5mm to 0.7mm so that the thickness of the formed corrugated sheet meets the usage requirements.

[0088] Through closed-loop control of roller gap adjustment device and thickness sensor, the thickness of stainless steel sheet is precisely adjusted to 0.5-0.7mm, and thickness deviation is corrected in real time.

[0089] Roller gap adjustment device: The upper and lower roller groups of the forming roll are connected by a ball screw pair (5mm lead, ISO 3 accuracy class), equipped with dual servo motor synchronous drive (1.5kW power, position feedback accuracy ±0.01mm), and the vertical gap can be adjusted from 0.4-0.8mm (covering the target thickness of 0.5-0.7mm ±0.1mm margin). The initial gap is preset according to the target thickness (e.g., 0.6mm thickness corresponds to an initial gap of 0.62mm, with a 20μm compensation allowance).

[0090] Real-time thickness detection and feedback: A β-ray thickness sensor (model: Mahr FT130, measurement range 0.1-2mm, accuracy ±0.01mm) is installed at the roller extrusion outlet, collecting thickness data every 0.5 seconds. When the detected value deviates from the target thickness by > ±0.03mm (e.g., target 0.5mm, actual measurement 0.54mm), the control box adjusts according to the following logic: Deviation < ±0.05mm: Automatically fine-tunes the roller gap (single adjustment amount 0.01mm), and waits for 3 board cycles (approximately 15 seconds) after adjustment to confirm thickness stability; Deviation ≥ ±0.05mm: Triggers an early warning and pauses roller pressing, prompting manual inspection of the incoming board thickness (incoming thickness fluctuation within ±0.02mm is acceptable), and recalibrates the gap after eliminating any abnormalities in the incoming material.

[0091] Displacement sensors (accuracy ±0.005mm) are installed at both ends of the roller to monitor the consistency of the gap between the two ends of the roller in real time. When the gap difference between the two ends is >0.02mm, the lead screw on one side is adjusted separately by the servo motor to ensure that the parallelism error of the roller is ≤0.01mm / m, so as to avoid uneven thickness caused by roller tilt (thickness difference of the same plate ≤0.02mm).

[0092] In some embodiments, the step of cutting the corrugated sheet into a desired stainless steel corrugated back plate using a hydraulic cutting module according to a preset size after roll forming includes: the hydraulic cutting module is equipped with a photoelectric sensor to detect the conveying length of the roll-formed sheet in real time; when the sheet is conveyed to a preset cutting position, the electrical control box sends a cutting command to the hydraulic pump station, which hydraulically drives the cutting blade to press down quickly to cut the sheet; during the cutting process, the positioning clamp of the hydraulic cutting module simultaneously clamps the sheet to prevent displacement of the sheet during cutting and ensure a smooth cut without burrs.

[0093] The hydraulic cutting module utilizes photoelectric sensors for positioning, combined with hydraulic drive for cutting and clamping, to achieve fixed-length cutting and ensure cut quality. Cutting position detection and triggering: A through-beam photoelectric sensor (detection distance 5m, response time ≤10μs) is installed at the inlet of the hydraulic cutting module. Using the front end of the sheet material cut in step S101 as the zero point, the conveying length is accumulated via an encoder (installed on the conveyor roller shaft, resolution 0.1mm). When the accumulated value reaches the preset cutting length (e.g., 2000mm±2mm), the sensor sends a pulse signal to the electrical control box, triggering a cutting command within 0.1 seconds. Hydraulic cutting actuator: The cutting blade is made of alloy steel (hardness HRC60), and the cutting edge angle is matched according to the sheet thickness (0.5mm→30°, 0.7mm→45°). The blade is driven by a hydraulic cylinder (80mm diameter, 100mm stroke, adjustable speed 50-100mm / s). During cutting, the hydraulic system first supplies air to the positioning clamp (double-sided pneumatic grippers, clamping force 800-1500N, clamping response time ≤0.05 seconds). The grippers simultaneously clamp both sides of the plate (100mm from the cut), and then drive the blade to press down. The cutting time is ≤0.3 seconds, ensuring that the flatness error of the cut is ≤0.3mm and the burr height is ≤0.1mm. Post-cutting quality inspection: The cut back plate is conveyed to the inspection station by a belt. A vision camera (resolution 2048×1536) installed above takes pictures to inspect the verticality of the cut (allowable deviation ≤0.5°) and burr defects. Defective products are automatically separated by a rejection cylinder (stroke 50mm, response time ≤0.2 seconds), and the defect rate is controlled below 0.3%.

[0094] In some embodiments, the hydraulic pump station provides power for the rolling action of the forming roll and the cutting action of the hydraulic cutting module, including: the hydraulic pump station is equipped with a pressure sensor and a flow regulating valve, which automatically adjusts the output pressure and flow rate according to the rolling stage of the forming roll and the cutting requirements of the hydraulic cutting module; it provides lower pressure in the pre-pressing stage to ensure smooth deformation of the sheet metal, increases pressure in the fine pressing stage to ensure the formation of the wave crest structure, and instantly increases pressure in the cutting stage to achieve rapid cutting, thereby improving the stability of equipment operation and forming accuracy through dynamic pressure control. The hydraulic pump station dynamically matches the pressure / flow requirements of each stage of rolling and the cutting action through the pressure sensor and flow regulating valve, thereby improving equipment stability. Hydraulic pump station hardware configuration: The pump station adopts a variable displacement piston pump (maximum flow rate 60L / min, pressure range 0-25MPa), integrates a proportional pressure valve (control accuracy ±1%FS) and an electromagnetic flow valve (accuracy ±2%FS), and is equipped with a pressure sensor (range 0-30MPa, accuracy ±0.5%FS) to provide real-time feedback of system pressure. The staged pressure and flow control is shown in the table below:

[0095]

[0096] The pump station is equipped with an overflow valve (opening pressure 25MPa) and a temperature sensor (alarm threshold 65℃). When the pressure exceeds 23MPa or the oil temperature exceeds 60℃, the system automatically reduces the output power by 10% and starts the cooling fan (airflow 1.5m³ / h). 3 ( / min) to ensure that the hydraulic oil temperature is stable at 40-55℃, and to extend the life of the seals (replacement cycle ≥1 year).

[0097] This invention relates to the manufacturing process of stainless steel corrugated backsheets for photovoltaic modules, specifically a method for achieving high-precision forming of stainless steel sheets through continuous rolling pressing with multiple rollers, belonging to the field of metal sheet forming and processing technology (specifically involving continuous rolling forming equipment and control methods).

[0098] By employing continuous, progressive rolling with multiple rollers (pre-pressing at the front and fine pressing at the rear), the large deformation in a single process is decomposed into multiple smaller deformations, significantly reducing stress concentration during the stainless steel sheet forming process. This lowers the risk of cracking compared to traditional stamping processes and increases the yield rate. Utilizing preset roller profile parameters and rolling path schemes in the control box, combined with real-time adjustment of roller position and angle by a servo motor, the wave pitch and wave height errors are controlled within ±0.5mm, and the sheet thickness can be precisely adjusted within the range of 0.5mm to 0.7mm, meeting the customized production needs of photovoltaic modules with different strength requirements. The use of a hydraulic automatic feeding rack, feeding guide plate, and hydraulic cutting device creates a fully automated production line, significantly reducing production costs. The backsheet strength is improved without the need for additional reinforcing ribs, making it suitable for mass production of high-strength photovoltaic modules, especially suitable for module production in coastal high-wind-pressure and high-corrosion environments, effectively extending the service life of photovoltaic modules.

[0099] This application also provides a continuous roll forming apparatus for stainless steel corrugated back panels. This apparatus is used to perform the steps of the continuous roll forming method for stainless steel corrugated back panels shown in the above embodiments. The continuous roll forming apparatus for stainless steel corrugated back panels can be a single server or a server cluster, or it can be a terminal, such as a handheld terminal, a laptop computer, a wearable device, or a robot.

[0100] The continuous roll forming apparatus for stainless steel corrugated back plates includes:

[0101] The state adjustment unit is used to unfold and feed the stainless steel sheet through the hydraulic automatic feeding rack so that the stainless steel sheet enters the forming process; and to use the manual front shear to cut the front end of the stainless steel sheet to adjust the initial state of the sheet for subsequent processes.

[0102] The thickness adjustment unit guides the cut stainless steel sheet to the forming roll via a feed guide plate. The forming roll adopts a multi-segment roller structure, and the stainless steel sheet passes through each segment of rollers in sequence. Each segment of rollers continuously rolls the stainless steel sheet, processing it into a corrugated sheet with multiple sets of wave crests. During the rolling process, the wave pitch and wave height structural parameters of the corrugated sheet can be precisely controlled by adjusting the rolling path and the roller profile design. The thickness of the stainless steel sheet can be adjusted to 0.5mm to 0.7mm according to the usage requirements.

[0103] The backplate obtaining unit is used to cut the corrugated sheet into the required stainless steel corrugated backplate according to the preset size using a hydraulic cutting module after the corrugated sheet has been roll-formed. The hydraulic pump station provides power for the rolling action of the forming rolls and the cutting action of the hydraulic cutting module. It also includes: establishing the mapping relationship between rolling parameters and forming quality using a machine learning model; and generating the optimal rolling path and roller profile adjustment scheme through an intelligent algorithm module based on the material of the current stainless steel sheet and the target product parameters.

[0104] In some embodiments, the step of unfolding and feeding the stainless steel sheet through the hydraulic automatic feeding rack to allow the stainless steel sheet to enter the forming process includes: monitoring the feeding tension of the stainless steel sheet in real time through the tension control mechanism of the hydraulic automatic feeding rack; when an abnormal tension is detected, automatically adjusting the feeding speed of the feeding rack and the coil support force through the hydraulic system, so that the stainless steel sheet is unfolded flat with constant tension and enters the subsequent process at a uniform speed, avoiding wrinkles or stretching deformation of the sheet due to uneven tension.

[0105] In some embodiments, the method of using a manual front shear to cut the front end of the stainless steel sheet to adjust the initial state of the sheet entering the subsequent process includes: determining the cutting position by using the positioning ruler of the manual front shear, cutting the irregular part or rough edge of the front end of the stainless steel sheet, so that the front end of the sheet forms a flat cut perpendicular to the length direction of the sheet, and ensuring that the width of the cut sheet is consistent with the width of the guide channel of the feed guide plate.

[0106] In some embodiments, guiding the cut stainless steel sheet to the forming roll via the feed guide plate includes: the feed guide plate is provided with an adjustable guide groove, and the distance between the limiting plates on both sides of the guide groove is adjusted according to the actual width of the stainless steel sheet, so that the sheet is smoothly conveyed along the center line of the guide groove to the roll pressing inlet of the forming roll, avoiding the sheet from shifting or tilting during the conveying process and ensuring the accuracy of the roll pressing position.

[0107] In some embodiments, the stainless steel sheet passes through various rollers in sequence, with each roller continuously rolling the stainless steel sheet to process it into a corrugated sheet with multiple sets of wave crests. This includes: the multiple rollers of the forming roll are arranged in a preset rolling sequence; the front rollers pre-press the stainless steel sheet to form an initial wave crest profile; the rear rollers perform precision pressing and shaping on the sheet, gradually increasing the wave crest height and correcting the wave crest spacing. Through the continuous progressive rolling of the multiple rollers, the deformation of a single rolling is reduced, and cracking or wrinkling of the sheet due to stress concentration is avoided.

[0108] In some embodiments, during the rolling process, the precise control of the wave pitch and wave height structural parameters of the corrugated sheet is achieved by adjusting the rolling path and the contour design of the rollers. This includes: the electrical control box pre-stores multiple sets of roller contour parameters and rolling path schemes; according to the design requirements of the target corrugated sheet, the corresponding parameter scheme is called and control commands are sent to the drive system of the forming roller; the lateral position or rotation angle of each section of roller is adjusted by a servo motor; the rolling path is corrected in real time; and the wave pitch and wave height errors of the finally formed corrugated sheet are controlled within a preset range.

[0109] In some embodiments, adjusting the thickness of the stainless steel sheet to 0.5mm to 0.7mm according to usage requirements includes: adjusting the vertical distance between adjacent rollers according to the target thickness parameter using the roller gap adjustment device of the forming roller; simultaneously detecting the sheet thickness in real time using a thickness sensor during the rolling process; and automatically fine-tuning the roller gap by the electrical control box when the detected value deviates from 0.5mm to 0.7mm so that the thickness of the formed corrugated sheet meets the usage requirements.

[0110] In some embodiments, the step of cutting the corrugated sheet into a desired stainless steel corrugated back plate using a hydraulic cutting module according to a preset size after roll forming includes: the hydraulic cutting module is equipped with a photoelectric sensor to detect the conveying length of the roll-formed sheet in real time; when the sheet is conveyed to a preset cutting position, the electrical control box sends a cutting command to the hydraulic pump station, which hydraulically drives the cutting blade to press down quickly to cut the sheet; during the cutting process, the positioning clamp of the hydraulic cutting module simultaneously clamps the sheet to prevent displacement of the sheet during cutting and ensure a smooth cut without burrs.

[0111] In some embodiments, the hydraulic pump station provides power for the rolling action of the forming roll and the cutting action of the hydraulic cutting module, including: the hydraulic pump station is equipped with a pressure sensor and a flow regulating valve, and automatically adjusts the output pressure and flow according to the rolling stage of the forming roll and the cutting requirements of the hydraulic cutting module; it provides lower pressure in the pre-pressing stage to ensure smooth deformation of the sheet metal, increases pressure in the fine pressing stage to ensure the formation of the wave crest structure, and instantly increases pressure in the cutting stage to achieve rapid cutting, thereby improving the stability of equipment operation and forming accuracy through dynamic pressure control.

[0112] It should be noted that those skilled in the art will clearly understand that, for the sake of convenience and brevity, the specific working process of the continuous roll forming device and each module of the stainless steel corrugated back plate described above can be referred to the corresponding process in the embodiments of the continuous roll forming method of the stainless steel corrugated back plate described above, and will not be repeated here.

[0113] The aforementioned continuous roll forming method for stainless steel corrugated back plates can be implemented as a computer program that can run on the provided device.

[0114] Please see Figure 3 , Figure 3 This is a schematic block diagram of the electrical control box provided in an embodiment of this application. The electrical control box includes a processor, a memory, and a network interface connected via a device bus, wherein the memory may include a storage medium and internal memory.

[0115] The storage medium may store operating equipment and computer programs. The computer program includes program instructions that, when executed, cause the processor to perform any continuous roll forming method for stainless steel corrugated backing plates.

[0116] The processor provides computing and control capabilities to support the operation of the entire electrical control box.

[0117] The internal memory provides an environment for the execution of computer programs in non-volatile storage media. When the computer program is executed by the processor, it enables the processor to perform any continuous roll forming method for stainless steel corrugated backing plates.

[0118] This network interface is used for network communication, such as sending assigned tasks. Those skilled in the art will understand that... Figure 3 The structure shown is merely a block diagram of a portion of the structure related to the present application and does not constitute a limitation on the terminal to which the present application is applied. The specific electrical control box may include more or fewer components than those shown in the figure, or combine certain components, or have different component arrangements.

[0119] It should be understood that the processor can be a Central Processing Unit (CPU), but it can also be other general-purpose processors, digital signal processors (DSPs), application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc. Among these, a general-purpose processor can be a microprocessor or any conventional processor.

[0120] In one embodiment, the processor is configured to run a computer program stored in memory to perform the following steps:

[0121] The stainless steel sheet is unfolded and fed by a hydraulic automatic feeding rack, allowing it to enter the forming process; the front end of the stainless steel sheet is trimmed by a manual front shear to adjust the initial state of the sheet for subsequent processes.

[0122] The cut stainless steel sheet is guided to the forming roller by the feed guide plate. The forming roller adopts a multi-segment roller structure. The stainless steel sheet passes through each segment of roller in sequence. Each segment of roller continuously rolls the stainless steel sheet, so that the stainless steel sheet is processed into a corrugated sheet with multiple sets of crests. During the rolling process, the wave pitch and wave height structural parameters of the corrugated sheet can be precisely controlled by adjusting the rolling path and the contour design of the roller. The thickness of the stainless steel sheet can be adjusted to 0.5mm to 0.7mm according to the application requirements.

[0123] After the corrugated sheet is roll-formed, the sheet is cut according to the preset size using a hydraulic cutting module to obtain the required stainless steel corrugated back plate. The hydraulic pump station provides power for the rolling action of the forming rolls and the cutting action of the hydraulic cutting module. The system also includes: establishing a mapping relationship between rolling parameters and forming quality using a machine learning model; and generating the optimal rolling path and roller profile adjustment scheme through an intelligent algorithm module based on the material of the current stainless steel sheet and the target product parameters.

[0124] In some embodiments, the step of unfolding and feeding the stainless steel sheet through the hydraulic automatic feeding rack to allow the stainless steel sheet to enter the forming process includes: monitoring the feeding tension of the stainless steel sheet in real time through the tension control mechanism of the hydraulic automatic feeding rack; when an abnormal tension is detected, automatically adjusting the feeding speed of the feeding rack and the coil support force through the hydraulic system, so that the stainless steel sheet is unfolded flat with constant tension and enters the subsequent process at a uniform speed, avoiding wrinkles or stretching deformation of the sheet due to uneven tension.

[0125] In some embodiments, the method of using a manual front shear to cut the front end of the stainless steel sheet to adjust the initial state of the sheet entering the subsequent process includes: determining the cutting position by using the positioning ruler of the manual front shear, cutting the irregular part or rough edge of the front end of the stainless steel sheet, so that the front end of the sheet forms a flat cut perpendicular to the length direction of the sheet, and ensuring that the width of the cut sheet is consistent with the width of the guide channel of the feed guide plate.

[0126] In some embodiments, guiding the cut stainless steel sheet to the forming roll via the feed guide plate includes: the feed guide plate is provided with an adjustable guide groove, and the distance between the limiting plates on both sides of the guide groove is adjusted according to the actual width of the stainless steel sheet, so that the sheet is smoothly conveyed along the center line of the guide groove to the roll pressing inlet of the forming roll, avoiding the sheet from shifting or tilting during the conveying process and ensuring the accuracy of the roll pressing position.

[0127] In some embodiments, the stainless steel sheet passes through various rollers in sequence, with each roller continuously rolling the stainless steel sheet to process it into a corrugated sheet with multiple sets of wave crests. This includes: the multiple rollers of the forming roll are arranged in a preset rolling sequence; the front rollers pre-press the stainless steel sheet to form an initial wave crest profile; the rear rollers perform precision pressing and shaping on the sheet, gradually increasing the wave crest height and correcting the wave crest spacing. Through the continuous progressive rolling of the multiple rollers, the deformation of a single rolling is reduced, and cracking or wrinkling of the sheet due to stress concentration is avoided.

[0128] In some embodiments, during the rolling process, the precise control of the wave pitch and wave height structural parameters of the corrugated sheet is achieved by adjusting the rolling path and the contour design of the rollers. This includes: the electrical control box pre-stores multiple sets of roller contour parameters and rolling path schemes; according to the design requirements of the target corrugated sheet, the corresponding parameter scheme is called and control commands are sent to the drive system of the forming roller; the lateral position or rotation angle of each section of roller is adjusted by a servo motor; the rolling path is corrected in real time; and the wave pitch and wave height errors of the finally formed corrugated sheet are controlled within a preset range.

[0129] In some embodiments, adjusting the thickness of the stainless steel sheet to 0.5mm to 0.7mm according to usage requirements includes: adjusting the vertical distance between adjacent rollers according to the target thickness parameter using the roller gap adjustment device of the forming roller; simultaneously detecting the sheet thickness in real time using a thickness sensor during the rolling process; and automatically fine-tuning the roller gap by the electrical control box when the detected value deviates from 0.5mm to 0.7mm so that the thickness of the formed corrugated sheet meets the usage requirements.

[0130] In some embodiments, the step of cutting the corrugated sheet into a desired stainless steel corrugated back plate using a hydraulic cutting module according to a preset size after roll forming includes: the hydraulic cutting module is equipped with a photoelectric sensor to detect the conveying length of the roll-formed sheet in real time; when the sheet is conveyed to a preset cutting position, the electrical control box sends a cutting command to the hydraulic pump station, which hydraulically drives the cutting blade to press down quickly to cut the sheet; during the cutting process, the positioning clamp of the hydraulic cutting module simultaneously clamps the sheet to prevent displacement of the sheet during cutting and ensure a smooth cut without burrs.

[0131] In some embodiments, the hydraulic pump station provides power for the rolling action of the forming roll and the cutting action of the hydraulic cutting module, including: the hydraulic pump station is equipped with a pressure sensor and a flow regulating valve, and automatically adjusts the output pressure and flow according to the rolling stage of the forming roll and the cutting requirements of the hydraulic cutting module; it provides lower pressure in the pre-pressing stage to ensure smooth deformation of the sheet metal, increases pressure in the fine pressing stage to ensure the formation of the wave crest structure, and instantly increases pressure in the cutting stage to achieve rapid cutting, thereby improving the stability of equipment operation and forming accuracy through dynamic pressure control.

[0132] It should be noted that those skilled in the art will clearly understand that, for the sake of convenience and brevity, the specific working process of the processor described above can be referred to the corresponding process in the embodiments of the continuous roll forming method for stainless steel corrugated back plates described above, and will not be repeated here.

[0133] This application also provides a computer-readable storage medium storing a computer program that, when executed by a processor, causes the processor to implement the steps of the continuous roll forming method for stainless steel corrugated backing plates as described in the first aspect above.

[0134] The computer-readable storage medium can be an internal storage unit of the electrical control box described in the foregoing embodiments, such as the hard drive or memory of the electrical control box. Alternatively, the computer-readable storage medium can be an external storage device of the electrical control box, such as a plug-in hard drive, Smart Media Card (SMC), Secure Digital (SD) card, or Flash Card equipped on the electrical control box.

[0135] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any person skilled in the art can easily conceive of various equivalent modifications or substitutions within the technical scope disclosed in this application, and these modifications or substitutions should all be covered within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A continuous roll forming method of a stainless steel corrugated backer panel, characterized by, The application relates to an electric control box applied to a continuous roller forming equipment, wherein the continuous roller forming equipment further comprises an oil pressure automatic material discharging frame, a manual front shearing machine, a feeding guide plate, a forming roller, a hydraulic cutting module and a hydraulic pump station; the electric control box is internally provided with an intelligent algorithm module, so that the roller pressing path and the roller contour design parameters are optimized through a machine learning model based on historical production data and real-time monitoring parameters, and the forming data of stainless steel corrugated back plates with different thicknesses, wave distances and wave heights in historical production are collected; the method comprises the following steps: The stainless steel plate is unfolded and broadcast through the oil pressure automatic material discharging frame, so that the stainless steel plate enters a forming process; the front end of the stainless steel plate is sheared through the manual front shearing machine, so that the initial state of the plate entering a subsequent process is adjusted; The sheared stainless steel plate is guided to the forming roller through the feeding guide plate; the forming roller adopts a multi-section roller structure, the stainless steel plate sequentially passes through each section of the roller, and each section of the roller continuously presses the stainless steel plate, so that the stainless steel plate is processed into a corrugated plate with multiple groups of wave peak structures; in the roller pressing process, the wave distance and wave height structure parameters of the corrugated plate are accurately controlled by adjusting the roller pressing path and the roller contour design, and the thickness of the stainless steel plate is adjusted to 0.5mm-0.7mm according to use requirements. When the corrugated plate is rolled and formed, the hydraulic cutting module is used to cut the plate according to the preset size, and the required stainless steel corrugated back plate is obtained, including: the hydraulic cutting module is provided with a photoelectric sensor, which detects the conveying length of the rolled and formed plate in real time, when the plate is conveyed to the preset cutting position, the electric control box sends a cutting instruction to the hydraulic pump station, and the cutting blade is quickly pressed down by hydraulic drive to cut the plate; during the cutting process, the positioning clamp of the hydraulic cutting module synchronously clamps the plate to avoid displacement of the plate during cutting, and ensure that the cut is smooth and free of burrs; wherein the blade angle corresponding to the hydraulic cutting module is matched according to the thickness of the plate, the blade angle corresponding to the 0.5mm plate thickness is 30°, and the blade angle corresponding to the 0.7mm plate thickness is 45°, when cutting, the hydraulic system first supplies air to the positioning clamp, the clamping jaw synchronously clamps the plate on both sides at a position 100mm away from the cut, and then drives the blade to press down, the cut back plate is conveyed to the detection station by the belt, the visual camera installed above takes a picture to detect the perpendicularity and burr defect of the cut, and the unqualified product is automatically separated by the rejection cylinder; wherein the hydraulic pump station provides power for the rolling action of the forming roller and the cutting action of the hydraulic cutting module; further comprising: using a machine learning model to establish a mapping relationship between the rolling parameters and the forming quality; according to the material quality of the current stainless steel plate and the target product parameters, the intelligent algorithm module generates the optimal rolling path and roller contour adjustment scheme, the machine learning model adopts the gradient boosting tree algorithm to construct the prediction model, the input layer is the plate material, thickness, target wave distance or wave height, and the output layer is the adjustment parameters of the transverse displacement, angle and gap of each section roller, the model training process is through one-hot encoding of the defect rate data, and the normalized continuous variables are normalized to [0, 1]; the generalization ability of the model is evaluated by 5-fold cross-validation, and the objective function is the root mean square error; after inputting the target parameters, the real-time intelligent control generates the optimal adjustment scheme through the intelligent algorithm module, including: the angle of each roller in the pre-pressing section, the transverse distance of the roller in the fine pressing section and the roller gap compensation value.

2. The method of claim 1, wherein, The oil pressure automatic material uncoiling frame is used to uncoil and broadcast the stainless steel plate, so that the stainless steel plate enters the forming process, including: The tension control mechanism of the oil pressure automatic material uncoiling frame monitors the broadcasting tension of the stainless steel plate in real time, and when an abnormal tension is detected, the hydraulic system automatically adjusts the uncoiling speed and the material support force of the uncoiling frame, so that the stainless steel plate is evenly uncoiled at a constant tension and enters the subsequent process at a constant speed, avoiding wrinkles or tensile deformation of the plate due to uneven tension.

3. The method of claim 1, wherein, The manual front cutter is used to cut the front end of the stainless steel plate to adjust the starting state of the plate entering the subsequent process, including: The positioning scale of the manual front cutter is used to determine the cutting position, and the irregular part or burr of the front end of the stainless steel plate is cut, so that the front end of the plate forms a smooth and vertical cut to the length direction of the plate, ensuring that the width of the cut plate is consistent with the width of the guide channel of the feeding guide plate.

4. The method of claim 1, wherein, The feeding guide plate is used to guide the cut stainless steel plate to the forming roller, including: The feeding guide plate is provided with an adjustable guide groove, the spacing between the two side limiting plates of the guide groove is adjusted according to the actual width of the stainless steel plate, so that the plate is stably conveyed along the center line of the guide groove to the rolling entrance of the forming roller, avoiding deviation or skew of the plate during conveying and ensuring the accuracy of the rolling position.

5. The method of claim 1, wherein, The stainless steel plate sequentially passes through each section of the roller, and each section of the roller continuously rolls the stainless steel plate to process the stainless steel plate into a corrugated plate with multiple groups of wave peak structures, comprising: The multiple sections of the forming roller are arranged in sequence according to a preset rolling sequence, the front section of the roller pre-presses and forms the stainless steel plate into a preliminary wave peak profile, and the rear section of the roller precisely shapes the plate, gradually increases the wave peak height and corrects the wave peak spacing, and through the continuous progressive rolling of the multiple sections of the roller, the deformation amount of single rolling is reduced, avoiding cracking or wrinkling of the plate due to stress concentration.

6. The method of claim 1, wherein, During the rolling process, the wave distance and wave height structure parameters of the corrugated plate are accurately controlled by adjusting the rolling path and the profile design of the roller, comprising: The electric control box pre-stores multiple sets of roller profile parameters and rolling path schemes, according to the design requirements of the target corrugated plate, calls the corresponding parameter scheme and sends control instructions to the drive system of the forming roller, adjusts the transverse position or rotation angle of each section of the roller through the servo motor, and real-time corrects the rolling path, so that the wave distance and wave height error of the finally formed corrugated plate are controlled within the preset range.

7. The method of claim 1, wherein, According to the use requirement, the thickness of the stainless steel plate is adjusted to 0.5mm-0.7mm, comprising: Through the roller gap adjusting device of the forming roller, the vertical spacing between adjacent rollers is adjusted according to the target thickness parameter, and at the same time, the thickness of the plate is detected in real time through the thickness sensor during the rolling process, when the detected value deviates from 0.5mm-0.7mm, the roller gap is automatically fine-tuned by the electric control box, so that the thickness of the formed corrugated plate meets the use requirement.

8. The method of claim 1, wherein, The hydraulic pump station provides power for the rolling action of the forming roller and the cutting action of the hydraulic cutting module, comprising: The hydraulic pump station is provided with a pressure sensor and a flow regulating valve, which automatically adjusts the output pressure and flow according to the rolling stage of the forming roller and the cutting requirement of the hydraulic cutting module; in the pre-pressing stage, a lower pressure is provided to ensure the stable deformation of the plate, in the fine pressing stage, the pressure is increased to ensure the formation of the wave peak structure, and in the cutting stage, the pressure is instantaneously increased to realize rapid cutting, thereby improving the equipment operation stability and forming precision through dynamic pressure control.

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