Insulation monitoring method and system for copper foil surface treatment machine

Abstract

The invention provides an insulation monitoring method for a copper foil surface treatment machine, which comprises the following steps: S1, an insulation monitoring system obtains leakage current values of a plurality of key rollers in the copper foil surface treatment machine, and the key rollers comprise conductive rollers and tension rollers; s2, the leakage current values are calculated and analyzed through a main control unit, and the insulation resistance of each key roller is determined; s3, transmitting the insulation resistance data to a remote upper computer through a network switch, and generating an equipment comprehensive insulation monitoring report; and S4, according to the insulation grade in the insulation monitoring report, judging whether the equipment meets a startup condition or not. The method is very suitable for multi-point poor insulation monitoring of the copper foil surface processor equipment, has the characteristics of high reliability, high precision and integrated programming, realizes simultaneous monitoring of a plurality of points and a plurality of parameters, and a generated insulation evaluation report serves as an important basis for production personnel to judge whether the machine can be normally started or not.

Description

Technical Field

[0001] This invention relates to the field of information technology, and in particular to an insulation monitoring method and system for a copper foil surface treatment machine. Background Technology

[0002] Copper foil production, as one of the core processes in modern electronics industry, plays an irreplaceable role in manufacturing high-performance circuit boards and battery materials. During its production, the insulation performance of critical rollers directly affects equipment safety and product quality; even minor insulation failures can lead to leakage accidents, resulting in equipment downtime or product quality degradation. Therefore, ensuring the stability and real-time monitoring of the insulation performance of critical rollers has become a crucial technical requirement in copper foil production. However, current methods for monitoring the insulation performance of critical rollers in copper foil production have significant shortcomings. Traditional monitoring methods often rely on manual inspections or simple voltage tests, making it difficult to capture dynamic changes in insulation performance in real time. For example, during production, conductive rollers and tension rollers may be affected by dust, oil, or changes in temperature and humidity over long-term operation, leading to a gradual decline in insulation performance, but existing methods cannot detect these subtle changes in a timely manner. Furthermore, monitoring equipment often lacks effective suppression of electromagnetic interference in complex production environments, resulting in distorted measurement results that fail to accurately reflect the insulation status.

[0003] The root of these limitations lies in a core technical challenge: how to accurately acquire weak leakage current signals in complex production environments. Weak leakage current is a crucial indicator for assessing insulation performance, but its signal strength is low and easily masked by environmental electromagnetic noise. For example, on copper foil production lines, the operation of motors and high-voltage equipment generate strong electromagnetic interference, making the acquisition of weak current signals exceptionally difficult. This interference not only affects measurement accuracy but can also lead to misjudgments, causing potential insulation faults to be overlooked.

[0004] Therefore, on a high-speed copper foil production line, how to achieve high-precision real-time acquisition of weak leakage current under strong electromagnetic interference, and accurately determine the insulation status of key rollers through this data, has become a key issue in improving equipment safety and production stability. Summary of the Invention

[0005] This invention provides an insulation monitoring method for a copper foil surface treatment machine, mainly comprising: S1. The insulation monitoring system acquires the leakage current values ​​of multiple key rollers in the copper foil surface treatment machine, the key rollers including conductive rollers and tension rollers; S2. The main control unit performs calculation and analysis on the leakage current values ​​to determine the insulation resistance of each key roller; S3. The insulation resistance data is transmitted to a remote host computer through a network switch to generate a comprehensive insulation monitoring report for the equipment; S4. The insulation level in the insulation monitoring report is used to determine whether the equipment meets the start-up conditions.

[0006] A second aspect of the present invention provides an insulation monitoring system for a copper foil surface treatment machine, comprising: The data acquisition unit is configured to acquire leakage current values ​​of multiple key rollers in the copper foil surface treatment machine, the key rollers including conductive rollers and tension rollers; The main control unit, which is communicatively connected to the data acquisition unit, is configured to receive the leakage current value and perform calculations and analyses to determine the insulation resistance of each key roller. A network communication unit, connected to the main control unit, is configured to transmit the insulation resistance data to a remote host computer. The remote host computer is configured to receive and process the insulation resistance data, generate a comprehensive insulation monitoring report for the equipment, and determine whether the equipment meets the start-up conditions based on the insulation level in the insulation monitoring report.

[0007] A third aspect of the present invention provides an electronic device, comprising: a memory and at least one processor, wherein the memory stores instructions, and the memory and the at least one processor are interconnected via a circuit; the at least one processor invokes the instructions in the memory to cause the electronic device to perform the above-described method for monitoring the insulation of a copper foil surface treatment machine.

[0008] A fourth aspect of the present invention provides a computer-readable storage medium storing instructions that, when executed on a computer, cause the computer to perform the above-described method for monitoring the insulation of a copper foil surface treatment machine.

[0009] The technical solutions provided by the embodiments of the present invention may include the following beneficial effects: This invention discloses an insulation monitoring method for copper foil surface treatment machines. It addresses the problems of insufficient real-time monitoring of the insulation performance of critical rollers in copper foil production, the susceptibility to leakage accidents caused by insulation aging or contamination, and the impact on equipment safety and production continuity. The invention proposes a systematic solution. It uses a distributed sensor network to collect leakage current from conductive and tension rollers in real time, employs fully differential signal acquisition technology to suppress electromagnetic interference, and ensures the accuracy of weak current measurements. An adjustable DC voltage is applied through a power protection unit, combined with high-precision analog-to-digital conversion and Modbus protocol transmission, to calculate and dynamically analyze insulation resistance. Based on environmental temperature and humidity correction and an insulation dynamic model, it generates graded early warnings and comprehensive monitoring reports, automatically determining equipment start-up conditions. The most significant innovation of this invention lies in integrating high-precision acquisition, dynamic analysis, and intelligent early warning to achieve real-time monitoring and fault prevention of the insulation status of critical rollers, effectively improving equipment safety and production stability, reducing leakage risks, and ensuring the quality of copper foil processing.

[0010] This invention is ideal for multi-point insulation failure monitoring of copper foil surface treatment equipment. It features high reliability, high precision, and integrated programming, enabling simultaneous monitoring of multiple points and parameters. The generated insulation evaluation report serves as an important basis for production personnel to determine whether the machine can be started normally. Attached Figure Description

[0011] Figure 1 This is a flowchart of an insulation monitoring method for a copper foil surface treatment machine according to the present invention.

[0012] Figure 2 This is a schematic diagram of the insulation monitoring system provided by the present invention.

[0013] Figure 3 This is a schematic diagram of the monitoring points of the copper foil surface treatment machine described in this invention. Detailed Implementation

[0014] To further understand the content of this invention, a detailed description of the invention is provided in conjunction with the accompanying drawings and embodiments. The specific embodiments described herein are for illustrative purposes only and are not intended to limit the invention. It should also be noted that, for ease of description, only the parts relevant to the invention are shown in the accompanying drawings.

[0015] To ensure the insulation of the copper foil contact mechanisms on the surface treatment machine used in copper foil production, particularly the insulation performance of the coarse curing conductive roller, tension roller, transition roller, and the machine frame, it is crucial to prevent leakage and partial discharge. This ensures that the rectifier output current is fully utilized in each electrolytic cell during the electroplating process, meeting process requirements. This approach not only guarantees copper foil production quality and reduces defective products but also minimizes energy waste, which is of significant importance to copper foil production and sales.

[0016] See Figure 3 In the operation of copper foil surface treatment machines, multiple electrolytic cells are involved, such as roughening, curing, blackening, graying, and passivation. The copper foil continuously passes through each electrolytic cell for surface electroplating. The insulation performance of the copper foil faces many challenges. For example, when the equipment is running, electrolyte splashes onto the frame insulation plate, acid and water spray pipes drip onto the insulation plate, conductive copper ring oil leaks onto the insulation plate, and residual liquid on the acid and water squeezing rollers flows onto the roller bearing seats, all of which damage the insulation performance. In addition, poor electrolyte composition ratio in the process leads to the need to rinse copper powder on the copper foil surface, which will damage the roller system and frame insulation layer. There are also situations such as fiberglass insulation boards being soaked in acid.

[0017] Copper foil post-processing is a continuous production process. The copper foil, acting as the cathode in continuous electroplating, comes into direct contact with all conductive rollers, tension rollers, and transition steel rollers. Inspecting and locating areas of poor insulation is a time-consuming and difficult task. Current detection methods involve monitoring the insulation status of individual rollers with portable instruments, but this method suffers from poor real-time performance and low efficiency.

[0018] like Figure 1 The insulation monitoring method for a copper foil surface treatment machine in this embodiment may specifically include: This invention provides an insulation monitoring method for a copper foil surface treatment machine. This method, through a systematic insulation monitoring process, enables real-time monitoring and early warning of the insulation status of critical rollers in the copper foil surface treatment machine, ensuring the safe operation of the equipment.

[0019] Before use, configure the polling monitoring sequence of the 16 monitoring points, the single-point detection duration, the on / off status of the liquid valves in each electrolytic cell, the copper foil extraction detection, and the electrolysis power switch detection. Once configured, no further configuration is needed; configuration is only required when changes are needed.

[0020] After monitoring begins, the system will first determine whether the copper foil has been removed, whether the liquid valves of each electrolytic cell are closed, whether the electrolytic power supply is turned off, whether the 36V power supply is normal, and whether the communication of the acquisition module is normal. If any abnormal state is found, the monitoring will be terminated, and the local and remote host computers will report the corresponding faults. The faults need to be checked and resolved before retrying.

[0021] The system sequentially applies voltage to the detection points through the power protection unit according to the set inspection sequence. The current acquisition module samples the leakage current value of the point 4 times per second, performs analog-to-digital conversion, and transmits it to the main control unit in the form of a master-slave station.

[0022] After receiving a set of leakage current values, the main control unit analyzes, calculates, and judges them to obtain the leakage current value of the monitored point, and stores it in the main control unit's register. When network communication fails or stored insulation parameters are lost, the host computer and the field operation panel send a notification command to the main control unit to activate the watchdog reset function.

[0023] The local operation screen records the insulation value of each point in sequence, for a total of 16 insulation values. The insulation level is determined according to the insulation standard of each point.

[0024] The remote host computer records the monitoring time, leakage current sampling values ​​for each point, and insulation values, enters them into the database, performs judgment and analysis, and generates this insulation monitoring evaluation report.

[0025] The evaluation report is specifically an insulation dynamic model established by the host computer. The received insulation parameter information is input into the insulation dynamic model, and then the dynamic model is run to obtain the overall insulation evaluation report of the surface treatment machine. The parameters used in the dynamic model include the voltage at each point of the equipment, the ambient temperature, the ambient humidity, and the leakage current value.

[0026] The insulation evaluation report can display the insulation level of each point. Poor insulation is marked with yellow and red characters for warning. When the insulation evaluation report judges that the insulation is seriously poor, the equipment will issue a "Do Not Start" warning without specifying the start-up conditions.

[0027] Specifically, it includes the following steps: Step S1: The insulation monitoring system acquires leakage current values ​​from multiple key rollers in the copper foil surface treatment machine, including conductive rollers and tension rollers. During the production process of the copper foil surface treatment machine, conductive rollers and tension rollers, as core transmission components, directly affect the safe operation of the equipment and product quality due to their insulation performance. Conductive rollers are primarily responsible for the conductive transmission of the copper foil. Operating in a high-voltage environment, the integrity of their insulation layer is crucial to preventing leakage accidents. Tension rollers, on the other hand, are responsible for controlling the tension distribution of the copper foil, ensuring that the copper foil maintains an appropriate stretch during processing. The stability of their insulation performance directly affects the continuity and safety of the production line.

[0028] In one embodiment, the insulation monitoring system monitors each critical roller in real time via a distributed sensor network. The system first identifies the location of all critical rollers in the copper foil surface treatment machine, including the main drive conductive roller, the secondary drive conductive roller, the front tension roller, the rear tension roller, and the auxiliary guide roller. Each critical roller is equipped with a dedicated leakage current detection device, which accurately measures the leakage current between the roller and the ground. The magnitude of the leakage current directly reflects the integrity of the roller's insulation layer; when the insulation layer ages, is damaged, or contaminated, the leakage current increases significantly.

[0029] Step S11: Leakage current signals from multiple key rollers are acquired using a current acquisition module employing a fully differential analog signal acquisition scheme. This scheme is a high-precision signal acquisition technology that simultaneously acquires both forward and reverse signals and calculates the difference between them to obtain the accurate measurement result. This approach effectively suppresses common-mode interference and improves the signal-to-noise ratio, making it particularly suitable for acquiring weak current signals in industrial environments. In the complex electromagnetic environment of copper foil surface treatment machines, various motors, frequency converters, and heating equipment generate significant electromagnetic interference; the fully differential acquisition scheme can significantly improve the accuracy of leakage current measurement.

[0030] Specifically, the current acquisition module contains multiple differential amplifiers, each corresponding to the leakage current signal of a key roller. The positive input of the differential amplifier is connected to the signal output of the current sensor, and the negative input is connected to ground. The amplified current signal is obtained by calculating the voltage difference between the two inputs. The amplifier gain can be adjusted according to the rated current range of different rollers, typically set to 100 to 1000 times to ensure that microampere-level leakage current can be accurately detected.

[0031] In step S12, DC voltage is sequentially applied to each critical roller via the power protection unit, with the DC voltage provided by a DC power supply. The power protection unit is the core component of the insulation monitoring system, responsible for providing a stable DC voltage source for insulation testing, and also providing overcurrent and short-circuit protection functions. During the insulation test, the system needs to apply a DC voltage of a certain amplitude to the roller under test, and calculate the insulation resistance value by measuring the leakage current generated under this voltage.

[0032] In one embodiment, the power protection unit employs switching power supply technology, capable of providing an adjustable DC voltage ranging from 0V to 250V. The voltage selection is determined based on the operating voltage level of the roller under test and the characteristics of the insulation material, and is typically set to 1.5 to 2 times the operating voltage. For example, for a conductive roller with an operating voltage of 50V, the test voltage is typically set to 0V to 250V. The power protection unit integrates a current limiting circuit; when leakage current is detected to exceed a preset threshold, the system automatically cuts off the test voltage to prevent further damage to the insulation layer.

[0033] The strategy of applying voltage sequentially avoids mutual interference that occurs when multiple rollers are tested simultaneously. The system performs insulation tests on each critical roller one by one according to a preset test sequence, with each test lasting 10 to 30 seconds to ensure the leakage current value reaches a stable state. The test interval is set to 5 to 10 seconds for voltage switching and data processing.

[0034] Step S13: The leakage current values ​​of each key roller are acquired using current sensors and transmitted to the current acquisition module. The current sensor is the front-end detection device of the insulation monitoring system, responsible for converting the leakage current of the rollers into a measurable electrical signal. In copper foil surface treatment machines, the current sensor needs to possess high accuracy, a wide measurement range, and strong anti-interference capabilities.

[0035] For example, the system employs a Hall effect current sensor, which measures current by detecting changes in the magnetic field around a current-carrying conductor based on the Hall effect principle. Hall sensors offer advantages such as non-contact measurement, fast response, and good linearity, making them particularly suitable for current monitoring in industrial environments. The sensor's measurement range is typically set from 1 microamp to 100 milliamps, with a resolution of 0.1 microamps, meeting the accuracy requirements for insulation monitoring.

[0036] The installation location of the current sensor is crucial to ensure accurate capture of leakage current in the roller. In one embodiment, the sensor is installed in the roller's grounding line, and the leakage status of the roller is reflected by measuring the grounding current. The analog signal output by the sensor is transmitted to the current acquisition module via a shielded cable, typically limited to 50 meters in length, to minimize signal attenuation and external interference.

[0037] In step S14, the current acquisition module performs analog-to-digital conversion on the acquired leakage current signal to generate leakage current value data. Analog-to-digital conversion is the process of converting continuous analog signals into discrete digital signals, and it is a key component of a digital measurement system. In insulation monitoring applications, the accuracy and sampling rate of the analog-to-digital converter directly affect the accuracy of the measurement results.

[0038] Specifically, the current acquisition module employs a 24-bit high-precision analog-to-digital converter (ADC), which features extremely low noise levels and excellent linearity. 24-bit resolution means the converter can divide the input signal into 16,777,216 discrete levels; for a 100 mA full-scale current signal, the theoretical resolution can reach 6 nanoamps. In practical applications, considering factors such as noise and temperature drift, the effective resolution is typically 20 to 22 bits.

[0039] The sampling rate is set to 1000 times per second to ensure the capture of transient changes in leakage current. Within each sampling period, the converter performs an integral averaging of the input signal, effectively suppressing the effects of high-frequency noise. The converted digital signal is stored in hexadecimal format in the acquisition module's buffer, awaiting subsequent data processing and transmission.

[0040] Step S15: The leakage current value data is transmitted to the main control unit via the Modbus RTU protocol. Modbus RTU is a serial communication protocol widely used in industrial automation, characterized by its simple structure, high reliability, and good compatibility. In the insulation monitoring system, the Modbus RTU protocol is used to realize data communication between the current acquisition module and the main control unit.

[0041] In one embodiment, communication uses an RS485 physical interface, supporting multi-point communication and long-distance transmission. The communication rate is set to 9600 baud, and the data format is 8 data bits, 1 stop bit, and even parity. Each current acquisition module is assigned a unique slave address, and the master control unit, acting as the master station, periodically polls the data from each slave station. The polling period is set to 1 second to ensure timely acquisition of leakage current changes in each critical roller.

[0042] Data transmission uses standard Modbus function codes, primarily employing function code 03 to read the leakage current value from the holding register. Each transmission includes a timestamp, device address, register address, data length, and CRC checksum to ensure data integrity and reliability. When a communication error is detected, the system automatically retransmits the data, up to a maximum of three times.

[0043] Step S2 involves the main control unit analyzing the leakage current values ​​to determine the insulation resistance of each critical roller. The main control unit is the core processor of the insulation monitoring system, responsible for receiving leakage current data from each current acquisition module and calculating the corresponding insulation resistance value using a specific algorithm. Insulation resistance is a crucial indicator for evaluating the insulation performance of electrical equipment; its value directly reflects the integrity and aging state of the insulation material.

[0044] In step S21, the main control unit receives the leakage current value data and performs group calculations. Group calculation is a data processing strategy that improves calculation efficiency and accuracy by classifying and processing key roller data of different types or locations. In copper foil surface treatment machines, different types of rollers have different operating characteristics and insulation requirements, necessitating the use of corresponding calculation methods and judgment criteria.

[0045] Specifically, the main control unit first groups the received data according to the roller type. The conductive roller group includes leakage current data for the main drive conductive roller and the auxiliary drive conductive roller. These rollers typically bear high voltage and current and have the most stringent insulation requirements. The tension roller group includes data for the front tension roller, the rear tension roller, and the intermediate tension roller. These rollers primarily bear mechanical stress but also require good insulation to ensure operational safety. The auxiliary roller group includes data for other auxiliary equipment such as guide rollers and pressure rollers.

[0046] The data within each group is arranged in a time series, and the main control unit uses a sliding window algorithm to preprocess the data. The sliding window size is set to 10 sampling points, equivalent to 10 seconds of data history. Within each window, the system calculates the average, maximum, minimum, and standard deviation of the leakage current for subsequent insulation resistance calculation and anomaly detection.

[0047] Step S22: Generate the insulation resistance value for each key roller based on the group calculation results. The insulation resistance is calculated based on Ohm's law, that is, resistance equals voltage divided by current. In insulation monitoring, the applied test voltage is a known value, and the insulation resistance can be calculated by measuring the resulting leakage current. However, the actual calculation process needs to consider various influencing factors, including temperature compensation, humidity correction, and capacitance effects.

[0048] In one embodiment, the insulation resistance is calculated as follows: the insulation resistance value equals the test voltage divided by the steady-state leakage current, multiplied by a temperature correction factor and a humidity correction factor. The temperature correction factor compensates for the effect of ambient temperature on the resistivity of the insulating material and typically decreases as temperature increases. The humidity correction factor compensates for the effect of ambient humidity on the surface conductivity of the insulation; higher humidity results in more severe surface leakage.

[0049] For conductive rollers, due to their relatively harsh working environment, the impact of surface contamination must be considered in the calculations. The system determines whether the decrease in insulation resistance is due to material aging or surface contamination by comparing the trends of multiple consecutive measurements. If the resistance value drops sharply in a short period of time, it usually indicates the presence of surface contamination; if the resistance value shows a slow decreasing trend, it may be normal aging of the insulation material.

[0050] Step S23: Store the insulation resistance value in the register of the main control unit. The register is a data storage area inside the main control unit, used to store the calculated insulation resistance value and related status information. A reasonable data storage strategy can not only provide real-time monitoring data, but also support historical data analysis and fault diagnosis.

[0051] For example, the main control unit adopts a hierarchical storage structure, dividing the registers into a real-time data area, a historical data area, and a configuration parameter area. The real-time data area stores the current insulation resistance value, leakage current value, test voltage value, and environmental parameters of each key roller, with a data update cycle of 1 second. The historical data area adopts a circular buffer structure, capable of storing monitoring data for the most recent 24 hours, recording the average value once per minute. The configuration parameter area stores various threshold settings, correction coefficients, and equipment parameters.

[0052] Each insulation resistance value is stored with a timestamp, device identifier, and data quality flag. The timestamp uses a standard Unix time format, accurate to the millisecond level. The device identifier, used to distinguish different critical rollers, is encoded using two hexadecimal digits. The data quality flag indicates the reliability of the data, including states such as normal, questionable, and invalid.

[0053] Step S24: If a network communication failure is detected, a watchdog reset command is sent to the main control unit via the local operation panel. Network communication failures are common problems in industrial automation systems and can be caused by various factors such as electromagnetic interference, aging wiring, and equipment malfunction. Watchdog reset is a reliable fault recovery mechanism that clears potential software errors and communication blockages by periodically restarting the system.

[0054] Specifically, the main control unit integrates network communication monitoring functionality, periodically sending heartbeat packets to detect the communication status with the host computer and various acquisition modules. If three consecutive heartbeat packet transmissions fail or a reception times out, the system determines it as a network communication failure. At this time, the local operation screen will display a communication failure warning message and prompt the operator to perform a watchdog reset.

[0055] The watchdog reset command is sent via a dedicated button on the local operating panel or through the touchscreen interface. The reset process includes saving current important data, closing ongoing test tasks, reinitializing the communication interface, and re-establishing the network connection. The entire reset process typically takes 30 to 60 seconds, during which the system suspends insulation monitoring functions but does not affect the normal production of the copper foil surface treatment machine.

[0056] In step S25, the main control unit classifies the insulation resistance values ​​according to preset insulation standards to determine the insulation level of each critical roller. Insulation level classification is an important function of the insulation monitoring system. By comparing the measured insulation resistance values ​​with preset standards, the insulation status of the equipment is determined and corresponding maintenance suggestions are given.

[0057] In one embodiment, the insulation class is divided into five levels: Excellent, Good, Acceptable, Caution, and Hazardous. The Excellent level corresponds to an insulation resistance value greater than 100 megohms, indicating excellent insulation performance and long-term stable operation of the equipment. The Good level corresponds to an insulation resistance value between 50 and 100 megohms, indicating good insulation performance, and regular inspection is recommended. The Acceptable level corresponds to an insulation resistance value between 10 and 50 megohms, meeting basic safety requirements, but requiring enhanced monitoring. The Caution level corresponds to an insulation resistance value between 1 and 10 megohms, indicating a potential safety hazard and requiring timely maintenance. The Hazardous level corresponds to an insulation resistance value less than 1 megohm, indicating a serious safety risk, and immediate shutdown and maintenance are necessary.

[0058] Different types of critical rollers are classified according to different standards. Conductive rollers, due to their high voltage load, have the most stringent insulation standards, with a hazard level threshold of 5 megohms. Tension rollers have relatively lenient insulation standards, with a hazard level threshold of 1 megohm. Auxiliary rollers have insulation standards that fall between the two.

[0059] Step S3: The insulation resistance data is transmitted to the remote host computer via a network switch to generate a comprehensive insulation monitoring report. The network switch is the core device of the industrial Ethernet network, responsible for enabling data communication between the main control unit and the remote host computer. The remote host computer has powerful data processing and analysis capabilities, enabling in-depth analysis of large amounts of insulation monitoring data to generate a comprehensive monitoring report.

[0060] Step S31: Insulation resistance data and ambient temperature and humidity data are transmitted via a network switch using the Modbus TCP protocol. Modbus TCP is an implementation of the Modbus protocol over Ethernet, inheriting the simplicity and reliability of the Modbus protocol while also possessing the advantages of high-speed transmission and remote access of Ethernet. In the insulation monitoring system, the Modbus TCP protocol is used to realize real-time data exchange between the main control unit and the remote host computer.

[0061] Specifically, the network switch is an industrial-grade Ethernet switch with 24 Fast Ethernet ports and 2 Gigabit uplink ports. The switch supports advanced features such as VLAN segmentation, QoS priority control, and port mirroring, ensuring priority transmission of insulation monitoring data. The main control unit connects to the switch via a standard RJ45 interface, with a communication rate of 100Mbps and full-duplex communication mode.

[0062] Environmental temperature and humidity data are acquired using dedicated temperature and humidity sensors. These sensors are installed in key locations on the copper foil surface treatment machine, including the main control room, electrical cabinets, and production workshop. The temperature measurement range is -40°C to 85°C, with an accuracy of ±0.5°C. The humidity measurement range is 0% to 100% relative humidity, with an accuracy of ±3%. The digital signals output by the sensors are transmitted to the main control unit via an RS485 interface, and then uploaded to a remote host computer via the Modbus TCP protocol.

[0063] In step S32, the remote host computer receives the insulation resistance data and inputs it into the pre-established insulation dynamic model. The insulation dynamic model is a mathematical model based on historical data and physical laws, used to predict and analyze the performance change trends of insulation materials. This model comprehensively considers the influence of multiple factors such as temperature, humidity, voltage stress, mechanical stress, and time on insulation performance, enabling a more accurate assessment of the equipment's insulation status.

[0064] In one embodiment, the insulation dynamic model is established using a multiple regression analysis method. The model's input parameters include the current insulation resistance value, historical insulation resistance variation trends, ambient temperature, ambient humidity, operating time, and load current. The model establishes a mathematical relationship between insulation resistance and various influencing factors by analyzing the correlations between these parameters. The model's training data comes from long-term monitoring records of a large number of similar equipment, covering insulation performance data under different operating conditions and environmental conditions.

[0065] The core algorithm of the insulation dynamic model is based on an extended form of the Arrhenius equation, which describes the effect of temperature on the rate of chemical reactions. During the aging process of insulating materials, the breakage and recombination of molecular chains follow similar patterns. By introducing humidity and electric field strength correction factors, the model can more accurately describe the insulation aging process under complex environments.

[0066] Each time the remote host computer receives new insulation resistance data, it inputs it into the insulation dynamic model for processing. The model first verifies the validity of the input data, removing obviously abnormal data points. Then, it compares and analyzes the valid data with historical data, calculating the rate of change and trend of insulation resistance. Finally, based on current environmental conditions and operating status, the model predicts the changes in insulation resistance over a future period.

[0067] Step S33: Based on the insulation resistance data and ambient temperature and humidity data analyzed using the insulation dynamic model, the insulation level of each key roller is generated. The generation of the insulation level is not only based on the current insulation resistance value, but also comprehensively considers the changing trend of insulation performance and the influence of environmental factors. This dynamic assessment method can detect potential insulation problems earlier, providing a scientific basis for preventative maintenance.

[0068] Specifically, the insulation dynamic model uses a weighted scoring method to generate the insulation class. The current insulation resistance value accounts for 60% of the total score, the trend of insulation resistance change accounts for 20%, environmental factors account for 15%, and operating time accounts for 5%. Each factor has a corresponding scoring standard and weight coefficient, and the final comprehensive score determines the insulation class.

[0069] The analysis of environmental temperature and humidity data employs a multi-dimensional evaluation method. Temperature primarily affects the molecular activity and aging rate of insulation materials; high temperatures accelerate the aging process. The model calculates the temperature influence coefficient based on the deviation between the actual measured temperature value and the standard operating temperature. When the ambient temperature exceeds 40 degrees Celsius, the insulation grade score decreases by 10% for every 10-degree Celsius increase. When the ambient temperature is below 0 degrees Celsius, the insulation material may become brittle, its mechanical strength may decrease, and the score will be adjusted accordingly.

[0070] Humidity primarily affects the surface conductivity and volume conductivity of insulating materials. In high humidity environments, a water film easily forms on the surface of insulating materials, leading to an increase in surface leakage current. The model calculates the humidity influence coefficient based on relative humidity values; when the relative humidity exceeds 80%, the insulation grade score decreases by 15% to 25%. The model also considers the interaction between temperature and humidity; the combination of high temperature and high humidity has a more severe impact on insulation performance.

[0071] Step S331: Acquire ambient temperature and humidity data as input parameters for the insulation dynamic model. Accurate acquisition of ambient temperature and humidity data is the foundation of insulation dynamic analysis. This requires deploying high-precision temperature and humidity sensors at key locations and establishing a comprehensive data acquisition and transmission system.

[0072] In one embodiment, the temperature and humidity sensor is a digital integrated sensor, which integrates a temperature-sensitive element, a humidity-sensitive element, a signal conditioning circuit, and a digital interface. The temperature-sensitive element uses a platinum resistance thermometer or a thermistor, which has good linearity and long-term stability. The humidity-sensitive element uses a capacitive or resistive humidity-sensitive material, which can respond quickly to changes in humidity.

[0073] The sensor installation locations were carefully selected to ensure they accurately represent the actual environmental conditions of the equipment. Primary installation locations include inside electrical control cabinets, near equipment racks, at different heights in the production workshop, and near ventilation openings. Each sensor in each location has a unique number and label for easy data management and fault location.

[0074] The data acquisition frequency is set to once per minute, which ensures timely reflection of environmental changes without creating excessive data overhead. The collected temperature and humidity data undergoes preliminary processing locally, including data validity checks, outlier removal, and smoothing filtering. The processed data is then transmitted to a remote host computer via industrial Ethernet. Data compression and error detection mechanisms are employed during transmission to ensure data integrity and reliability.

[0075] Step S332: Calculate the insulation performance indicators of each key roller based on insulation resistance data and ambient temperature and humidity data. Insulation performance indicators are quantitative parameters that comprehensively evaluate the insulation state. They are obtained by performing mathematical operations and logical analysis on various measurement data to obtain numerical values ​​that intuitively reflect the insulation performance.

[0076] The insulation performance indicators are calculated using a multi-parameter fusion algorithm. First, the system performs temperature compensation on the raw insulation resistance data to eliminate the influence of ambient temperature changes on the measurement results. The temperature compensation formula is based on the temperature coefficient of the insulating material; for common polymer insulating materials, the temperature coefficient is approximately 2% to 5% per degree Celsius. The compensated insulation resistance value more accurately reflects the true performance of the insulating material.

[0077] Next, the system calculates the time derivative of the insulation resistance, i.e., the rate of change of the insulation resistance over time. The rate of change is calculated using a moving average method to reduce the impact of random fluctuations. Under normal circumstances, the insulation resistance should remain relatively stable or decrease slowly. If the rate of change exceeds a preset threshold, it indicates that the insulation performance may be abnormal.

[0078] Humidity correction is another crucial step in calculating insulation performance indicators. In high humidity environments, moisture absorption on the surface of insulating materials increases surface conductivity, thus affecting the measured insulation resistance. The system corrects the insulation resistance using an empirical formula based on the measured relative humidity value. This correction formula considers the varying degrees of humidity sensitivity of different insulating materials, ensuring the accuracy of the correction results.

[0079] Step S333: Classify the insulation performance indicators according to the preset insulation level standards. The insulation level standards are classification criteria based on industry specifications, equipment characteristics, and operating experience. They are used to convert continuous insulation performance indicators into discrete level identifiers, making it easier for operators to understand and make decisions.

[0080] In one embodiment, the insulation rating standard adopts a five-level classification system, with each level corresponding to different insulation performance ranges and maintenance requirements. Level 1 is the excellent level, with an insulation performance index greater than 0.9, indicating excellent insulation condition, allowing for long-term stable operation of the equipment, and the maintenance cycle can be appropriately extended. Level 2 is the good level, with an insulation performance index between 0.7 and 0.9, indicating good insulation condition, requiring maintenance according to the standard maintenance cycle.

[0081] Level 3 is the acceptable level, with insulation performance indicators between 0.5 and 0.7. The insulation condition basically meets the operational requirements, but monitoring needs to be strengthened and maintenance cycles shortened. Level 4 is the warning level, with insulation performance indicators between 0.3 and 0.5. The insulation condition has potential risks, requiring the development of a maintenance plan and the preparation of spare parts and repair resources. Level 5 is the dangerous level, with insulation performance indicators less than 0.3. The insulation condition has severely deteriorated, requiring immediate shutdown for inspection and repair to eliminate safety hazards.

[0082] Different types of critical rollers employ differentiated grading standards. Conductive rollers, being high-voltage equipment, have the most stringent grading standards, with a threshold of 0.4 for level four warnings and 0.2 for level five danger. Tension rollers have relatively lenient grading standards, with a threshold of 0.3 for level four warnings and 0.15 for level five danger. This differentiated standard ensures safety while avoiding excessively conservative approaches that lead to frequent maintenance.

[0083] In step S334, if the insulation performance index is detected to be lower than a preset threshold, a yellow or red warning message is generated. The warning message is an important output of the insulation monitoring system, conveying the equipment's insulation status and maintenance requirements to operators through intuitive color coding and detailed text descriptions.

[0084] The system employs a tiered warning mechanism to generate early warning information. When the insulation performance index drops to the fourth warning level, the system generates a yellow warning message to remind operators to pay attention to the equipment status and arrange appropriate maintenance plans. The yellow warning message includes the equipment number, roller type, current insulation class, insulation performance index value, reason for the warning, and recommended measures.

[0085] When the insulation performance index drops to level five (hazard level), the system generates a red alert, requiring immediate action to prevent accidents. In addition to all the information from a yellow alert, the red alert includes an urgency level indicator, contact information, and emergency response procedures. The system automatically sends SMS or email notifications to relevant personnel to ensure timely delivery of the alert information.

[0086] Warning information is displayed in multiple ways, including local operation screen display, remote host computer interface display, mobile APP push notifications, and audible and visual alarms. The local operation screen uses large fonts and high contrast to ensure clear visibility even in noisy production environments. The remote host computer interface uses a graphical display to intuitively show the insulation status of each key roller through an equipment layout diagram.

[0087] In step S335, the remote host computer integrates the insulation level and early warning information into the insulation monitoring report. The insulation monitoring report is a comprehensive document output by the system, containing complete information on the insulation status of the equipment, providing a scientific basis for equipment management and maintenance decisions. The insulation monitoring report adopts a standardized format, including a report header, equipment overview, monitoring data, analysis results, early warning information, and maintenance recommendations. The report header contains basic information such as the report generation time, report number, equipment name, and responsible person. The equipment overview section describes the basic parameters, installation location, and operating status of the monitored equipment.

[0088] The monitoring data section presents raw data such as insulation resistance, leakage current, and ambient temperature and humidity for each key roller in tabular and chart format. The data is displayed using time-series graphs, which visually reflect the changing trends of insulation performance. The analysis results section, based on calculations from the insulation dynamic model, provides the insulation performance indicators and insulation class for each key roller.

[0089] The early warning information section summarizes all yellow and red warnings, sorted by urgency and equipment importance. Each warning includes a detailed description and handling suggestions to help maintenance personnel quickly locate problems and develop solutions. The maintenance recommendations section provides targeted maintenance guidance and spare parts demand forecasts based on historical data and expert experience.

[0090] Step S4: Determine whether the equipment meets the start-up conditions based on the insulation level in the insulation monitoring report. Determining the start-up conditions is the ultimate goal of the insulation monitoring system. By comprehensively analyzing the insulation status of each critical roller, it determines whether the equipment has the conditions for safe operation, preventing safety accidents caused by poor insulation.

[0091] Step S41: The local operation screen acquires and displays the insulation level of each key roller. The local operation screen is the main interface for operators to interact with the insulation monitoring system. It needs to display the insulation status information of the equipment in an intuitive and clear manner so that operators can quickly understand the equipment status and make correct decisions.

[0092] In one embodiment, the local operation screen uses a 10.4-inch color LCD display with a resolution of 1024×768 pixels, providing good display effects and a good touch operation experience. The display interface adopts a graphical design, using the equipment layout diagram of the copper foil surface treatment machine as the background, with each key roller represented by a circular icon of a different color. Green icons indicate an excellent or good insulation level, yellow icons indicate a qualified or warning insulation level, and red icons indicate a dangerous insulation level.

[0093] The main interface of the control panel is divided into four parts: equipment status area, data display area, early warning information area, and operation button area. The equipment status area displays the overall operating status of the equipment and the working status of the insulation monitoring system. The data display area displays the current insulation resistance value, leakage current value, and environmental parameters of each key roller in numerical and graphical form. The early warning information area displays the current early warning information in a scrolling manner, including the warning level, equipment location, and a brief description.

[0094] The operation button area provides various functions, including data refresh, history query, parameter setting, system reset, and help instructions. The operation buttons are large, making them easy to operate while wearing gloves. Button colors and shapes conform to industrial interface design standards; important operation buttons are red or orange, and frequently used operation buttons are blue or green.

[0095] Step S42: Determine the insulation status of each critical roller based on the preset insulation level threshold. The insulation level threshold is a key parameter for determining the equipment's start-up conditions and needs to be set reasonably based on the equipment's safety requirements, industry standards, and operating experience. Different threshold settings will directly affect the equipment's availability and safety.

[0096] Specifically, the startup condition judgment adopts a layered judgment mechanism. The first layer of judgment is a mandatory safety requirement: if the insulation level of any critical roller reaches level five (dangerous), the system will prohibit the equipment from starting; this is an inviolable safety bottom line. The second layer of judgment is a comprehensive assessment: when the insulation level of multiple critical rollers simultaneously reaches level four (warning), the system will decide whether to allow startup based on the specific circumstances.

[0097] For conductive rollers, due to their direct bearing of high voltage, safety requirements are the most stringent. When the insulation level of a conductive roller reaches warning level four, the system recommends temporarily suspending startup and conducting further inspections. Start-up under monitoring is only permitted if it is confirmed that the insulation issue will not affect safe operation. For tension rollers, safety requirements are relatively relaxed; normal startup is still possible at warning level four, but enhanced monitoring is required.

[0098] The threshold determination also considers the equipment's operating history and maintenance records. For newly installed equipment or equipment that has just undergone maintenance, the threshold can be appropriately relaxed, allowing operation at lower insulation levels. For equipment that has been in operation for a long time or is nearing its maintenance cycle, the threshold should be appropriately tightened to increase the safety margin.

[0099] Step S43: If the insulation level of any critical roller is detected to be lower than a preset threshold, a warning message is displayed on the local operation screen. Displaying the warning message is a crucial step in ensuring operational safety; it requires prominent visual effects and clear text descriptions to ensure that operators can promptly identify and correctly address insulation problems.

[0100] In one embodiment, the warning information display employs a multi-level alert mechanism. When the insulation level is detected to be below a threshold, the control panel first attracts the operator's attention with a flashing red border and a buzzer sound. Subsequently, a warning dialog box pops up in the center of the screen, displaying the warning content in large font, including the problematic equipment, insulation level, degree of danger, and handling suggestions.

[0101] The warning dialog box uses a modal display and can only be closed after operator confirmation to ensure that warning information is not ignored. The dialog box provides multiple operation options, including viewing detailed information, contacting maintenance personnel, temporarily ignoring, and forced startup. The "view detailed information" option displays historical data and trends for the critical roller, helping operators assess the severity of the problem.

[0102] The "Contact Maintenance" option will automatically dial the preset maintenance hotline or send an SMS message containing equipment information and a description of the fault. The "Temporarily Ignore" option allows operators to temporarily ignore warning messages if they fully understand the risks, but the system will periodically remind them again. The "Force Power On" option requires an administrator password and should only be used in emergencies.

[0103] Step S44: If a serious insulation failure is detected, a command to prevent the equipment from starting is issued via the remote host computer. A serious insulation failure refers to an insulation level reaching level five danger or multiple critical rollers simultaneously showing level four warnings. In this case, the equipment poses a significant safety hazard, and mandatory measures must be taken to prevent the equipment from starting.

[0104] The power-off prohibition command employs a dual confirmation mechanism. First, the remote host computer automatically determines whether there is a serious insulation failure based on the received insulation monitoring data. The judgment algorithm comprehensively considers multiple factors, including insulation level, trend of change, environmental factors, and equipment importance. When the judgment result indicates a serious insulation failure, the system generates a power-off prohibition command.

[0105] Secondly, the command to prohibit power-on requires manual confirmation to take effect. The remote host computer will send a confirmation request to the on-duty engineer, including detailed insulation status information and risk assessment results. After fully understanding the situation, the on-duty engineer can choose to confirm the prohibition of power-on, request expert consultation, or activate the emergency plan.

[0106] Once the power-off prohibition command takes effect, it will be transmitted to the field through multiple methods. The remote host computer sends the power-off prohibition command to the main control unit via industrial Ethernet. Upon receiving the command, the main control unit will immediately cut off the device's startup circuit, physically preventing the device from starting. At the same time, the local operation screen will display a clear power-off prohibition indicator, and all start buttons will turn gray and become inoperable.

[0107] In step S45, the local control panel uses different colors to indicate normal and abnormal states according to the insulation level. Color coding is an effective way to intuitively display the equipment status. Through a unified color coding rule, operators can quickly identify the insulation status of the equipment, improving operational efficiency and safety.

[0108] In one embodiment, the color coding adopts the internationally recognized safety color standard. Green indicates a safe state, corresponding to insulation class 1 (excellent) and 2 (good), meaning the equipment can be started and operated normally. Blue indicates a cautious state, corresponding to insulation class 3 (acceptable), meaning the equipment can be started but requires enhanced monitoring. Yellow indicates a warning state, corresponding to insulation class 4 (warning), meaning the equipment needs careful evaluation before starting. Red indicates a dangerous state, corresponding to insulation class 5 (dangerous), meaning the equipment must not be started.

[0109] Color coding is applied not only to device icons but also extends to various interface elements such as data display, button status, and background color. The values ​​in the data display area are shown in different colors according to their corresponding insulation class; values ​​outside the normal range are highlighted in red or yellow. The colors of the operation buttons also adjust according to the current device status; the start button in a dangerous situation will turn red and display a prohibition icon.

[0110] The insulation monitoring method for copper foil surface treatment machine in the embodiments of the present invention has been described above, such as... Figure 2 The insulation monitoring device for the copper foil surface treatment machine in this embodiment of the invention is described below: The data acquisition unit is configured to acquire leakage current values ​​of multiple key rollers in the copper foil surface treatment machine, the key rollers including conductive rollers and tension rollers; The main control unit, which is communicatively connected to the data acquisition unit, is configured to receive the leakage current value and perform calculations and analyses to determine the insulation resistance of each key roller. A network communication unit, connected to the main control unit, is configured to transmit the insulation resistance data to a remote host computer. The remote host computer is configured to receive and process the insulation resistance data, generate a comprehensive insulation monitoring report for the equipment, and determine whether the equipment meets the start-up conditions based on the insulation level in the insulation monitoring report.

[0111] like Figure 2 As shown, this invention provides an insulation monitoring system, including a main control unit, a power protection unit, a DC power supply, a current acquisition module, a current sensor, a switch, a local operation panel, and a remote host computer. The main control unit is the control core, and its functions include: 1. Detecting whether the liquid inlet valves of each electrolytic cell are closed, whether the given current of each electrolytic cell is 0, and whether the processed copper foil has been removed, thus meeting the monitoring preparation conditions; 2. The system self-checks the status of the power protection unit, the status of each channel of the current acquisition module, whether the on-site temperature and humidity are abnormal, and whether communication is normal. If any abnormality is found, the local operation panel displays relevant alarm information; otherwise, the self-check is completed; 3. By controlling the switch of the inspection relay in the power protection unit, voltage is applied to the roughening roller I separately. The voltage comes from the DC power supply. The current sensor continuously transmits feedback current information to the current acquisition module for 10 seconds. The current acquisition module transmits the sampled value to the main control unit 4 times per second. Simultaneously, the on-site temperature and humidity information is acquired by the main control unit; 4. The main control unit receives the leakage current value array of the roller, a total of 40 data points, and performs grouping and calculation to obtain the following data: 5. An array of insulation resistance values ​​is generated, and these values ​​are packaged and transmitted to a remote host computer for insulation model analysis to obtain the final insulation value of the roller. 6. Steps 3-4 are repeated to sequentially inspect all 16 electrolytic cell roller systems, with each roller lasting 10 seconds, for a total of 160 seconds to complete leakage current data sampling for all roller systems. The remote host computer outputs the insulation values ​​of all key points of the equipment and generates an insulation assessment report. 7. The on-site operation panel obtains the insulation value of each key roller through a network switch and displays it on the screen, facilitating on-site production personnel to judge the insulation status of the production equipment and determine whether insulation improvements are needed. 8. The remote host computer uses the Visual Studio programming environment and the object-oriented C# language to integrate an SQL Server database for tabular storage, enabling large-scale data storage and convenient historical data retrieval.

[0112] In summary, the insulation monitoring system and method provided by this invention are very suitable for production environments such as copper foil surface treatment machines, which are prone to producing poor insulation. It can monitor the insulation of multiple key points, has high reliability and high accuracy, generates detailed insulation assessment reports, which serve as an important basis for determining whether the equipment is qualified, and is very simple and practical to operate. It reduces monitoring costs and time, and alleviates the workload of testing personnel.

[0113] This invention also provides an electronic device, which can vary significantly due to differences in configuration or performance. It may include one or more central processing units (CPUs) (e.g., one or more processors) and memory, and one or more storage media (e.g., one or more mass storage devices) for storing applications or data. The memory and storage media can be temporary or persistent storage. The program stored in the storage media may include one or more modules, each module including a series of instruction operations on the electronic device. Furthermore, the processor may be configured to communicate with the storage media and execute the series of instruction operations stored in the storage media on the electronic device.

[0114] The electronic device may also include one or more power supplies, one or more wired or wireless network interfaces, one or more input / output interfaces, and / or one or more operating systems, such as Windows Server, Mac OS X, Unix, Linux, FreeBSD, etc. Those skilled in the art will understand that the electronic device structure in this embodiment does not constitute a limitation on the electronic device itself, and may include more or fewer components, or combinations of certain components, or different component arrangements.

[0115] This invention provides an electronic device structure that can vary significantly depending on configuration or performance. It may include one or more central processing units (CPUs) (e.g., one or more processors) and memory, and one or more storage media (e.g., one or more mass storage devices) for storing applications or data. The memory and storage media can be temporary or persistent storage. The program stored in the storage media may include one or more modules, each module including a series of instruction operations on the electronic device. Furthermore, the processor may be configured to communicate with the storage media and execute the series of instruction operations stored in the storage media on the electronic device.

[0116] The electronic device may also include one or more power supplies, one or more wired or wireless network interfaces, one or more input / output interfaces, and / or one or more operating systems, such as Windows Server, Mac OS X, Unix, Linux, FreeBSD, etc. Those skilled in the art will understand that the structure of the electronic device does not constitute a limitation on the electronic device itself, and may include more or fewer components than described above, or combine certain components, or have different component arrangements.

[0117] The present invention also provides a computer-readable storage medium, which may be a non-volatile computer-readable storage medium or a volatile computer-readable storage medium, wherein the computer-readable storage medium stores instructions that, when executed on a computer, cause the computer to perform the steps of the aforementioned method.

[0118] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the specific working process of the system, device, or unit described above can be referred to the corresponding process in the foregoing method embodiments, and will not be repeated here.

[0119] If the integrated unit is implemented as a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the present invention, in essence, or the part that contributes to the prior art, or all or part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of the present invention. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0120] The above description is merely an embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural or procedural transformations made based on the content of the present invention's specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. A method for monitoring insulation in a copper foil surface treatment machine, characterized in that, The method includes: S1. The insulation monitoring system acquires the leakage current values ​​of multiple key rollers in the copper foil surface treatment machine, the key rollers including conductive rollers and tension rollers; S2. The main control unit performs calculation and analysis on the leakage current values ​​to determine the insulation resistance of each key roller; S3. The insulation resistance data is transmitted to a remote host computer through a network switch to generate a comprehensive insulation monitoring report for the equipment; S4. The insulation level in the insulation monitoring report is used to determine whether the equipment meets the start-up conditions.

2. The method as described in claim 1, characterized in that, The insulation monitoring system acquires leakage current values ​​of multiple key rollers in the copper foil surface treatment machine, including: S11. Acquiring leakage current signals of multiple key rollers through a current acquisition module, wherein the current acquisition module adopts a fully differential analog signal acquisition scheme; S12. Applying DC voltage to each key roller sequentially through a power protection unit, wherein the DC voltage is provided by a DC power supply; S13. Acquiring leakage current values ​​of each key roller through a current sensor and transmitting them to the current acquisition module; S14. The current acquisition module performs analog-to-digital conversion on the acquired leakage current signals to generate leakage current value data; S15. Transmitting the leakage current value data to the main control unit through the Modbus RTU protocol.

3. The method as described in claim 1, characterized in that, The step of calculating and analyzing the leakage current value through the main control unit to determine the insulation resistance of each critical roller includes: S21. The main control unit receives the leakage current value data and performs group calculations; S22. The insulation resistance value of each critical roller is generated based on the group calculation results; S23. The insulation resistance value is stored in the register of the main control unit; S24. If a network communication failure is detected, a watchdog reset command is sent to the main control unit through the local operation screen; S25. The main control unit classifies the insulation resistance value according to a preset insulation standard to determine the insulation level of each critical roller.

4. The method as described in claim 1, characterized in that, The step of transmitting the insulation resistance data to a remote host computer via a network switch to generate a comprehensive insulation monitoring report includes: S31. Transmitting the insulation resistance data and ambient temperature and humidity data via a network switch based on the Modbus TCP protocol; S32. The remote host computer receiving the insulation resistance data and inputting a pre-established insulation dynamic model; S33. Analyzing the insulation resistance data and ambient temperature and humidity data according to the insulation dynamic model to generate the insulation level of each key roller; S34. The remote host computer generating an insulation monitoring report containing early warning information based on the insulation level; S35. Storing the insulation monitoring report in a database to support historical data queries.

5. The method as described in claim 1, characterized in that, The step of determining whether the equipment meets the start-up conditions based on the insulation level in the insulation monitoring report includes: S41. The local operation screen acquires and displays the insulation level of each key roller; S42. The insulation status of each key roller is determined according to a preset insulation level threshold; S43. If the insulation level of any key roller is detected to be lower than the preset threshold, a warning message is displayed on the local operation screen; S44. If a serious insulation failure is detected, a start-up prohibition command is issued through the remote host computer; S45. The local operation screen marks the normal and abnormal states with different colors according to the insulation level.

6. The method as described in claim 2, characterized in that, The process of acquiring leakage current signals from multiple key rollers via a current acquisition module includes: S111. Determining the detection order of each key roller through a preset polling monitoring sequence; S112. For each key roller, the acquisition module samples the leakage current signal at a preset frequency; S113. Generating a digitized leakage current value through analog-to-digital conversion; S114. If an abnormal sampling frequency is detected, displaying fault information on the local operation screen; S115. The current acquisition module transmits the acquired leakage current value to the main control unit via a master-slave station configuration.

7. The method as described in claim 4, characterized in that, The step of analyzing the insulation resistance data and ambient temperature and humidity data based on the insulation dynamic model to generate the insulation level of each key roller includes: S331. Obtaining ambient temperature and humidity data as input parameters for the insulation dynamic model; S332. Calculating the insulation performance index of each key roller based on the insulation resistance data and ambient temperature and humidity data; S333. Classifying the insulation performance index according to a preset insulation level standard; S334. If the insulation performance index is detected to be lower than a preset threshold, generating a yellow or red warning message; S335. The remote host computer integrates the insulation level and warning message into the insulation monitoring report.

8. An insulation monitoring system for a copper foil surface treatment machine, characterized in that, The system includes: The data acquisition unit is configured to acquire leakage current values ​​of multiple key rollers in the copper foil surface treatment machine, the key rollers including conductive rollers and tension rollers; The main control unit, which is communicatively connected to the data acquisition unit, is configured to receive the leakage current value and perform calculations and analyses to determine the insulation resistance of each key roller. A network communication unit, connected to the main control unit, is configured to transmit the insulation resistance data to a remote host computer. The remote host computer is configured to receive and process the insulation resistance data, generate a comprehensive insulation monitoring report for the equipment, and determine whether the equipment meets the start-up conditions based on the insulation level in the insulation monitoring report.

9. An electronic device comprising a memory and at least one processor, wherein the memory stores instructions; The at least one processor invokes the instructions in the memory to cause the electronic device to perform the various steps of the copper foil surface treatment machine insulation monitoring method as described in any one of claims 1-7.

10. A computer-readable storage medium storing instructions thereon, characterized in that, When the instructions are executed by the processor, they implement the various steps of the insulation monitoring method for copper foil surface treatment machine as described in any one of claims 1-7.

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