Zero-landing-edge welding process for aluminum foil coiled material

Abstract

The invention relates to the technical field of intelligent manufacturing, and particularly discloses a zero-landing-edge welding process for an aluminum foil coiled material, which comprises the following steps of: constructing a one-dimensional coordinate system through a transmission roller, detecting theoretical coordinates and current coordinates of a central axis of an aluminum foil and a central clamping roller in real time by utilizing a linear array camera, and judging an offset state; when both the offset and the welding seam size deviation are offset, a control variable method is adopted to analyze the influence relation between the offset and the welding seam size deviation, an offset deviation influence factor is calculated, the aluminum foil offset threshold value is determined by combining the welding seam size deviation range, and a direct adjustment mode or a reverse continuous adjustment mode is selected; the position is directly adjusted according to the deviation direction of the clamping stick; according to reverse continuous adjustment, the reverse offset of the clamping stick is determined by calculating the reverse aluminum foil adjustment amount and the clamping stick aluminum foil correlation coefficient, and the position of the clamping stick is corrected after the aluminum foil is driven to return to theoretical coordinates. According to the method, accurate identification and dynamic compensation of the offset are achieved, the consistency of the welding seam quality is improved, and intelligent upgrading of the aluminum foil welding process is supported.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of intelligent manufacturing, in particular to a zero-edge welding process for aluminum foil coiled material. BACKGROUND

[0002] In today's high-speed development of intelligent manufacturing and precision machining technology, the zero-edge welding process for aluminum foil coiled material has become an indispensable key technology in the fields of food packaging, electronic materials, new energy batteries, etc. due to its high efficiency, continuity and environmental protection. This process realizes the continuous formation of non-overlapping welds by precisely controlling the aluminum foil transmission and welding parameters, significantly improving production efficiency and material utilization, and becoming an important technical support for product quality and cost control in modern industrial production.

[0003] However, in the current aluminum foil welding process, on the one hand, the center axis of the aluminum foil and the center clamp rod will deviate, directly leading to the size deviation of the weld beyond the specified range, reducing the product rejection rate and rework cost. On the other hand, for the deviation of the center axis of the aluminum foil and the center clamp rod, the correlation between the center clamp rod deviation and the aluminum foil deviation is not considered, and most of the deviations are directly corrected. However, due to the extremely thin thickness of the aluminum foil, it is difficult to directly correct the aluminum foil deviation, resulting in the need to adjust the aluminum foil position after production shutdown, reducing production efficiency. For example, in the welding production line of a certain enterprise 0.09mm food-grade aluminum foil, the center clamp rod contacts the sticky food residue to produce a 0.4mm position deviation, resulting in a 0.3mm lateral deviation of the aluminum foil, and the aluminum foil and the center clamp rod position are manually adjusted for 30 minutes after shutdown, the extremely thin aluminum foil deviates again after 1.5 hours, and the production capacity loss is 130,000 yuan.

[0004] Therefore, the present application provides a zero-edge welding process for aluminum foil coiled material. SUMMARY

[0005] The purpose of the present application is to provide a zero-edge welding process for aluminum foil coiled material to solve the problems in the above background.

[0006] The purpose of the present application can be achieved by the following technical solutions:

[0007] A zero-edge welding process for aluminum foil coiled material, comprising:

[0008] A one-dimensional coordinate system is constructed based on the transmission roller, the current axis coordinate, the current clamp rod coordinate and the theoretical coordinate are detected, and the deviation state of the center clamp rod and the aluminum foil is judged;

[0009] When the center clamp rod and the aluminum foil both deviate, the influence relationship between the aluminum foil deviation degree and the weld size deviation is analyzed, and the deviation influence factor is calculated;

[0010] The aluminum foil offset threshold is calculated based on the offset deviation influence factor to determine a center clamp rod adjustment mode, wherein the center clamp rod adjustment mode includes a direct adjustment mode and a reverse continuous adjustment mode.

[0011] If the direct adjustment mode is adopted, a direct adjustment direction of the center clamp rod is analyzed, an offset adjustment amount of the center clamp rod is calculated, and a direct correction of the offset of the center clamp rod is performed.

[0012] The reverse continuous adjustment mode analyzes the correlation between the offset of the center clamp rod and the offset of the aluminum foil, and performs a reverse continuous correction of the offset of the center clamp rod, wherein the reverse continuous correction includes a reverse offset of the center clamp rod and a reverse offset correction of the center clamp rod.

[0013] As a further scheme of the present application,

[0014] Further, the process of judging the offset state of the center clamp rod and the aluminum foil is:

[0015] If the current clamp rod coordinate and the theoretical coordinate do not coincide, it indicates that the current clamp rod is offset.

[0016] If the current axis coordinate and the theoretical coordinate coincide, it indicates that the current aluminum foil is not offset.

[0017] If the current axis coordinate and the theoretical coordinate do not coincide, it indicates that the current aluminum foil is offset.

[0018] Further, the process of analyzing the influence relationship between the offset degree of the aluminum foil and the weld size deviation is:

[0019] The influence relationship experiment is designed by using the control variable method, so as to ensure that the welding parameters, the aluminum foil specifications, the environmental temperature and humidity, and the equipment operation factors are unchanged, and only the offset amount of the aluminum foil is changed.

[0020] The offset amount of the aluminum foil is selected multiple times, and is arranged in ascending order to obtain a first aluminum foil offset sequence.

[0021] The left edge width and the right edge width of the weld corresponding to each offset amount of the aluminum foil are extracted.

[0022] The weld size deviation is calculated: |weld left edge width-weld right edge width|, and is arranged according to the position of the corresponding offset amount of the aluminum foil in the first aluminum foil offset sequence to obtain a size deviation sequence.

[0023] The Pearson correlation coefficient of the first aluminum foil offset sequence and the size deviation sequence is calculated, and if it is greater than or equal to a Pearson correlation coefficient threshold, it is determined that there is an influence between the offset degree of the aluminum foil and the weld size deviation.

[0024] Further, the process of calculating the offset deviation influence factor is:

[0025] respectively, to obtain a first aluminum foil deviation sequence;

[0026] respectively, to obtain a size absolute deviation sequence;

[0027] respectively, and then taking an average value to obtain a shift deviation influence factor.

[0028] Further, the process of determining the center clamp rod adjustment mode is:

[0029] When the center clamp rod is offset and the aluminum foil is not offset, a direct adjustment mode is selected;

[0030] When the center clamp rod and the aluminum foil are both offset:

[0031] Calculate the distance between the current axis coordinate and the theoretical coordinate to obtain the current aluminum foil offset;

[0032] Multiply the maximum value of the weld size deviation range and the shift deviation influence factor to obtain an aluminum foil offset threshold;

[0033] If the current aluminum foil offset is less than or equal to the aluminum foil offset threshold, a direct adjustment mode is selected;

[0034] If the current aluminum foil offset is greater than the aluminum foil offset threshold, a reverse continuous adjustment mode is selected.

[0035] Further, the process of directly correcting the center clamp rod offset is:

[0036] If the numerical difference between the current clamp rod coordinate and the theoretical coordinate is positive, the current clamp rod coordinate is on the right side of the theoretical coordinate, and the direct adjustment direction of the center clamp rod is left adjustment;

[0037] If the numerical difference between the current clamp rod coordinate and the theoretical coordinate is negative, the current clamp rod coordinate is on the left side of the theoretical coordinate, and the direct adjustment direction of the center clamp rod is right adjustment;

[0038] Calculate the distance between the current clamp rod coordinate and the theoretical coordinate to obtain the current clamp rod offset;

[0039] Adjust the current clamp rod coordinate according to the direct adjustment direction of the center clamp rod, and the adjustment amount is: the current clamp rod offset.

[0040] Further, the process of analyzing the correlation between the center clamp rod offset and the aluminum foil offset is:

[0041] The control variable method is adopted to design the influence relationship experiment, the aluminum foil specification, the environmental temperature and humidity and the equipment operation factors are kept unchanged, and only the center clamp pin offset is changed;

[0042] The center clamp pin offset and the aluminum foil offset are extracted, and it is judged that there is a correlation between the center clamp pin offset and the aluminum foil offset.

[0043] The absolute value of the difference between adjacent center clamp pin offsets in the clamp pin offset sequence is processed to obtain the clamp pin absolute deviation, which is summarized as the clamp pin absolute offset sequence.

[0044] The absolute value of the difference between adjacent aluminum foil offsets in the second aluminum foil offset sequence is processed to obtain the second aluminum foil deviation, which is summarized as the second aluminum foil deviation sequence.

[0045] The absolute value of the difference between adjacent aluminum foil offsets in the second aluminum foil offset sequence is processed to obtain the second aluminum foil deviation, which is summarized as the second aluminum foil deviation sequence.

[0046] Further, the process of extracting the clamp pin offset sequence and the second aluminum foil deviation sequence, and judging that there is a correlation between the center clamp pin offset and the aluminum foil offset is as follows:

[0047] The center clamp pin offset is selected multiple times and arranged in ascending order to obtain the clamp pin offset sequence.

[0048] The aluminum foil offset corresponding to each center clamp pin offset is extracted, and arranged according to the position of the corresponding center clamp pin offset in the clamp pin offset sequence to obtain the second aluminum foil offset sequence.

[0049] The Pearson correlation coefficient of the clamp pin offset sequence and the second aluminum foil offset sequence is calculated, and if it is greater than or equal to the Pearson correlation coefficient threshold, it is determined that there is a correlation between the center clamp pin offset and the aluminum foil offset.

[0050] Further, the process of performing the center clamp pin reverse offset is as follows:

[0051] The distance between the current axis coordinate and the theoretical coordinate is calculated to obtain the current aluminum foil offset.

[0052] The current aluminum foil offset and the aluminum foil offset threshold are processed by difference to obtain the reverse aluminum foil adjustment amount.

[0053] The reverse aluminum foil adjustment amount and the clamp pin aluminum foil correlation coefficient are processed by multiplication to obtain the center clamp pin reverse offset.

[0054] The numerical value of the current clamp pin coordinate and the numerical value of the current axis coordinate are processed by difference to obtain the aluminum foil clamp pin deviation.

[0055] The center clamp rod reverse offset amount is added to the aluminum foil clamp rod deviation amount to obtain a center clamp rod reverse adjustment amount.

[0056] The current clamp rod coordinate is adjusted in the reverse direction according to the direct adjustment direction of the center clamp rod, and the adjustment amount is the center clamp rod reverse adjustment amount.

[0057] Further, the process of the center clamp rod reverse offset correction is as follows:

[0058] The current axis coordinate is detected in real time, and when the current axis coordinate coincides with the theoretical coordinate, the current clamp rod coordinate is immediately corrected to the theoretical coordinate.

[0059] The beneficial effects of the present application are as follows:

[0060] Beneficial effect one: a one-dimensional coordinate system is constructed to detect the offset state of the aluminum foil center axis and the center clamp rod in real time, and the offset deviation influence factor is used to quantify the correlation between the aluminum foil offset and the weld size deviation, solving the problem of weld size deviation caused by aluminum foil and center clamp rod offset;

[0061] Beneficial effect two: a direct adjustment and reverse continuous adjustment dual-mode compensation mechanism is adopted to realize accurate identification and dynamic compensation of the offset of the aluminum foil during the welding process, and the position of the aluminum foil is corrected by the reverse offset of the center clamp rod, without the need for shutdown adjustment. BRIEF DESCRIPTION OF DRAWINGS

[0062] The present application will be further described below with reference to the accompanying drawings.

[0063] Figure 1 is a step flow chart of the zero-edge welding process of the aluminum foil coiled material of the present application;

[0064] Figure 2 is a step schematic diagram of the aluminum foil zero-edge welding offset automatic compensation method of the present application;

[0065] Figure 3 is a logic judgment diagram of the aluminum foil zero-edge welding offset automatic compensation method of the present application; DETAILED DESCRIPTION

[0066] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of protection of the present application.

[0067] Embodiment 1: Please refer to Figure 1 The present application is a zero-edge welding process of an aluminum foil coiled material, which comprises the following steps:

[0068] Step one: Prepare the master roll and complete the thickness, pinhole quality inspection, and after passing, the QA informs the production party to weld; after cutting the master roll, the second quality verification is carried out, and after confirming that it meets the requirements, it enters the wearing link.

[0069] Step two: After adjusting the knife table, the aluminum foil is wound on the wearing rod; after pressing the winding button, the wearing button is triggered, and when the chain runs to the specified position, the center clamp roller automatically clamps the aluminum foil, the aluminum foil zero edge welding offset automatic compensation method is enabled, and the center of the center clamp roller and the center axis of the aluminum foil are coincided and located in the center of the transmission shaft;

[0070] Among them, the aluminum foil zero edge welding offset automatic compensation method includes:

[0071] Based on the one-dimensional coordinate system, the real-time detection technology with linear array camera is constructed, and the offset state of the aluminum foil center axis and the center clamp roller is dynamically identified;

[0072] The correlation between the offset and the weld size deviation is quantified by the control variable method, and the offset deviation influence factor K is calculated;

[0073] According to the weld size deviation range (such as ≤0.2mm), the offset threshold is determined, and the direct adjustment method (adjusting the clamp roller position) or the reverse continuous adjustment method (driving the aluminum foil back through the clamp roller reverse offset) is selected;

[0074] When reverse adjustment, the reverse offset amount is calculated by using the aluminum foil correlation coefficient of the clamp roller, the synchronous correction of the aluminum foil center axis and the center clamp roller is realized, and finally the coordinate coincidence is ensured through real-time visual detection.

[0075] Step three: Apply 60# double oil to the aluminum foil before welding and spread it, control the tension to 60N for light point self-checking; after welding, perform quality inspection such as weld overlap ≤3mm, no damage hole, clean the oil stains and confirm that the joint misplacement is ≤1mm, and finally complete the second verification of welding quality;

[0076] Step four: The quality inspector and the production group leader check the weld together (weld width deviation ≤0.2mm, and welding is not allowed to have defects such as damage, hole, edge crack, virtual welding, and uneven overlap, etc., if any, it must be re-welded);

[0077] Example two: please refer to Figure 2 - Figure 3 As shown in the above step two, based on the aluminum foil zero edge welding offset automatic compensation method, the application provides the following embodiments; specifically including:

[0078] It should be noted that the transmission roller is located below the aluminum foil (function: transmitting the aluminum foil), and the center clamp pipe is located above the aluminum foil (function: ensuring that the aluminum foil transmission does not deviate), and when the center clamp rod deviates, the aluminum foil will deviate, which will further increase the size deviation of the welding seam, so that the size of the aluminum foil welding seam does not meet the welding process requirements;

[0079] S1: Constructing a one-dimensional coordinate system based on the transmission roller, extracting the theoretical coordinates of the center axis of the aluminum foil, detecting the current axis coordinates and the current clamp rod coordinates, and judging whether the center clamp rod and the aluminum foil deviate;

[0080] The process of constructing a one-dimensional coordinate system based on the transmission roller and extracting the theoretical coordinates of the center axis of the aluminum foil is as follows:

[0081] Taking the left end point of the transmission roller as the zero point and taking the transmission roller as the coordinate axis, a one-dimensional coordinate system is constructed;

[0082] The acquisition method of the coordinates of each point in the one-dimensional coordinate system can be: installing a line array camera directly above the transmission roller (directly above the aluminum foil transmission path), making the camera lens axis perpendicular to the surface of the aluminum foil, and ensuring that the line array camera can detect the complete transmission roller;

[0083] Through line array camera visual detection, the coordinates of the midpoint of the transmission roller are extracted, that is, the theoretical coordinates of the midpoint of the center clamp rod and the center axis of the aluminum foil, which are referred to as theoretical coordinates;

[0084] It should be noted that according to the aluminum foil welding process requirements, the midpoint of the center clamp rod should coincide with the center axis of the aluminum foil, and the center axis of the aluminum foil should be located at the center of the transmission roller (to avoid contacting the edge), so the midpoint of the transmission roller is the theoretical coordinates of the two;

[0085] The process of judging whether the aluminum foil and the center clamp rod deviate is as follows:

[0086] Through line array camera visual detection, the current axis coordinates (the coordinates of the current center axis of the aluminum foil) and the current clamp rod coordinates (the coordinates of the current midpoint of the center clamp rod) are extracted; the current clamp rod coordinates and the current axis coordinates are compared and analyzed with the theoretical coordinates respectively:

[0087] If the coordinates coincide, it means that no deviation has occurred;

[0088] If the coordinates do not coincide, it means that deviation has occurred (for example, the current clamp rod coordinates are 5, the current axis coordinates are 6, and both are different from the theoretical coordinates = 7, which means that the center clamp rod and the aluminum foil have deviated);

[0089] S2: When the center clamp rod and the aluminum foil both deviate, the influence relationship between the aluminum foil deviation degree and the welding seam size deviation is analyzed, and if there is an influence, the deviation influence factor is calculated;

[0090] The process of analyzing the influence relationship between the aluminum foil offset degree and the weld size deviation is:

[0091] An influence relationship experiment is designed by using the control variable method, the welding parameters (temperature 280±1℃, pressure 60±2N, speed 15±0.5mm / s) and the aluminum foil specifications (thickness 0.12±0.001mm, width 12±0.02mm) are fixed, and the environmental temperature and humidity (25±2℃, 55±5%RH) and the equipment operation factors are fixed, and only the aluminum foil offset amount Δx (0≤Δx≤Δx max ) is changed;

[0092] wherein, 0≤Δx≤Δx max is the effective offset range of the aluminum foil offset amount, that is, the maximum offset amount of the aluminum foil without leaving the transmission roller;

[0093] The aluminum foil offset amount Δx is selected multiple times and arranged in ascending order to obtain a first aluminum foil offset sequence X n =(Δx1, Δx2, Δx3.....Δx n ), wherein Δx n refers to the n-th aluminum foil offset amount in the first aluminum foil offset sequence X n ;

[0094] It should be noted that the aluminum foil offset amount refers to the coordinate offset amount of the center axis of the aluminum foil;

[0095] The weld left edge width and the weld right edge width corresponding to each aluminum foil offset amount are extracted through the line array camera vision detection;

[0096] The weld size deviation is calculated: |weld left edge width-weld right edge width|;

[0097] The weld size deviation is arranged according to the position of the corresponding aluminum foil offset amount in the first aluminum foil offset sequence to obtain a size deviation sequence W n =(Δw1, Δw2, Δw3.....Δw n ), wherein Δw n refers to the n-th weld size deviation in the size deviation sequence W n ;

[0098] The Pearson correlation coefficient of the first aluminum foil offset sequence and the size deviation sequence is calculated;

[0099] If the Pearson correlation coefficient is less than the Pearson correlation coefficient threshold value, it is determined that there is no influence between the aluminum foil offset degree and the weld size deviation;

[0100] It should be noted that the Pearson correlation coefficient threshold value is calculated in combination with the significance level (such as α=0.05) and the sample size (such as Δx nwherein when n=30, the two-side critical value corresponding to a=0.05 is about ±0.36) ;

[0101] If the Pearson correlation coefficient is greater than or equal to the Pearson correlation coefficient threshold value, it is determined that there is a significant linear correlation between the aluminum foil offset degree and the weld size deviation, that is, there is an influence between the aluminum foil offset degree and the weld size deviation;

[0102] If the Pearson correlation coefficient is less than the Pearson correlation coefficient threshold value, it is determined that there is no influence between the aluminum foil offset degree and the weld size deviation;

[0103] The process of calculating the offset deviation influence factor is as follows:

[0104] The absolute value of the difference between adjacent aluminum foil offset amounts in the first aluminum foil offset sequence is processed to obtain the first aluminum foil deviation amount, which is summarized as the first aluminum foil deviation sequence

[0105] That is,

[0106] wherein, refers to the first aluminum foil deviation sequence The n-1th first aluminum foil deviation amount in the first aluminum foil deviation sequence, that is, |Δx n-1 -Δx n |;

[0107] The absolute value of the difference between adjacent weld size deviations in the size deviation sequence is processed to obtain the size absolute deviation amount, which is summarized as the size absolute deviation sequence

[0108] That is,

[0109] wherein, refers to the size absolute deviation sequence The n-1th size absolute deviation amount in the size absolute deviation sequence, that is, |Δw n-1 -Δw n |;

[0110] The first aluminum foil deviation amount in the first aluminum foil deviation sequence and the corresponding size absolute deviation amount in the size absolute deviation sequence are respectively processed by ratio processing, and then the mean value is taken to obtain the offset deviation influence factor K (in the effective offset range, the weld size deviation increases by 1 mm on average when the aluminum foil offsets by K mm) ;

[0111] Exemplarily, the process of calculating the offset deviation influence factor is as follows:

[0112] The first aluminum foil offset sequence X n =(Δx1, Δx2, Δx3...Δx n) is (0, 0.5, 1.0, 1.5, 2.0); the size deviation sequence W n = (Aw1, Aw2, Aw3...Aw n ) is (0.1, 0.3, 0.4, 0.7, 0.8);

[0113] Then the first aluminum foil deviation sequence

[0114] The size absolute deviation sequence

[0115] The offset deviation influence factor = (0.2 / 0.5+0.1 / 0.5+0.3 / 0.5+0.1 / 0.5) / 4 = 0.35;

[0116] It should be noted that the beneficial effect of calculating the offset deviation influence factor is that:

[0117] Beneficial effect one: converting the fuzzy association of aluminum foil offset and weld deviation into a calculable quantitative relationship;

[0118] Beneficial effect two: providing a core quantitative basis for the accurate calculation of the aluminum foil offset threshold;

[0119] The aluminum foil offset threshold is determined by the weld size deviation range and the offset deviation influence factor K, which provides data support for subsequent selection of direct adjustment mode or reverse continuous adjustment mode;

[0120] Beneficial effect three: providing a data basis for calculating the reverse aluminum foil adjustment amount in the reverse continuous adjustment mode;

[0121] S3: based on the offset deviation influence factor, calculate the aluminum foil offset threshold, and determine the center clamp rod adjustment mode; wherein the center clamp rod adjustment mode includes direct adjustment mode and reverse continuous adjustment mode;

[0122] When the center clamp rod is offset and the aluminum foil is not offset, the direct adjustment mode is selected;

[0123] When the center clamp rod is offset and the aluminum foil is also offset:

[0124] Calculate the distance between the current axis coordinate and the theoretical coordinate to obtain the current aluminum foil offset amount;

[0125] Multiply the maximum value of the weld size deviation range and the offset deviation influence factor to obtain the aluminum foil offset threshold;

[0126] Wherein, the weld size deviation range is set according to the special standard of food packaging industry (such as weld width deviation ≤0.2mm);

[0127] Compare and analyze the current aluminum foil offset amount with the aluminum foil offset threshold:

[0128] If the current aluminum foil offset is less than or equal to the aluminum foil offset threshold, it indicates that the aluminum foil offset is small, and the direct adjustment mode is selected;

[0129] It should be noted that the current aluminum foil offset is less than the aluminum foil offset threshold, and the direct adjustment mode is selected because when the current aluminum foil offset is less than the aluminum foil offset threshold, the influence on the weld size deviation is still within the weld size deviation range, which meets the welding requirements of the weld;

[0130] If the current aluminum foil offset is greater than the aluminum foil offset threshold, it indicates that the aluminum foil offset is large, and the reverse continuous adjustment mode is selected;

[0131] S4: If the direct adjustment mode is selected, the direct adjustment direction of the center clamp is analyzed, the center clamp offset adjustment amount is calculated, and the direct correction of the center clamp offset is performed;

[0132] The direct adjustment mode refers to directly adjusting the center clamp coordinates without considering the aluminum foil coordinates.

[0133] If the numerical difference between the current clamp coordinate and the theoretical coordinate is positive, the current clamp coordinate is on the right side of the theoretical coordinate, and the direct adjustment direction of the center clamp is left.

[0134] The difference between the current clamp coordinate and the theoretical coordinate refers to the difference between the numerical value of the current clamp coordinate and the numerical value of the theoretical coordinate in the one-dimensional coordinate system (for example, the current clamp coordinate is 6 and the theoretical coordinate is 4, the difference between the current clamp coordinate and the theoretical coordinate is 2).

[0135] If the numerical difference between the current clamp coordinate and the theoretical coordinate is negative, the current clamp coordinate is on the left side of the theoretical coordinate, and the direct adjustment direction of the center clamp is right.

[0136] It should be noted that if the difference between the current clamp coordinate and the theoretical coordinate is 0, the current clamp coordinate coincides with the theoretical coordinate, and no adjustment is needed.

[0137] The distance between the current clamp coordinate and the theoretical coordinate is calculated to obtain the current clamp offset.

[0138] According to the direct adjustment direction of the center clamp, the current clamp coordinate is adjusted, and the adjustment amount is the current clamp offset.

[0139] S5: If the reverse continuous adjustment mode is selected, the correlation between the center clamp offset and the aluminum foil offset is analyzed, and the reverse continuous correction of the center clamp offset is performed, wherein the reverse continuous correction includes the reverse offset of the center clamp and the reverse offset correction of the center clamp.

[0140] The reverse continuous adjustment mode refers to: driving the aluminum foil to return to the theoretical coordinate by controlling the center clamp rod to offset reversely, and then correcting the position of the center clamp rod to the theoretical coordinate;

[0141] The process of analyzing the correlation between the center clamp rod offset and the aluminum foil offset is:

[0142] The influence relationship experiment is designed by using the control variable method, the aluminum foil specification and the environmental temperature and humidity are kept unchanged, and only the center clamp rod offset Δy (0≤Δy≤Δy max ) is changed;

[0143] Wherein, 0≤Δy≤Δy max is the effective offset range of the center clamp rod offset, that is, the maximum offset of the center clamp rod after offsetting, which can still normally clamp the aluminum foil, and the aluminum foil does not deviate from the conveying roller;

[0144] The center clamp rod offset Δy is selected multiple times and arranged in ascending order to obtain the clamp rod offset sequence Y n =(Δy1, Δy2, Δy3.....Δy n ), wherein Δy n is the n-th center clamp rod offset in Y n ;

[0145] The aluminum foil offset corresponding to each center clamp rod offset is extracted by line array camera vision detection, and arranged according to the position of the corresponding center clamp rod offset in the clamp rod offset sequence to obtain the second aluminum foil offset sequence Z n =(Δz1, Δz2, Δz3.....Δz n ), wherein Δz n is the n-th aluminum foil offset in Z n ;

[0146] The Pearson correlation coefficient of the clamp rod offset sequence and the second aluminum foil offset sequence is calculated;

[0147] If the Pearson correlation coefficient is greater than or equal to the Pearson correlation coefficient threshold, it is determined that there is a correlation between the center clamp rod offset and the aluminum foil offset;

[0148] If the Pearson correlation coefficient is less than the Pearson correlation coefficient threshold, it is determined that there is no correlation between the center clamp rod offset and the aluminum foil offset;

[0149] When there is a correlation between the center clamp rod offset and the aluminum foil offset:

[0150] The absolute value of the difference between adjacent center clamp rod offsets in the clamp rod offset sequence is processed to obtain the center clamp rod absolute deviation, which is summarized as the clamp rod absolute offset sequence

[0151] That is Wherein, Refers to the absolute offset sequence of the center clamp bar The n-1th center clamp bar absolute deviation in the sequence, that is, |Δy n-1 -Δy n |;

[0152] The absolute value of the difference between the adjacent aluminum foil offset amounts in the second aluminum foil offset sequence is processed to obtain the second aluminum foil deviation amount, which is summarized as the second aluminum foil deviation sequence

[0153] That is Wherein, Refers to the second aluminum foil deviation sequence The n-1th second aluminum foil deviation amount in the sequence, that is, |Δz n-1 -Δz n |;

[0154] The average value of the ratio of the center clamp bar absolute deviation amount in the center clamp bar absolute offset sequence and the corresponding second aluminum foil deviation amount in the second aluminum foil deviation sequence is obtained to obtain the clamp bar aluminum foil correlation coefficient α (that is, within the effective offset range of the center clamp bar offset amount, the center clamp bar offsets by α millimeters, and the aluminum foil offset amount increases by 1 millimeter on average);

[0155] Said, the process of reverse continuous correction of the center clamp bar offset is:

[0156] Center clamp bar reverse offset:

[0157] It should be noted that the center clamp bar exerts a transverse constraint on the aluminum foil through clamping friction - when the center clamp bar midpoint deviates from the theoretical coordinate, the clamping force of the center clamp bar on the aluminum foil will be unevenly distributed on one side (that is, the offset side pressure is greater than the other side), forming a transverse friction force, forcing the aluminum foil to offset in the same direction as the center clamp bar offset direction, so the aluminum foil offset direction is the same as the center clamp bar offset direction;

[0158] The distance between the current axis coordinate and the theoretical coordinate is calculated to obtain the current aluminum foil offset amount;

[0159] The difference between the current aluminum foil offset amount and the aluminum foil offset threshold is processed to obtain the reverse aluminum foil adjustment amount (that is, the distance that the aluminum foil needs to move in the reverse direction to return to the threshold from the current offset position);

[0160] It should be noted that the reverse continuous adjustment mode is selected, which means that the current aluminum foil offset amount has exceeded the threshold, so the reverse aluminum foil adjustment amount is necessarily positive and does not need to be calculated as an absolute value;

[0161] The reverse aluminum foil adjustment amount is multiplied by the clamp bar aluminum foil correlation coefficient to obtain the center clamp bar reverse offset amount;

[0162] The numerical value of the current clamp rod coordinate is subtracted from the numerical value of the current axis coordinate to obtain an aluminum foil clamp rod deviation;

[0163] The center clamp rod reverse offset is added to the aluminum foil clamp rod deviation to obtain a center clamp rod reverse adjustment amount;

[0164] It should be noted that the center clamp rod reverse offset refers to the distance required for the center clamp rod to move reversely from the current offset position to within the threshold value; the aluminum foil clamp rod deviation refers to the distance between the current center clamp rod and the aluminum foil (if the aluminum foil offset is higher, the center clamp rod midpoint is closer to the theoretical coordinate, so the aluminum foil clamp rod deviation is negative);

[0165] For example, the process of calculating the center clamp rod reverse adjustment amount is as follows:

[0166] The current axis coordinate is 7, the current clamp rod coordinate is 8, the theoretical coordinate is 5, the aluminum foil offset threshold is 0.5mm, and the clamp rod aluminum foil correlation coefficient is 2.5;

[0167] Then the current aluminum foil offset is 7-5=2mm, the reverse aluminum foil adjustment amount is 2-0.5=1.5mm, the center clamp rod reverse offset is 2.5*1.5=3.75mm, the aluminum foil clamp rod deviation is 8-7=1mm, and the center clamp rod reverse adjustment amount is 3.75+1=4.75mm.

[0168] According to the direct adjustment direction of the center clamp rod, the current clamp rod coordinate is adjusted in the reverse direction, and the adjustment amount is the center clamp rod reverse adjustment amount;

[0169] Center clamp rod reverse offset correction:

[0170] The current axis coordinate is detected in real time by a linear array camera vision, and when the current axis coordinate coincides with the theoretical coordinate, the current clamp rod coordinate is immediately corrected to the theoretical coordinate;

[0171] The working principle of the present application is: a one-dimensional coordinate system is constructed based on the transmission roller, the theoretical coordinates of the aluminum foil center axis are extracted, the current coordinates of the aluminum foil center axis and the center clamp rod coordinates are detected, and it is judged whether the center clamp rod and the aluminum foil are offset; when the center clamp rod and the aluminum foil are both offset, the influence relationship between the aluminum foil offset degree and the weld size deviation is analyzed, if there is an influence, the offset deviation influence factor is calculated, based on the offset deviation influence factor, the aluminum foil offset threshold is calculated, and the center clamp rod adjustment mode is determined; wherein the center clamp rod adjustment mode includes direct adjustment mode and reverse continuous adjustment mode, if it is direct adjustment mode, the direct adjustment direction of the center clamp rod is analyzed, and the center clamp rod offset adjustment amount is calculated, if it is reverse continuous adjustment mode, the correlation between the center clamp rod offset and the aluminum foil offset is analyzed, and the center clamp rod offset correction is carried out step by step.

[0172] The above describes one embodiment of the present application in detail, but the content described is only the preferred embodiment of the present application, and cannot be considered as limiting the implementation range of the present application. Any equivalent changes and improvements made according to the scope of the present application should still belong to the scope of the present application.

Claims

1. A zero-slit welding process for aluminum foil coiled material, characterized in that: a one-dimensional coordinate system is established based on the transmission roller, the current axis coordinate, the current clamp rod coordinate, and the theoretical coordinate are detected, and the offset state of the center clamp rod and the aluminum foil is judged; when both the center clamp rod and the aluminum foil are offset, the influence relationship between the aluminum foil offset degree and the weld size deviation is analyzed, and the offset deviation influence factor is calculated; based on the offset deviation influence factor, the aluminum foil offset threshold is calculated, and the center clamp rod adjustment mode is determined; wherein the center clamp rod adjustment mode includes direct adjustment mode and reverse continuous adjustment mode; if it is the direct adjustment mode, the direct adjustment direction of the center clamp rod is analyzed, the center clamp rod offset adjustment amount is calculated, and the direct correction of the center clamp rod offset is performed; if it is the reverse continuous adjustment mode, the correlation between the center clamp rod offset and the aluminum foil offset is analyzed, and the reverse continuous correction of the center clamp rod offset is performed, wherein the reverse continuous correction includes reverse offset of the center clamp rod and reverse offset correction of the center clamp rod.

2. A zero-skip welding process for aluminum foil web as defined in claim 1, characterized in that: The process of judging the offset state of the center clamp rod and the aluminum foil is: if the current clamp rod coordinate and the theoretical coordinate do not coincide, it means that the current clamp rod is offset; if the current axis coordinate and the theoretical coordinate coincide, it means that the current aluminum foil is not offset; if the current axis coordinate and the theoretical coordinate do not coincide, it means that the current aluminum foil is offset.

3. A process for zero-slit welding of aluminum foil web as claimed in claim 1, wherein: The process of analyzing the influence relationship between the aluminum foil offset degree and the weld size deviation is: use the control variable method to design the influence relationship experiment, ensure that the welding parameters, aluminum foil specifications, environmental temperature and humidity, and equipment operation factors remain unchanged, and only change the aluminum foil offset amount; select the aluminum foil offset amount multiple times and arrange it in ascending order to obtain the first aluminum foil offset sequence; extract the weld left edge width and weld right edge width corresponding to each aluminum foil offset amount; Calculate the weld size deviation: and arrange according to the corresponding aluminum foil offset in the position of the first aluminum foil offset sequence, to obtain the size deviation sequence; calculate the Pearson correlation coefficient of the first aluminum foil offset sequence and the size deviation sequence, if it is greater than or equal to the Pearson correlation coefficient threshold, it is determined that there is an influence between the aluminum foil offset degree and the weld size deviation.

4. A process for zero-slit welding of aluminum foil web as claimed in claim 3, wherein: The process of calculating the offset deviation influence factor is: respectively, the absolute value difference processing is performed on the adjacent aluminum foil offset amounts in the first aluminum foil offset sequence to obtain the first aluminum foil deviation amount, which is summarized as the first aluminum foil deviation sequence; respectively, the absolute value difference processing is performed on the adjacent weld size deviations in the size deviation sequence to obtain the size absolute deviation amount, which is summarized as the size absolute deviation sequence; the first aluminum foil deviation amount in the first aluminum foil deviation sequence and the corresponding size absolute deviation amount in the size absolute deviation sequence are respectively processed by ratio and then averaged to obtain the offset deviation influence factor.

5. The process of claim 1 wherein: The process of determining the center clamp rod adjustment mode is: when the center clamp rod is offset and the aluminum foil is not offset, select the direct adjustment mode; when both the center clamp rod and the aluminum foil are offset: calculate the distance between the current axis coordinate and the theoretical coordinate to obtain the current aluminum foil offset amount; multiply the maximum value of the weld size deviation range and the offset deviation influence factor to obtain the aluminum foil offset threshold; if the current aluminum foil offset amount is less than or equal to the aluminum foil offset threshold, select the direct adjustment mode; if the current aluminum foil offset amount is greater than the aluminum foil offset threshold, select the reverse continuous adjustment mode.

6. A process for zero-slit welding of aluminum foil web as claimed in claim 1, wherein: The process of performing direct correction of the center clamp bar offset is: If the numerical difference between the current clamp bar coordinate and the theoretical coordinate is positive, the current clamp bar coordinate is on the right side of the theoretical coordinate, and the direct adjustment direction of the center clamp bar is left adjustment; If the numerical difference between the current clamp bar coordinate and the theoretical coordinate is negative, the current clamp bar coordinate is on the left side of the theoretical coordinate, and the direct adjustment direction of the center clamp bar is right adjustment; The distance between the current clamp bar coordinate and the theoretical coordinate is calculated to obtain the current clamp bar offset; According to the direct adjustment direction of the center clamp bar, the current clamp bar coordinate is adjusted, and the adjustment amount is: the current clamp bar offset.

7. The process of claim 1 wherein: The process of analyzing the correlation between the center clamp bar offset and the aluminum foil offset is: The control variable method is used to design the influence relationship experiment, so that the aluminum foil specifications, environmental temperature and humidity, and equipment operation factors remain unchanged, and only the center clamp bar offset is changed; The clamp bar offset sequence and the second aluminum foil offset sequence are extracted to determine the correlation between the center clamp bar offset and the aluminum foil offset; The absolute value of the difference between adjacent center clamp bar offsets in the clamp bar offset sequence is processed to obtain the clamp bar absolute deviation, which is summarized as the clamp bar absolute offset sequence; The absolute value of the difference between adjacent aluminum foil offsets in the second aluminum foil offset sequence is processed to obtain the second aluminum foil deviation, which is summarized as the second aluminum foil deviation sequence; The ratio of the clamp bar absolute deviation in the clamp bar absolute offset sequence and the corresponding second aluminum foil deviation in the second aluminum foil deviation sequence is processed to obtain the clamp bar aluminum foil correlation coefficient.

8. A process for zero-skip welding of aluminum foil web as claimed in claim 7, wherein: The process of extracting the clamp bar offset sequence and the second aluminum foil deviation sequence to determine the correlation between the center clamp bar offset and the aluminum foil offset is: The center clamp bar offset is selected multiple times and arranged in ascending order to obtain the clamp bar offset sequence; The aluminum foil offset corresponding to each center clamp bar offset is extracted and arranged according to the position of the corresponding center clamp bar offset in the clamp bar offset sequence to obtain the second aluminum foil offset sequence; The Pearson correlation coefficient of the clamp bar offset sequence and the second aluminum foil offset sequence is calculated, and if it is greater than or equal to the Pearson correlation coefficient threshold, it is determined that there is a correlation between the center clamp bar offset and the aluminum foil offset.

9. The process of claim 1 wherein: The process of performing reverse offset of the center clamp bar is: The distance between the current axis coordinate and the theoretical coordinate is calculated to obtain the current aluminum foil offset; The difference between the current aluminum foil offset and the aluminum foil offset threshold is processed to obtain the reverse aluminum foil adjustment amount; The product of the reverse aluminum foil adjustment amount and the clamp bar aluminum foil correlation coefficient is processed to obtain the center clamp bar reverse offset; The difference between the numerical value of the current clamp bar coordinate and the numerical value of the current axis coordinate is processed to obtain the aluminum foil clamp bar deviation; The sum of the center clamp bar reverse offset and the aluminum foil clamp bar deviation is processed to obtain the center clamp bar reverse adjustment amount; According to the direct adjustment direction of the center clamp bar, the current clamp bar coordinate is adjusted in the reverse direction, and the adjustment amount is: the center clamp bar reverse adjustment amount.

10. The process of claim 1 wherein: The process of performing center clamp bar reverse offset correction is: The current axis coordinate is detected in real time, and when the current axis coordinate coincides with the theoretical coordinate, the current clamp bar coordinate is immediately corrected to the theoretical coordinate.

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