A method for adaptive cutting of misaligned two-section pre-press aluminum-plastic film

Abstract

This invention relates to the field of aluminum-plastic film forming and processing technology for soft-pack batteries, and discloses an adaptive cutting method for two-stage pre-pressed aluminum-plastic film with staggered spacing. It is applicable to the cutting process of aluminum-plastic film. While maintaining the existing punching machine structure, this invention introduces a series of adaptive adjustment mechanisms at the control system level to achieve dynamic optimization control of the entire cutting process of aluminum-plastic film. It solves the problems of poor cutting stability, poor synchronization and insufficient continuity in the prior art, significantly improves production efficiency and product quality, and has good industrial application prospects.

Description

Technical Field

[0001] This invention relates to the field of aluminum-plastic film forming and processing technology for soft-pack batteries, and specifically to an adaptive cutting method for misaligned two-segment pre-pressed aluminum-plastic film. Background Technology

[0002] Pouch batteries are increasingly widely used in consumer electronics, power batteries, and energy storage due to their advantages such as light weight and high flexibility. As one of the key packaging materials for pouch batteries, aluminum-plastic film is typically composed of an outer nylon layer, a middle aluminum foil layer, and an inner heat-sealing layer, exhibiting certain structural layering characteristics. In actual processing, to meet the requirements of die-cutting dimensional accuracy and edge neatness, the aluminum-plastic film needs to undergo a precise punching process. However, due to the multi-layered composite characteristics of the material itself and its sensitivity to edge stress, improper control of the punching process can easily lead to quality problems such as delamination, microcracks, or plastic layer peeling, affecting the battery's sealing performance and subsequent safety.

[0003] Currently, the industry has developed several publicly available or universally accepted technical solutions in the field of aluminum-plastic film punching. Traditional methods often employ a single-stroke mechanical punch press with an integral die, utilizing the die's closing motion to complete the positioning and cutting of the film material within a single stroke. To mitigate delamination caused by the instantaneous impact of the cutting edge, some manufacturers place high-resilience polyurethane pads or multi-layer elastic pads under the die. The cushioning effect of these pads allows the plastic and aluminum layers to bond rapidly, thus reducing the risk of delamination.

[0004] Another technical approach employs a multi-station progressive die structure, dividing the single sheet of film into multiple processing stations to sequentially complete processes such as positioning, pre-pressing, punching, forming, and blanking. Each station provides graded output pressure through mechanical cams or hydraulic cushions, supplemented by a feeding system to achieve continuous feeding and step-by-step cutting, thereby effectively alleviating the problem of stress concentration at the cut. However, this type of solution requires customized elongated progressive dies, which have high requirements for die manufacturing precision and feeding synchronization. It usually requires a roller feeder or servo roller feeding system, resulting in a long equipment modification cycle and a complex changeover process, limiting its widespread application in small-batch, multi-specification flexible production scenarios.

[0005] With the development of laser processing technology, some companies have begun to apply CO2 lasers or fiber lasers to the slitting and cutting of aluminum-plastic films. By scanning and melting the film surface with a laser and then using airflow to blow away slag, high-quality edge cutting without mechanical deformation can be achieved. With a flying optical path compensation mechanism, rapid switching between different patterns can also be realized. Furthermore, to reduce the heat-affected zone, research has also focused on using pulsed fiber lasers to control the output waveform and placing a ceramic substrate on the back of the film to suppress laser reflection. However, laser cutting places high demands on the processing environment. Not only must the equipment be kept at a constant temperature, but a fume extraction system and dust filtration device are also required. The high reflectivity of the aluminum layer also necessitates the installation of anti-reflection modules and multi-stage cooling systems, resulting in significantly higher overall investment costs and maintenance complexity compared to traditional punching and cutting equipment.

[0006] Within the realm of mechanical punching, some manufacturers have attempted to introduce servo-hydraulic composite punch presses to achieve segmented cutting control of low-speed pre-compression and high-speed main punch. The main principle is as follows: a slow-closing control is set before the bottom dead center of the stroke, allowing the pressure plate to contact the film material at low speed and low pressure and maintain pressure briefly before the main cylinder completes the cutting at high speed. This method typically relies on dual oil circuit switching for segmented speed control, with pressure closed-loop regulation achieved through a built-in differential pressure sensor and proportional valve. To ensure consistent pre-compression, a displacement gauge needs to be integrated into the die holder structure and periodically calibrated at zero point to compensate for oil temperature drift. However, this type of equipment has high requirements for oil temperature control, hydraulic response, and displacement accuracy, making it difficult to directly transplant to existing mechanical punch presses. Furthermore, recalibration is required every shift, affecting production cycle stability.

[0007] In addition, some processes employ a combination of hot-blade and cold-sealing cutting methods. This involves first softening the surface of the film material locally with a ceramic-coated hot blade, then using a lower die cold block to shear and quickly seal the softened area. Alternatively, ultrasonic micro-vibration can be introduced to assist shearing, reducing tangential resistance during the cutting process through localized high-frequency micro-vibration. While these processes can improve edge quality under specific conditions, they place higher demands on heat source control, electroacoustic unit matching, and die material. Furthermore, they require the integration of temperature feedback or amplitude control modules into the control system, making it difficult for most existing punching machines to integrate them due to space constraints.

[0008] While existing technologies have improved the punching quality of aluminum-plastic film to some extent, they generally suffer from high modification costs, reliance on complex equipment, or frequent calibration, making it difficult to achieve long-term stable batch processing while preserving the original punching machine's main structure. Especially in one-time punching mode, it remains difficult to effectively suppress issues such as edge delamination and hidden cracks, affecting product reliability.

[0009] Therefore, it is necessary to provide a technical solution that, while keeping the existing punching press structure unchanged, achieves stable cutting of aluminum-plastic film with continuous cut edges and no delamination or hidden cracks through a small amount of mechanical adjustment and reconfiguration of punching parameters, so as to improve production efficiency and product consistency. Summary of the Invention

[0010] This invention provides an adaptive cutting method for two-segment pre-pressed aluminum-plastic film with misalignment, which solves the problem in the prior art that it is impossible to ensure the stability and continuity of aluminum-plastic film cutting while maintaining the existing punching machine structure, resulting in low production efficiency and poor product quality.

[0011] This invention provides an adaptive cutting method for misaligned two-segment pre-compressed aluminum-plastic film, applicable to the cutting process of aluminum-plastic film, comprising the following steps:

[0012] S1. With the punching machine powered off, release the pressure block and move it in the opposite direction of the feed by a preset misalignment amount so that the working surface of the pressure block is in the leading position relative to the punch cutting edge at the dead point position on the crank. After correcting the parallelism between the pressure block and the lower die surface, re-lock it.

[0013] S2. Set the equipment to inching mode and collect the displacement curves of the pressure block and the punch, respectively, to confirm the crank angle at which the pressure block first contacts the film surface. And the crank angle where the punch completely penetrates the aluminum-plastic film and will and Write into the control system to generate two stroke references for the preload section and the shear section;

[0014] S3. Under the condition of material-loaded test pressing, obtain multiple sets of peak pressures in the pre-compression section, calculate and lock the minimum sealing pressure. and the minimum sealing pressure and , Bind to write read-only parameter pages;

[0015] S4. During the batch punching operation, the pre-compression peak pressure of each punching is collected in real time, and the pre-compression peak pressure is compared with the minimum sealing pressure. When the deviation exceeds the preset tolerance range, the servo valve opening is adjusted, and this adjustment is performed continuously. After all punching pressures are within the preset tolerance range, the valve opening is locked.

[0016] S5. During continuous feeding, the crank angle output and the feeding servo motor pulse feedback are compared to monitor the feeding step distance between each punching. When the step distance deviation exceeds the step distance setting threshold, pause for one cycle and compensate the counting pulse to restore geometric synchronization.

[0017] S6. Utilize an optical edge sensor fixed to the punching exit to detect the edge reflection signal; when continuous... When the difference between punching operations exceeds the set threshold, the servo drive frequency of the shearing section is reduced until the cutting edge signal returns to the target range. After continuous punching stabilizes, the current pressure, speed and pitch formula is solidified to enter long-cycle operation.

[0018] Beneficial effects:

[0019] By adjusting the position and parallelism of the pressure block while the punching machine is powered off, the pressure block pre-presses the aluminum-plastic film before reaching the top dead center of the crank, ensuring material control during the punch's descent. This reduces the risk of film warping and displacement from the source and improves cutting consistency. Displacement curves of the pressure block and punch are collected to accurately obtain the pre-pressing initiation angle and shearing completion angle, establishing a two-stage stroke reference based on the crank angle. This provides a precise reference for subsequent motion control, significantly improving the equipment's response accuracy and control stability. Multiple peak pressures during the pre-pressing stage are collected, and the minimum sealing pressure value is selected and locked. As a read-only reference for the control system, it effectively prevents poor cutting and interlayer peeling caused by insufficient material pressure, ensuring product molding quality. During batch operation, by comparing and analyzing with the minimum sealing pressure, the servo valve opening is adjusted in real time, and closed-loop feedback control is performed based on multiple punching results to achieve adaptive response of the system to material changes or operating condition fluctuations, further improving process stability. By comparing the crank angle and feeding pulse feedback, the feeding step distance is monitored for each time, and pause and compensation are performed when the deviation exceeds the threshold, effectively suppressing the impact of cumulative error on punching position accuracy and ensuring high-precision synchronization in continuous punching process. The exit optical edge sensor detects the cutting edge reflection signal, and dynamically adjusts the shearing section drive frequency when continuous deviation occurs, thereby achieving dynamic compensation for complex factors such as tool drift and film elasticity changes, improving the long-term operating stability of the system. After the system detects that each parameter is stable, it automatically solidifies the current pressure, speed, and step distance formula, reducing manual intervention and improving the intelligence level of the equipment and the continuity and consistency of batch production. While maintaining the existing punch press structure, this invention introduces a series of adaptive adjustment mechanisms at the control system level to achieve dynamic optimization control of the entire aluminum-plastic film cutting process. This solves the problems of poor cutting stability, poor synchronization, and insufficient continuity in the existing technology, significantly improving production efficiency and product quality, and has good prospects for industrial application.

[0020] According to some embodiments of the present invention, in step S1, the pressing block is translated a distance in the reverse direction of the feeding process. This is used to indicate the misalignment between the pressure surface and the punch cutting edge, so that the pressure surface at the dead center position on the crank leads the punch cutting edge.

[0021] A dial indicator was used to check the perpendicularity between the working surface of the pressure block and the fixed reference surface of the machine, and a right-angle ruler was used to conduct a preliminary inspection of its inclination angle.

[0022] According to some embodiments of the present invention, in step S2, the device control module switches to the jog-type air-jet mode and sets the feeding mechanism to be unloaded, continuously performing multiple air-jet operations, while simultaneously calling the crank angle encoder inside the device to obtain the crank angle. The displacement curves of the pressure block and the punch are obtained by combining the output values ​​of the dual-channel displacement sensors.

[0023] According to some embodiments of the present invention, for Compare the data within the range at the same angle to confirm that the displacement curve of the pressure block is within the range. The first contact feature point on the membrane surface appears within a preset range, and the feature point is earlier than the corresponding angle at which the punch enters the membrane surface, in order to verify the amount of misalignment. The resulting misalignment action meets the pre-compression requirements and eliminates the actual misalignment deviation caused by mechanism clearance or compensation error.

[0024] According to some embodiments of the present invention, the crank angle at which the pressure block first contacts the film surface is defined as the starting angle of the pre-compression section. The crank angle at which the punch completely penetrates the aluminum-plastic film is defined as the end angle of the cutting segment. ;Will and Write the parameters to the machine parameter page and automatically generate a two-segment stroke reference table. The first stroke segment corresponds to the pre-compression segment, and the second stroke segment corresponds to the shearing segment. Based on the obtained parameter conditions, perform a single-pass test punch with material, check the cut edges, and mark them to solidify the current status. Value and Configuration.

[0025] According to some embodiments of the present invention, the obtained displacement curve of the pressure block and the displacement curve of the punch are imported into the controller as a whole. Two displacement data points are retrieved degree by degree for a preset angle interval after the top dead point of the crank, and the degree difference within the interval is searched. The first contact angle of the pressure block entering the film surface is determined by the maximum difference point identification method. Combined with the total thickness of the aluminum-plastic film and the overtravel distance reserved after the punch penetrates. Regarding the first antennae Move backward by a fixed angular distance to generate the preload end angle. ; Set the preload end angle Write the control parameters to the page so that the machine completes the preload section convergence at that angle.

[0026] According to some embodiments of the present invention, the preload end angle Archive the data and switch the control system to segmented control mode; when the crank angle reaches... The automatic switching of the punch downward speed to the preset low speed will be activated. Simultaneously, the pressure block is locked in its current position to prevent it from sliding with the punch; through speed steps, the aluminum layer and the two plastic layers on both sides are fully pressed together before shearing, blocking the interlayer slippage channel during the subsequent shearing; at the same time, , Write the data in association with the device model number;

[0027] Under the condition that segmented control is in effect, the control system schedules the output angle and force reference table of the punch displacement sensor and pressure sensor at the same sampling time; subsequently, the crank angle is... From the preload end angle From The process of traversing step by step is stopped, and the termination determination method of the monotonically increasing segment is used to capture the shear force of the punch. The peak position is determined, and the angle corresponding to this position is recorded as the maximum shear force angle. ;right Leave a safety angle distance forward Then, the minimum separation angle of the pre-compression and shearing section is superimposed. Based on this, the endpoint angle of the shear segment is generated. :

[0028]

[0029] in, The end angle of the sheared segment; This represents the maximum shear force angle. For safety angular distance; This is the preload end angle; These are the two minimum separation angles.

[0030] According to some embodiments of the present invention, the obtained Write to the controller parameter page, then call the controller's internal timer to... and The angular distance is the numerator, and the rated crank speed is the denominator. The system automatically calculates the pre-compression time ratio and the shearing time ratio, and simultaneously corrects the feeding wait pulse to ensure the feeding cycle time matches the two strokes in integer multiples. After writing the data, a single-cycle verification is performed on the number of strokes: when the punch is in... The cutting endpoint is considered complete when the blade stops cutting and just penetrates the membrane without overshooting; if undercutting occurs, the process is automatically adjusted. Decrease and recalculate Continue cutting until the cut is complete and there are no aluminum layer dents.

[0031] Will and After writing the two angle parameters, start the no-load segment verification program to stop the pressure block and punch at the respective positions. , Position and hold stationary; after confirming smooth mechanism operation, load the aluminum-plastic film and perform three trial cuts, inspecting the cut edges before proceeding. , And the corresponding speed is used to solidify into a fixed formula.

[0032] According to some embodiments of the present invention, step S3 includes:

[0033] S31. Roll the aluminum-plastic film of the preset length. Load the feeder into the feeding mechanism and set the tension of the guide rollers to the standard tension for room temperature. Perform zero-point calibration on the pressure block displacement sensor and the punch force sensor; after the hydraulic oil temperature rises to the normal operating range, record the no-load output of the force sensor as the baseline pressure. ;

[0034] S32. Switch the control mode to manual single-stroke while keeping the two-stage stroke parameters unchanged. After each feeding cycle, jog the punch to complete one full downward stroke; at the end of the pre-compression section... The force sensor output is captured in real time to record peak pressure. At least five consecutive cuts must be made within a three-second timeframe.

[0035] S33, regarding the information obtained in step S32 Fill in the pressure test record sheet in order, arranged from highest to lowest; take the arithmetic mean of the three highest groups to obtain the reference pressure for this batch of pre-loading sections. The average of the remaining two groups is taken to obtain the initial low pressure value. ;

[0036] S34. Adjust the stroke pressure knob in increments. Adjust downwards while maintaining the angle of travel. and feeding step distance Perform a single punching operation under unchanged conditions; if the cut edge is intact and without indentations, adjust the speed again. Repeat the punching process; if edge warping or interlayer loosening occurs, immediately revert to the previous pressure setting and record the peak value measured at that setting as the minimum sealing pressure. ;

[0037] S35, apply the minimum sealing pressure The three membrane samples cut under the given conditions were numbered sequentially, removed, and examined.

[0038] S36. The minimum sealing pressure verified in S35. The numerical input control system pressure setting page is set and read-only locking is enabled; simultaneously, a new entry is created in the production formula management module, binding the current two-stage stroke angle. and feeding pitch .

[0039] According to some embodiments of the present invention, step S4 includes:

[0040] S41. Switch the sampling mode of the preload section force sensor to single-stroke trigger, so that the sensor detects the force when the punch reaches the preload end point. And stop at the moment of peak output; for this impulse sequence number and the current opening degree of the servo valve port Synchronous writing to the temporary storage area; using a fixed-length first-in-first-out queue. Item management: when the queue is full, the oldest record is overwritten in chronological order to ensure that the temporary storage area always reflects the most recent working conditions;

[0041] S42, store the latest peak pressure in the temporary storage area. Minimum sealing pressure for curing in step S36 Perform a one-to-one difference operation and write the result to the deviation register:

[0042]

[0043] in, The unit is kN, representing the current pressure deviation; The unit is kN, representing the current peak pressure; The unit is kN, representing the minimum sealing pressure;

[0044] like If so, the control panel will prompt you to hold and will directly jump to the next pulse monitoring; if If the valve port is not corrected, the sealing layer will be prevented from failing due to batch differences in the membrane material or temperature rise drift.

[0045] S43, Display the deviation register as The number of times The issue is identified as an underpressure surge; a boost command is immediately injected into the servo valve control word, causing the valve core to shift in the opening direction. To avoid excessive pressure boosting at once, which could cause instantaneous pressure surges on the diaphragm, a single-stage incremental method is used, increasing the pressure by only one fixed step. And calculate the new valve opening degree in real time:

[0046]

[0047] in, Indicates the valve opening degree before the next stroke; This indicates the valve opening at the end of the current stroke; Indicates the increment of single-level opening; This indicates the maximum opening degree allowed by the hydraulic station hardware;

[0048] Complete the calculation, Along with the sequence number Write the parameters to the parameter stack and send update pulses to the hydraulic actuator; feed back the valve spool displacement to the target. A one-time matching verification is performed. Only after the verification passes can the punch interlock be released, allowing the next punch to proceed.

[0049] S44, When the deviation register displays That is, the pressure is higher than At this time, the servo valve control command is set to valve-off mode; according to the same Decrease valve opening by step and write Pause the feeding cycle for half a beat to allow the system oil pressure to drop fully;

[0050] S45. Update the valve opening. After writing to the hydraulic actuator register, the punch interlock is released and the next punching operation begins; the punch reaches the preload endpoint. At that time, the force sensor captured the peak pressure. The system then automatically completes the serial processing.

[0051] According to some embodiments of the present invention, the serial processing in step S45 includes:

[0052] S451, will OP sequence number and valve opening Write The queue is used to discard the oldest entry when it overflows.

[0053] S452, Calculate the punch force deviation And then transfer to the deviation register;

[0054] S453, Update the continuous stability counter The following formula can be used for recursion:

[0055]

[0056] in, This represents the cumulative number of strokes that have reached the tolerance window. This indicates the count value of the previous stroke; Indicates the first Pressure deviation during punching; Indicates the width of the tolerance window;

[0057] when If necessary, jump to S42 to perform the next round of deviation judgment;

[0058] If the counter is cleared, the system will return to S42 to start a new round of valve port correction.

[0059] When continuous Second punching all showed If the cutting edge is visually inspected and shows no delamination or warping, adjust the current valve opening. Lock this as the final operating value for this batch and write a pressure stabilization marker into the production formula; if any subsequent stroke results in... It will automatically return to S42 to restart the valve port correction process to ensure that the seal quality remains under control throughout the entire mass production period.

[0060] According to some embodiments of the present invention, step S5 includes:

[0061] S51. Set the pre-pressure stabilization signal as the starting condition for unloading the roll feeder, and drive the roll feeder motor to keep the aluminum-plastic film under constant tension. The die passes through the guide roller and enters the feed roller; the spatial distance from the center of the die to the leading edge of the pressure block is measured and recorded using a photoelectric tool setting line detection method. In the Control Panel Edge allowance around the superimposed cutting edge The input is the theoretical step size. ;

[0062] Complete the input, lock the tension controller and fix the position of the guide roller, establish the geometric reference for continuous feeding, and add the settings to the task settings table. The record is set to the default value for the current model.

[0063] S52, Regarding the theoretical step size After confirmation, the step distance signal is bound to the servo feed motor pulse counter, and a no-step test is performed using a single-stroke trigger method; the actual step distance obtained from the test is then... Perform visual size measurement, if Less than or equal to the allowable error Then immediately the corresponding pulse number The energy is stored in the counter; then the system switches to automatic mode, instructing the servo motor to press the button the instant each pressure block is lifted. Promote the use of aluminum-plastic film to achieve a smooth transition from intermittent feeding to continuous feeding;

[0064] S53. When continuous feeding enters the stable operation stage, the angle output of the crank stroke encoder will be... Pulse feedback with servo feed motor Simultaneously, data is written to the comparison register to monitor the step distance maintenance between each stroke in real time; if the register calculates the step distance offset... Exceeding the threshold If this happens, the pulse will automatically pause for one beat, and a single-stage correction pulse will be applied to the counter. This ensures that the next stroke enters the preload zone in the correct position; once the correction is completed, the pause is lifted, and subsequent strokes are monitored.

[0065] According to some embodiments of the present invention, step S6 includes:

[0066] S61. Fix the optical edge sensor to the side of the punching exit, and use the positioning fixture to fine-tune the probe's focal length and tilt angle in micrometer increments so that the detection spot can completely cover the newly formed cutting edge; after completing the physical fixation, perform a step-by-step amplification calibration on the sensor sensitivity knob, and set the sensor output reference level when the cutting edge burr height is approximately 50µm. ;

[0067] Will Write the quality comparison register of the controller as a reference value;

[0068] Connect the sensor signal line to the high-speed acquisition port of the controller, and use the rising edge of the punching completion as the trigger condition in the program to ensure that a frame of the cut feature is captured immediately after each punching.

[0069] S62, The controller acquires the current cutting level. The reference level cured in step S61 Perform a difference calculation and write it to a temporary storage register; use a counter to record the difference trend, and when the difference increases three consecutive times and exceeds the allowable threshold... When the speed control module is activated, a deceleration trigger bit is immediately written to it, and a prompt to start speed fine-tuning appears on the operation screen when the cutting edge deviation increases. If the difference does not exceed the threshold, the counter is reset and the current punching speed is maintained to avoid affecting the production cycle.

[0070] S63. Map the received deceleration trigger bit to a frequency decrement command for the second segment of the servo drive; in fixed increments. The frequency was lowered once, and the speed and pressure of the pre-compression section were locked to ensure that the sealing operation was not disturbed. After the speed adjustment was completed, the edge cutting level of the subsequent three strokes was monitored. If all return If the frequency falls within the specified range, a new frequency will be automatically frozen; if the frequency still exceeds the limit, it will be reduced again. Repeat the monitoring until the cutting edge quality returns to the target range;

[0071] S64. When the cutting edge of 20 consecutive punches is stable within the target range and the feeding step distance is... When there is no offset, the current minimum sealing pressure will be used. The corrected second frequency band and stride Write the production formula for this model in read-only format; then start the automatic stacking mechanism so that the finished film sheets fall into the receiving box in sequence via vacuum suction cups. Attached Figure Description

[0072] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0073] Figure 1 This is a flowchart of an adaptive cutting method for misaligned two-segment pre-compressed aluminum-plastic film proposed in this invention.

[0074] Figure 2 This is a flowchart of step S3 of the adaptive cutting method for misaligned two-segment pre-compressed aluminum-plastic film proposed in this invention.

[0075] Figure 3 This is a flowchart of step S4 of the adaptive cropping method proposed in this invention.

[0076] Figure 4 This is a flowchart of step S5 of the adaptive cutting method for misaligned two-segment pre-compressed aluminum-plastic film proposed in this invention.

[0077] Figure 5 This is a flowchart of step S6 of the adaptive cutting method for misaligned two-segment pre-compressed aluminum-plastic film proposed in this invention. Detailed Implementation

[0078] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0079] This invention provides an adaptive cutting method for misaligned two-segment pre-compressed aluminum-plastic film, applicable to the cutting process of aluminum-plastic film, comprising the following steps:

[0080] S1. With the punching machine powered off, release the pressure block and move it in the opposite direction of the feed by a preset misalignment amount so that the working surface of the pressure block is in the leading position relative to the punch cutting edge at the dead point position on the crank. After correcting the parallelism between the pressure block and the lower die surface, re-lock it.

[0081] S2. Set the equipment to inching mode and collect the displacement curves of the pressure block and the punch, respectively, to confirm the crank angle at which the pressure block first contacts the film surface. And the crank angle where the punch completely penetrates the aluminum-plastic film and will and Write into the control system to generate two stroke references for the preload section and the shear section;

[0082] S3. Under the condition of material-loaded test pressing, obtain multiple sets of peak pressures in the pre-compression section, calculate and lock the minimum sealing pressure. and the minimum sealing pressure and , Bind to write read-only parameter pages;

[0083] S4. During the batch punching operation, the pre-compression peak pressure of each punching is collected in real time, and the pre-compression peak pressure is compared with the minimum sealing pressure. When the deviation exceeds the preset tolerance range, the servo valve opening is adjusted, and this adjustment is performed continuously. After all punching pressures are within the preset tolerance range, the valve opening is locked.

[0084] S5. During continuous feeding, the crank angle output and the feeding servo motor pulse feedback are compared to monitor the feeding step distance between each punching. When the step distance deviation exceeds the step distance setting threshold, pause for one cycle and compensate the counting pulse to restore geometric synchronization.

[0085] S6. Utilize an optical edge sensor fixed to the punching exit to detect the edge reflection signal; when continuous... When the difference between punching operations exceeds the set threshold, the servo drive frequency of the shearing section is reduced until the cutting edge signal returns to the target range. After continuous punching stabilizes, the current pressure, speed and pitch formula is solidified to enter long-cycle operation.

[0086] Specifically, by adjusting the position and parallelism of the pressure block while the punching machine is powered off, the pressure block pre-presses the aluminum-plastic film before reaching the dead center of the crank, ensuring material control during the punch's descent. This reduces the risk of film warping and displacement from the source, improving cutting consistency. Displacement curves of the pressure block and punch are collected to accurately obtain the pre-pressing initiation angle and shearing completion angle, establishing a two-stage stroke reference based on the crank angle. This provides a precise reference for subsequent motion control, significantly improving the equipment's response accuracy and control stability. Multiple peak pressures during the pre-pressing stage are collected, and the minimum sealing pressure value is selected and locked. As a read-only reference for the control system, it effectively prevents poor cutting and interlayer peeling caused by insufficient material pressure, ensuring product molding quality. During batch operation, by comparing and analyzing with the minimum sealing pressure, the servo valve opening is adjusted in real time, and closed-loop feedback control is performed based on multiple punching results to achieve adaptive response of the system to material changes or operating condition fluctuations, further improving process stability. By comparing the crank angle and feeding pulse feedback, the feeding step distance is monitored for each time, and pause and compensation are performed when the deviation exceeds the threshold, effectively suppressing the impact of cumulative error on punching position accuracy and ensuring high-precision synchronization in continuous punching process. The exit optical edge sensor detects the cutting edge reflection signal, and dynamically adjusts the shearing section drive frequency when continuous deviation occurs, thereby achieving dynamic compensation for complex factors such as tool drift and film elasticity changes, improving the long-term operating stability of the system. After the system detects that each parameter is stable, it automatically solidifies the current pressure, speed, and step distance formula, reducing manual intervention and improving the intelligence level of the equipment and the continuity and consistency of batch production. While maintaining the existing punch press structure, this invention introduces a series of adaptive adjustment mechanisms at the control system level to achieve dynamic optimization control of the entire aluminum-plastic film cutting process. This solves the problems of poor cutting stability, poor synchronization, and insufficient continuity in the existing technology, significantly improving production efficiency and product quality, and has good prospects for industrial application.

[0087] In some embodiments of the present invention, in step S1, the pressing block is translated a distance in the reverse direction of the feeding direction. This is used to indicate the misalignment between the pressure surface and the punch cutting edge, so that the pressure surface at the dead center position on the crank leads the punch cutting edge.

[0088] A dial indicator was used to check the perpendicularity between the working surface of the pressure block and the fixed reference surface of the machine, and a right-angle ruler was used to conduct a preliminary inspection of its inclination angle.

[0089] Specifically, in step S1, the pressure block is precisely shifted a distance in the reverse direction of the feeding process. This creates a pre-displacement between the pressing surface and the punch cutting edge, which not only clarifies the timing reference for pre-pressing but also effectively improves the repeatability and controllability of the pressing action, facilitating standardized settings and maintenance.

[0090] A dial indicator is used to check the perpendicularity of the working surface of the pressing block to the fixed reference surface of the machine. A right-angle ruler is used to conduct a preliminary inspection of its tilt angle. This can achieve a dual detection method for the installation posture of the pressing mechanism, effectively avoiding problems such as local contact, uneven indentation or material displacement caused by improper installation of the pressing block, thereby further improving the stability and membrane positioning accuracy in the pre-pressing stage.

[0091] By optimizing the above methods, the punching system's adaptability to the film material's posture is enhanced, laying a higher geometric accuracy foundation for the smooth operation of the subsequent shearing section, which helps to further improve the overall punching quality and the service life of the die.

[0092] In some embodiments of the present invention, in step S2, the device control template is switched to the jog-type dry-stroke mode, and the feeding mechanism is set to be unloaded, and multiple dry strokes are performed continuously. At the same time, the crank angle encoder inside the device is called to obtain the crank angle. The displacement curves of the pressure block and the punch are obtained by combining the output values ​​of the dual-channel displacement sensors.

[0093] Specifically, by switching the equipment to the inching air-punching mode in step S2 and setting the feeding mechanism to an unloaded state, the punching action is carried out under conditions without material interference. This helps to eliminate the interference of external factors such as material resistance and mold reaction force on the displacement curve, thereby improving the accuracy and repeatability of displacement data.

[0094] The crank angle is synchronously acquired using the device's built-in crank angle encoder. In conjunction with dual-channel displacement sensors, the complete displacement curves of the pressure block and the punch are collected separately, enabling high-precision motion trajectory analysis of the two key components within the same stroke cycle. This hyperbolic data not only provides a reliable basis for determining the pre-compression start angle and the shear termination angle, but also provides data support for the subsequent control system to generate a precise two-stage stroke control strategy.

[0095] The above methods significantly improve the accuracy of data acquisition during equipment parameter initialization, enhance the system's ability to model the collaborative relationships of multiple mechanisms during the punching stroke, lay the foundation for achieving high-precision, adaptive cutting control, and further improve the overall intelligence level of the machine and the stability of the punching process.

[0096] In some embodiments of the present invention, for Compare the data within the range at the same angle to confirm that the displacement curve of the pressure block is within the range. The first contact feature point on the membrane surface appears within a preset range, and the feature point is earlier than the corresponding angle at which the punch enters the membrane surface, in order to verify the amount of misalignment. The resulting misalignment action meets the pre-compression requirements and eliminates the actual misalignment deviation caused by mechanism clearance or compensation error.

[0097] Specifically, through the explanation of By comparing and analyzing the data within the same range at the same angle, the displacement curve of the pressure block and the displacement curve of the punch can be accurately compared under a unified crank angle reference. This effectively eliminates time-domain errors caused by sensor response delay or differences in mechanism inertia, making feature point extraction more accurate and stable.

[0098] By identifying the displacement curve of the pressure block at the crank angle The first contact film surface feature point appearing within the range, including the crank angle Scope Furthermore, by verifying that its position precedes the corresponding angle at which the punch enters the film surface, the amount of misalignment can be accurately determined. Whether the introduced pre-compression action actually occurs. This comparison method not only logically verifies the misalignment action, but also effectively detects false misalignment phenomena caused by mechanism clearance, installation error, or software compensation deviation, thus providing an accurate reference for the starting point of subsequent control strategies.

[0099] By introducing a comparative analysis mechanism in the angle domain, the control system's ability to identify and determine the timing relationship of the pressing and punching actions is enhanced, improving the reliability of misaligned actions and the system's self-correction capability. This helps to further improve the coordination and process stability of the aluminum-plastic film pre-pressing and shearing process.

[0100] In some embodiments of the present invention, the crank angle at which the pressure block first contacts the film surface is defined as the starting angle of the pre-compression section. The crank angle at which the punch completely penetrates the aluminum-plastic film is defined as the end angle of the cutting segment. ;Will and Write the parameters to the machine parameter page and automatically generate a two-segment stroke reference table. The first stroke segment corresponds to the pre-compression segment, and the second stroke segment corresponds to the shearing segment. Based on the obtained parameter conditions, perform a single-pass test punch with material, check the cut edges, and mark them to solidify the current status. Value and Configuration.

[0101] To elaborate further, by adjusting the crank angle at which the pressure block first contacts the film surface... Defined as the starting angle of the pre-compression section, the crank angle at which the punch completely penetrates the aluminum-plastic film. Defined as the endpoint angle of the cutting segment, and written into the machine parameter page, two stroke reference tables are automatically generated, enabling the control system to achieve structured management and fine segmented control of the entire punching stroke. Clearly dividing the functional sections of pre-compression and shearing also facilitates the control logic to apply differentiated parameters to different stages, such as pressure adjustment, speed switching, and response tolerance setting, thereby more effectively addressing the process characteristics of aluminum-plastic film materials.

[0102] After generating the stroke baseline, a single-pass test punch is performed, and the cutting edge results are checked and marked. Specifically, the cutting edge is visually inspected and manually bent. If no delamination or warping occurs, physical marks are immediately made on the working surface of the pressure block near the reference edge. This operation achieves closed-loop verification between the process setting and the actual forming effect. If the test punch results meet the process requirements, the current misalignment amount can be adjusted. With crank angle , This will be solidified as the optimal setting to ensure that the system performs actions based on the verified parameters during subsequent batch operations.

[0103] This configuration method closely integrates key angle parameters with actual process effects, achieving closed-loop optimization of the entire process from parameter setting, process segmentation to process verification. It effectively improves equipment debugging efficiency and system operation stability, providing a reliable guarantee for long-term operation.

[0104] In some embodiments of the present invention, the obtained displacement curve of the pressure block and the displacement curve of the punch are imported into the controller as a whole. Two displacement data points are retrieved degree by degree for a preset angle interval after the top dead point of the crank, and the degree difference within the interval is searched. The maximum difference point identification method is used to determine the first contact angle of the pressure block entering the film surface. Combined with the total thickness of the aluminum-plastic film and the overtravel distance reserved after the punch penetrates. Regarding the first antennae Move backward by a fixed angular distance to generate the preload end angle. ; Set the preload end angle Write the control parameters to the page so that the machine completes the preload section convergence at that angle.

[0105] Specifically, by importing the complete displacement curves of the pressure block and the punch into the controller, and by sequentially calling and comparing the two displacement data points within a preset angle range after the crank's top dead center, a refined analysis of the relative motion state of the pressure block and punching is achieved, providing a high-resolution data foundation for the extraction of dynamic feature points. The difference maxima identification method is used to retrieve sequential differences, and the extreme points are used to determine the initial contact angle of the pressure block upon first entering the film surface. This can significantly improve the objectivity and robustness of feature point recognition, avoid recognition deviations caused by manual thresholding or sensor errors, and thus more accurately define the true starting state of the pre-compression action.

[0106] Based on this, combined with the total thickness of the aluminum-plastic film and the required overtravel distance after the punch is fully penetrated. , towards the first antennae Move backward by a fixed angular distance to generate the preload end angle. The data is then written into the control parameter page, enabling the control system to complete the pre-compression section's convergence switch at that angle point, achieving a natural transition and precise connection from pre-compression to shearing. This method not only achieves intelligent setting and adaptive adjustment of the pre-compression endpoint but also significantly enhances the system's adaptability to aluminum-plastic films of different thicknesses and materials. It improves the consistency of the machine's movements and the stability of its cutting quality under complex working conditions, providing a key control node for the precision punching process.

[0107] In some embodiments of the present invention, the preload end angle is... Archive the data and switch the control system to segmented control mode; when the crank angle reaches... The automatic switching of the punch downward speed to the preset low speed will be activated. Simultaneously, the pressure block is locked in its current position to prevent it from sliding with the punch; through speed steps, the aluminum layer and the two plastic layers on both sides are fully pressed together before shearing, blocking the interlayer slippage channel during the subsequent shearing; at the same time, , Write the data in association with the device model number;

[0108] Under the condition that segmented control is in effect, the control system schedules the output angle and force reference table of the punch displacement sensor and pressure sensor at the same sampling time; subsequently, the crank angle is... From the preload end angle From The process of traversing step by step is stopped, and the termination determination method of the monotonically increasing segment is used to capture the shear force of the punch. The peak position is determined, and the angle corresponding to this position is recorded as the maximum shear force angle. ;right Leave a safety angle distance forward Then, the minimum separation angle of the pre-compression and shearing section is superimposed. Based on this, the endpoint angle of the shear segment is generated. :

[0109]

[0110] in, The end angle of the sheared segment; This represents the maximum shear force angle. For safety angular distance; This is the preload end angle; These are the two minimum separation angles.

[0111] Specifically, by adjusting the preload end angle... By archiving the data and switching the control system to segmented control mode, the motion state of the punch can be switched at key angle points, i.e., in... Automatically switch to preset low speed The pressure block is locked in place to prevent it from slipping with the punch, thus forming a controlled and stable pre-pressure holding zone. This stage utilizes a speed gradient to ensure that the aluminum layer and the two plastic layers are fully pressed together before the actual shearing, effectively blocking the interlayer slippage channels during the shearing process and avoiding problems such as film warping, tearing, or edge burrs. This significantly improves the cutting quality and edge neatness of the multilayer composite film material.

[0112] At the same time, the preload end angle low speed By binding parameters to the machine model number and writing them into the control system, the system achieves model-specific parameter storage, allowing different models of equipment to access their respective optimal settings, thus improving system compatibility and standardized management capabilities. After segmented control takes effect, the control system schedules the punch displacement sensor and pressure sensor to output an angle force comparison table within a unified sampling time base. This allows for degree-by-degree monitoring of the shear force during the punch's movement, ensuring data synchronization and accurate sampling, thereby supporting the analysis of shear force variation curves. Precise analysis.

[0113] By adjusting the crank angle from to The range is traversed sequentially, and the peak position of the shear force is identified using a monotonically increasing segment termination determination method. It can accurately identify the maximum load point during the material shearing process, providing a basis for the safe control and energy consumption optimization of the shearing action.

[0114] In some embodiments of the present invention, the obtained Write to the controller parameter page, then call the controller's internal timer to... and The angular distance is the numerator, and the rated crank speed is the denominator. The system automatically calculates the pre-compression time ratio and the shearing time ratio, and simultaneously corrects the feeding wait pulse to ensure the feeding cycle time matches the two strokes in integer multiples. After writing the data, a single-cycle verification is performed on the number of strokes: when the punch is in... The cutting endpoint is considered complete when the blade stops cutting and just penetrates the membrane without overshooting; if undercutting occurs, the process is automatically adjusted. Decrease and recalculate Continue cutting until the cut is complete and there are no aluminum layer dents.

[0115] Will and After writing the two angle parameters, start the no-load segment verification program to stop the pressure block and punch at the respective positions. , Position and hold stationary; after confirming smooth mechanism operation, load the aluminum-plastic film and perform three trial cuts, inspecting the cut edges before proceeding. , And the corresponding speed is used to solidify into a fixed formula.

[0116] Specifically, the calculated shear segment endpoint angle is explained below. Write to the controller parameter page and call the controller's internal timer to... and With the angular distance as the numerator and the crank rated speed as the denominator, the system automatically calculates the time ratio of the pre-compression and shearing sections, enabling dynamic timing matching of the two strokes and ensuring a scientifically sound cycle distribution during operation. Synchronous correction of the feeding waiting pulse ensures that the feeding cycle time matches the time ratio of the two strokes as an integer multiple, effectively preventing rhythm misalignment between feeding and cutting, improving step distance accuracy and cutting synchronization during continuous feeding, and significantly reducing cumulative errors.

[0117] After the parameters are written, a single punching verification is performed through the control system to determine the punch's position. The system assesses the rationality of the shear endpoint angle setting by checking whether the blade precisely penetrates the diaphragm without overshoot when the angle stops; if undercutting occurs, the system will automatically reduce the safety angle distance. and recalculate Continue cutting until the aluminum layer is completely cut without leaving any dents, ensuring the quality of the finished product. Then... and Two key angle parameters are written into the control system, and the no-load segment verification program is started, so that the pressure block and the punch stop at the corresponding angle and remain stationary for 2 seconds. The smoothness of mechanical action is used to verify the consistency between the control logic of each movement segment and the actual execution, so as to avoid jamming, conflict or overtravel during operation.

[0118] After successful no-load verification, three trial cuts were performed with the aluminum-plastic film loaded. The cut edges were then manually or via sensors to ensure clean edges, no film separation, and appropriate cutting depth. Once the process requirements were confirmed to be met, the " , The corresponding operating speeds are all fixed into a single formula for subsequent mass production. This method automates and standardizes the setting and verification process of multiple angles and parameters, forming a closed-loop control mechanism centered on the feature angles. This greatly improves the adaptability, process stability, and intelligent operation of the cutting process, making it particularly suitable for multi-variety, high-precision aluminum-plastic film cutting applications.

[0119] In some embodiments of the present invention, step S3 includes:

[0120] S31. Roll the aluminum-plastic film of the preset length. Load the feeder into the feeding mechanism and set the tension of the guide rollers to the standard tension for room temperature. Perform zero-point calibration on the pressure block displacement sensor and the punch force sensor; after the hydraulic oil temperature rises to the normal operating range, record the no-load output of the force sensor as the baseline pressure. ;

[0121] S32. Switch the control mode to manual single-stroke while keeping the two-stage stroke parameters unchanged. After each feeding cycle, jog the punch to complete one full downward stroke; at the end of the pre-compression section... The force sensor output is captured in real time to record peak pressure. At least five consecutive cuts must be made within a three-second timeframe.

[0122] S33, regarding the information obtained in step S32 Fill in the pressure test record sheet in order, arranged from highest to lowest; take the arithmetic mean of the three highest groups to obtain the reference pressure for this batch of pre-loading sections. The average of the remaining two groups is taken to obtain the initial low pressure value. ;

[0123] S34. Adjust the stroke pressure knob in increments. Adjust downwards while maintaining the angle of travel. and feeding step distance Perform a single punching operation under unchanged conditions; if the cut edge is intact and without indentations, adjust the speed again. Repeat the punching process; if edge warping or interlayer loosening occurs, immediately revert to the previous pressure setting and record the peak value measured at that setting as the minimum sealing pressure. ;

[0124] S35, apply the minimum sealing pressure The three membrane samples cut under the given conditions were numbered sequentially, removed, and examined.

[0125] S36. The minimum sealing pressure verified in S35. The numerical input control system pressure setting page is set and read-only locking is enabled; simultaneously, a new entry is created in the production formula management module, binding the current two-stage stroke angle. and feeding pitch .

[0126] Specifically, through this step, the system realizes a complete closed-loop process from parameter setting, pressure testing, effect verification to formula archiving, which significantly improves the intelligence level of the control system, the stability of the production process and the consistency of finished product quality. It is especially suitable for aluminum-plastic film product manufacturing scenarios with strict requirements for punching strength and film layer pressing.

[0127] Specifically, in step S31, the aluminum-plastic film roll of the preset length is... Load the feeder into the feeding mechanism and set the guide roller tension to the room temperature reference tension. This ensures the film material unfolds and flattens naturally, facilitating subsequent pressing accuracy control. Simultaneously, the displacement sensor of the pressing block and the punch force sensor are zero-point calibrated, and the no-load baseline pressure is recorded after the hydraulic oil temperature rises to the normal operating range. It can effectively eliminate the interference of external factors such as temperature rise drift and oil pressure fluctuation on the test accuracy.

[0128] In S32 and S33, at least five material-carrying punches are completed using manual single-punch mode, with each punch ending at the pre-pressing endpoint. The pressure peak at the test point is captured and entered into the pressure test record sheet to distinguish it from the reference high pressure. With initial low pressure This enables multi-level classification of the pressure state of the punching and shearing system, providing a clear gradient for the next stage of minimum sealing pressure testing.

[0129] In S34, fine step size is combined The stroke pressure knob was gradually lowered, and punching and trimming were repeatedly observed while keeping the angle parameters and feeding cycle constant. This effectively controlled variables and ensured the comparability of test results. When trimming defects, such as warping or delamination, were detected, the pressure was returned to the previous level and the peak value of that level was locked. This enables automatic identification and optimal setting of the minimum effective sealing pressure.

[0130] In S35, the membrane samples are recovered by numbering for appearance and edge quality inspection to ensure... The finished product meets the process requirements under the given conditions; in S36, the verified minimum sealing pressure will be... Write the system pressure settings page and enable read-only locking to prevent accidental adjustments or tampering. Simultaneously... With the angle parameters of the two travel segments and feeding pitch It is bound together as a new production formula entry, making it easy to quickly call up in the same batch or with the same specifications of materials in the future.

[0131] In some embodiments of the present invention, step S4 includes:

[0132] S41. Switch the sampling mode of the preload section force sensor to single-stroke trigger, so that the sensor detects the force when the punch reaches the preload end point. And stop at the moment of peak output; for this impulse sequence number and the current opening degree of the servo valve port Synchronous writing to the temporary storage area; using a fixed-length first-in-first-out queue. Item management: when the queue is full, the oldest record is overwritten in chronological order to ensure that the temporary storage area always reflects the most recent working conditions;

[0133] S42, store the latest peak pressure in the temporary storage area. Minimum sealing pressure for curing in step S36 Perform a one-to-one difference operation and write the result to the deviation register:

[0134]

[0135] in, The unit is kN, representing the current pressure deviation; The unit is kN, representing the current peak pressure; The unit is kN, representing the minimum sealing pressure;

[0136] like If so, the control panel will prompt you to hold and will directly jump to the next pulse monitoring; if If the valve port is not corrected, the sealing layer will be prevented from failing due to batch differences in the membrane material or temperature rise drift.

[0137] S43, Display the deviation register as The number of times The issue is identified as an underpressure surge; a boost command is immediately injected into the servo valve control word, causing the valve core to shift in the opening direction. To avoid excessive pressure boosting at once, which could cause instantaneous pressure surges on the diaphragm, a single-stage incremental method is used, increasing the pressure by only one fixed step. And calculate the new valve opening degree in real time:

[0138]

[0139] in, Indicates the valve opening degree before the next stroke; This indicates the valve opening at the end of the current stroke; Indicates the increment of single-level opening; This indicates the maximum opening degree allowed by the hydraulic station hardware;

[0140] Complete the calculation, Along with the sequence number Write the parameters to the parameter stack and send update pulses to the hydraulic actuator; feed back the valve spool displacement to the target. A one-time matching verification is performed. Only after the verification passes can the punch interlock be released, allowing the next punch to proceed.

[0141] S44, When the deviation register displays That is, the pressure is higher than At this time, the servo valve control command is set to valve-off mode; according to the same Decrease valve opening by step and write Pause the feeding cycle for half a beat to allow the system oil pressure to drop fully;

[0142] S45. Update the valve opening. After writing to the hydraulic actuator register, the punch interlock is released and the next punching operation begins; the punch reaches the preload endpoint. At that time, the force sensor captured the peak pressure. The system then automatically completes the serial processing.

[0143] Specifically, by introducing a pressure closed-loop control strategy based on real-time feedback and dynamic self-adjustment mechanism in step S4, the pressure control in the pre-pressing section not only possesses responsiveness but also stability and safety, significantly improving the overall system's adaptability to external disturbances such as material fluctuations and environmental changes. By integrating peak pressure acquisition, FIFO dynamic buffering, single-stage step adjustment, interlock protection mechanisms, and real-time feedback verification of the servo valve, this method constructs a punching pressure control system with high sensitivity, high safety, and high robustness. This ensures that each pressing during continuous punching precisely meets the minimum requirements of the forming process, effectively improving finished product yield and equipment operational stability.

[0144] Specifically, in S41, the force sensor sampling mode is switched to single-stroke trigger, and the force is activated when the punch reaches the preload end angle. Instantly record peak pressure This achieves high-precision capture of key pressing nodes; combined with the current pressing sequence number With the corresponding servo valve port opening Write to First-In-First-Out Queue Ensure the system only stores the latest version. This record effectively prevents adjustment delays caused by redundant historical data.

[0145] In S42, by using the current pressure Minimum sealing pressure for curing in step S36 Perform a one-to-one difference calculation to obtain the pressure deviation under the current punching condition. And by setting an allowable error range Perform a quick determination. When When the tolerance is exceeded, the system immediately enters the valve correction process to avoid insufficient or excessive sealing pressure caused by factors such as material batch differences and temperature rise drift.

[0146] In S43, when When the value is less than 0, indicating a risk of undervoltage, the system automatically injects a pressure boosting control command into the servo valve and employs a single-stage incremental strategy with a fixed step size. Increase the valve opening, while setting it to not exceed the maximum opening. The constraints effectively avoid the risk of membrane surface impact or indentation caused by overcompensation. The updated opening... With the number of strokes After being written into the parameter stack, the valve core displacement feedback and the set value are used for closed-loop verification to ensure the accuracy and safety of the system action; the punch interlock is only released after the verification is passed to ensure that the next punching process is executed under sufficient pressure conditions.

[0147] In S44, when When the pressure is greater than 0, meaning it exceeds the target value, the system automatically executes a pressure reduction command, using equal step sizes. The valve ports are closed step by step, and feeding is paused for half a cycle after the valve ports are adjusted to allow the hydraulic system pressure to drop fully, preventing the system from entering the next cycle under high pressure residual conditions, thereby improving the temperature control stability and hydraulic response reliability of the system operation.

[0148] Finally, in S45, after writing the refreshed valve opening into the hydraulic actuator register, the punch interlock is released and the next punching is started. At the same time, new peak pressure is captured, realizing the serial adaptive adjustment of the punching pressure by the system and constructing a continuous, dynamic and stable pressure control closed loop.

[0149] In some embodiments of the present invention, the serial processing in step S45 includes:

[0150] S451, will OP sequence number and valve opening Write The queue is used to discard the oldest entry when it overflows.

[0151] S452, Calculate the punch force deviation And then transfer to the deviation register;

[0152] S453, Update the continuous stability counter The following formula can be used for recursion:

[0153]

[0154] in, This represents the cumulative number of strokes that have reached the tolerance window. This indicates the count value of the previous stroke; Indicates the first Pressure deviation during punching; Indicates the width of the tolerance window;

[0155] when If necessary, jump to S42 to perform the next round of deviation judgment;

[0156] If the counter is cleared, the system will return to S42 to start a new round of valve port correction.

[0157] When continuous Second punching all showed If the cutting edge is visually inspected and shows no delamination or warping, adjust the current valve opening. Lock this as the final operating value for this batch and write a pressure stabilization marker into the production formula; if any subsequent stroke results in... It will automatically return to S42 to restart the valve port correction process to ensure that the seal quality remains under control throughout the entire mass production period.

[0158] Specifically, by introducing a serial processing mechanism in step S45, the peak pressure and servo valve control status during each punching process are tracked and their stability is determined in real time. This enables the control system to intelligently identify, dynamically judge, and ultimately converge to the optimal operating parameters, thereby significantly improving the accuracy of the overall machine control and the consistency in mass production. This serial processing logic not only achieves real-time response and tolerance judgment to pressure deviations, but also constructs a closed-loop pressure control system through continuous recursion and automatic locking mechanisms. This significantly improves the stability, adaptability, and product consistency of the system operation, making it particularly suitable for precision cutting scenarios of aluminum-plastic film where punching quality requirements are high and process fluctuations are sensitive.

[0159] Specifically, in S451, the peak pressure obtained from the current punching is... OP sequence number and valve opening By writing data to the FIFO_m queue and discarding the oldest entry when the capacity is exceeded, not only is the real-time data storage ensured, but the system response lag caused by too much historical data is also avoided.

[0160] In S452, the system automatically calculates the pressure deviation for the current stroke. The data is then written into the deviation register to provide a basis for subsequent judgment on whether the state has entered a steady state.

[0161] In S453, a continuous stable counter is introduced. The dynamic update is performed using a recursive method: if the deviation of the punch force satisfies... If the condition is met, the counter is incremented by 1; otherwise, it is immediately reset to zero. This strategy achieves tolerance for short-term fluctuations and strong determination of long-term stability, preventing misjudgments of out-of-control situations due to occasional anomalies. It also ensures that continuous performance is met before entering steady-state determination, thus possessing greater engineering practicality.

[0162] When N consecutive punching operations meet the tolerance conditions, and manual or sensor confirmation confirms that there is no delamination or warping of the cut edge, the system automatically adjusts the current servo valve opening. This setting is solidified as the final operating parameter for this batch and written into the production formula as a "pressure stability mark". This setting eliminates the need for repeated adjustments in subsequent production, effectively improving batch changeover efficiency and operational stability.

[0163] If in any subsequent stroke The system will immediately exit the steady state and return to S42 to start a new round of valve port correction process, building a triple control mechanism of real-time monitoring, condition self-correction and formula locking to ensure that the sealing pressure is always within a precise and controllable range during the entire batch production period.

[0164] According to some embodiments of the present invention, step S5 includes:

[0165] S51. Set the pre-pressure stabilization signal as the starting condition for unloading the roll feeder, and drive the roll feeder motor to keep the aluminum-plastic film under constant tension. The die passes through the guide roller and enters the feed roller; the spatial distance from the center of the die to the leading edge of the pressure block is measured and recorded using a photoelectric tool setting line detection method. In the Control Panel Edge allowance around the superimposed cutting edge The input is the theoretical step size. ;

[0166] Complete the input, lock the tension controller and fix the position of the guide roller, establish the geometric reference for continuous feeding, and add the settings to the task settings table. The record is set to the default value for the current model.

[0167] S52, Regarding the theoretical step size After confirmation, the step distance signal is bound to the servo feed motor pulse counter, and a no-step test is performed using a single-stroke trigger method; the actual step distance obtained from the test is then... Perform visual size measurement, if Less than or equal to the allowable error Then immediately the corresponding pulse number The energy is stored in the counter; then the system switches to automatic mode, instructing the servo motor to press the button the instant each pressure block is lifted. Promote the use of aluminum-plastic film to achieve a smooth transition from intermittent feeding to continuous feeding;

[0168] S53. When continuous feeding enters the stable operation stage, the angle output of the crank stroke encoder will be... Pulse feedback with servo feed motor Simultaneously, data is written to the comparison register to monitor the step distance maintenance between each stroke in real time; if the register calculates the step distance offset... Exceeding the threshold If this happens, the pulse will automatically pause for one beat, and a single-stage correction pulse will be applied to the counter. This ensures that the next stroke enters the preload zone in the correct position; once the correction is completed, the pause is lifted, and subsequent strokes are monitored.

[0169] Specifically, by introducing a feeding synchronization mechanism based on geometric reference and pulse feedback in step S5, high-precision control of the entire process of aluminum-plastic film from initial tool setting and step distance confirmation to continuous feeding can be achieved, ensuring that each punching is completed in the accurate position, greatly improving the die-cutting quality and equipment operating efficiency. By introducing a triple mechanism of geometric tool setting, step distance verification, and closed-loop correction, a high-precision mapping relationship between the geometric reference of the feeding path and the control system is established, enabling the feeding process to have self-inspection, self-correction, and self-recovery capabilities, effectively preventing the spread of cumulative errors, and ensuring the consistency of punching accuracy and edge quality. It is particularly suitable for aluminum-plastic film processing technology with high requirements for finished product position accuracy and visual inspection.

[0170] Specifically, in S51, the system uses the pre-pressure stabilization signal as the starting condition for unloading the roll, ensuring that the film is in a stable pressed state before entering the feeding path, effectively preventing film position drift caused by tension fluctuations. By employing photoelectric die-setting line detection technology, the spatial distance from the die center to the leading edge of the pressure block is monitored. Perform high-precision measurements and overlay the margin allowance in the control panel. Forming theoretical step size This not only improves the accuracy of the initial feeding settings but also provides a clear geometric reference for subsequent step distance control. The theoretical step distance... equal to the feeding step distance Subsequently, the tension controller is locked, and the position of the guide roller is fixed to form a stable and repeatable feeding path, providing consistent tension and trajectory assurance for continuous feeding, while simultaneously adjusting the theoretical step distance. Record these as the default parameters for the current model to facilitate quick recall and parameter reuse in subsequent production.

[0171] In S52, a pulse counter is bound to the servo feed motor to perform a no-step test in a single-stroke trigger mode, and the actual step distance is determined by visual inspection. Take measurements. When When the system feed accuracy reaches the control requirements, the corresponding pulse count can be immediately updated. This parameter is embedded in the controller to ensure the feeding system operates stably. Afterward, switch to automatic mode, causing the servo feed motor to press a button the instant each pressure block is lifted. Advance the film material to ensure synchronization between feeding and punching operations, achieving a seamless transition from intermittent to continuous feeding and avoiding problems such as material stretching, over-punching, or damage.

[0172] In S53, a crank encoder angle output is introduced. Pulse feedback from the feeding servo motor The comparison mechanism synchronously writes it into the comparison register and calculates the step offset between each stroke. Perform real-time monitoring. Once an offset exceeds the error threshold is detected... The system will automatically pause for one stroke and execute a single-stage correction pulse. This is to correct the feeding position of the next stroke and ensure that the film material enters the pre-compression zone accurately again.

[0173] In some embodiments of the present invention, step S6 includes:

[0174] S61. Fix the optical edge sensor to the side of the punching exit, and use the positioning fixture to fine-tune the probe's focal length and tilt angle in micrometer increments so that the detection spot can completely cover the newly formed cutting edge; after completing the physical fixation, perform a step-by-step amplification calibration on the sensor sensitivity knob, and set the sensor output reference level when the cutting edge burr height is approximately 50µm. ;

[0175] Will Write the quality comparison register of the controller as a reference value;

[0176] Connect the sensor signal line to the high-speed acquisition port of the controller, and use the rising edge of the punching completion as the trigger condition in the program to ensure that a frame of the cut feature is captured immediately after each punching.

[0177] S62, The controller acquires the current cutting level. The reference level cured in step S61 Perform a difference calculation and write it to a temporary storage register; use a counter to record the difference trend, and when the difference increases three consecutive times and exceeds the allowable threshold... When the speed control module is activated, a deceleration trigger bit is immediately written to it, and a prompt to start speed fine-tuning appears on the operation screen when the cutting edge deviation increases. If the difference does not exceed the threshold, the counter is reset and the current punching speed is maintained to avoid affecting the production cycle.

[0178] S63. Map the received deceleration trigger bit to a frequency decrement command for the second segment of the servo drive; in fixed increments. The frequency was lowered once, and the speed and pressure of the pre-compression section were locked to ensure that the sealing operation was not disturbed. After the speed adjustment was completed, the edge cutting level of the subsequent three strokes was monitored. If all return If the frequency falls within the specified range, a new frequency will be automatically frozen; if the frequency still exceeds the limit, it will be reduced again. Repeat the monitoring until the cutting edge quality returns to the target range;

[0179] S64. When the cutting edge of 20 consecutive punches is stable within the target range and the feeding step distance is... When there is no offset, the current minimum sealing pressure will be used. The corrected second frequency band and stride Write the production formula for this model in read-only format; then start the automatic stacking mechanism so that the finished film sheets fall into the receiving box in sequence via vacuum suction cups.

[0180] Specifically, by introducing an integrated control process in step S6 that combines optical detection, quality comparison, speed adjustment, and parameter solidification, real-time monitoring and adaptive adjustment of the cut edge quality of the film after punching are achieved. This effectively solves problems such as burrs, delamination, or uneven cuts caused by changes in film material condition, mold wear, or excessive punching speed, significantly improving product appearance quality and stability. By constructing an online quality inspection link centered on sensors, coupled with the multi-level response mechanism of the intelligent control system, the three parameters of punching speed, pressure, and step distance are linked and adjusted. This not only allows for intervention and optimization at the initial stage of problems but also supports the punching equipment to maintain a stable and high-quality operating state under different material batches, environmental changes, or mold aging. It is particularly suitable for the mass production of aluminum-plastic film end products with extremely high appearance requirements.

[0181] In S61, a high-sensitivity optical edge sensor is fixed to the side of the punching exit, and its focal length and tilt angle are finely adjusted at the micrometer level using a positioning fixture to ensure that the detection spot always covers the newly generated cutting edge area, thereby improving the representativeness and reliability of the acquired data. A stepped-increment sensitivity adjustment knob is used to make the sensor output a reference level U0 when the burr height reaches a preset reference. This value is written to the controller's quality comparison register as the benchmark for subsequent cutting edge quality determination, effectively constructing a quality quantification model. The preset reference is 50µm.

[0182] In S62, the controller uses the rising edge of the punch completion signal as the sampling trigger point to ensure that a frame of edge level is immediately acquired after each punch. and with Perform difference calculation. If the difference increases three consecutive times and exceeds the allowable threshold... When the system is in operation, it immediately writes a deceleration trigger bit to prompt the operator that the system will make fine adjustments to curb the trend of quality deterioration. If the difference fluctuation is within the allowable range, the counter is automatically reset to maintain the current punching speed, thereby ensuring product quality while avoiding unnecessary cycle time interference and improving overall production efficiency.

[0183] In S63, the deceleration trigger bit is mapped by the system to a command to lower the second segment of the servo drive frequency, in fixed increments. The execution frequency is decreased while the speed and pressure of the pre-compression stage are locked to ensure that the sealing layer stability is not disturbed. The system then continues to acquire the edge cutting level of subsequent three strokes and verify whether it has returned to the target tolerance range. If the frequency is consistently within acceptable limits, it will be automatically frozen as the new process parameter; if it still exceeds the limits, it will be pressed again. By slowing down and repeatedly monitoring, adaptive callback closed-loop control of die-cutting quality is achieved.

[0184] In S64, if the edge quality of 20 consecutive punching cuts remains stable within the tolerance range and the feed step distance D does not deviate, the system will apply the current minimum sealing pressure. The corrected second frequency band and feeding pitch The production formula for this model is written in read-only format, enabling parameter solidification and version management. Subsequently, the stacking mechanism is automatically activated, allowing qualified films to fall into the receiving box in sequence, initiating a stable long-cycle operation mode and significantly improving the automation and unmanned operation level of the entire production line.

[0185] Although embodiments of the invention have been described in conjunction with the accompanying drawings, those skilled in the art can make various modifications and variations without departing from the spirit and scope of the invention, and such modifications and variations all fall within the scope defined by the appended claims.

Claims

1. A method for adaptive cutting of a staggered two-segment pre-compressed aluminum-plastic film, applicable to the cutting process of aluminum-plastic film, characterized in that, Includes the following steps: S1. With the punching machine powered off, release the pressure block and move it in the opposite direction of the feed by a preset misalignment amount so that the working surface of the pressure block is in the leading position relative to the punch cutting edge at the dead point position on the crank. After correcting the parallelism between the pressure block and the lower die surface, re-lock it. S2. Set the equipment to inching mode and collect the displacement curves of the pressure block and the punch, respectively, to confirm the crank angle at which the pressure block first contacts the film surface. And the crank angle where the punch completely penetrates the aluminum-plastic film and will and Write into the control system to generate two stroke references for the preload section and the shear section; S3. Under the condition of material-loaded test pressing, obtain multiple sets of peak pressures in the pre-compression section, calculate and lock the minimum sealing pressure. and the minimum sealing pressure and , Bind to write read-only parameter pages; S4. During the batch punching operation, the pre-compression peak pressure of each punching is collected in real time, and the pre-compression peak pressure is compared with the minimum sealing pressure. When the deviation exceeds the preset tolerance range, the servo valve opening is adjusted, and this adjustment is performed continuously. After all punching pressures are within the preset tolerance range, the valve opening is locked. S5. During continuous feeding, the crank angle output and the feeding servo motor pulse feedback are compared to monitor the feeding step distance between each punching. When the step distance deviation exceeds the step distance setting threshold, pause for one cycle and compensate the counting pulse to restore geometric synchronization. S6. Utilize an optical edge sensor fixed to the punching exit to detect the edge reflection signal; when continuous... When the difference between the two punching operations exceeds the set threshold, the servo drive frequency of the shearing section is reduced until the cutting edge reflection signal returns to the target range. After continuous punching stabilizes, the current pressure, speed and pitch formula is solidified to enter long-cycle operation.

2. The adaptive cutting method for misaligned two-segment pre-compressed aluminum-plastic film according to claim 1, characterized in that, In step S1, the pressure block is moved a distance in the opposite direction of the feeding direction. , to indicate the misalignment between the working surface of the pressure block and the cutting edge of the punch, so that the pressure surface at the dead point position on the crank produces a leading state relative to the cutting edge of the punch; A dial indicator was used to check the perpendicularity between the working surface of the pressure block and the fixed reference surface of the machine, and a right-angle ruler was used to conduct a preliminary inspection of its inclination angle.

3. The adaptive cutting method for misaligned two-segment pre-compressed aluminum-plastic film according to claim 2, characterized in that, In step S2, the device control panel switches to the jog-type dry-stroke mode and sets the feeding mechanism to no-load, performing multiple dry strokes continuously. Simultaneously, the crank angle encoder within the device is invoked to obtain the crank angle. The displacement curves of the pressure block and the punch are obtained by combining the output values ​​of the dual-channel displacement sensors.

4. The adaptive cutting method for misaligned two-segment pre-compressed aluminum-plastic film according to claim 3, characterized in that, right Compare the data within the range at the same angle to confirm that the displacement curve of the pressure block is within the range. The first contact feature point on the membrane surface appears within a preset range, and the feature point is earlier than the corresponding angle at which the punch enters the membrane surface, in order to verify the amount of misalignment. The resulting misalignment action meets the pre-compression requirements and eliminates the actual misalignment deviation caused by mechanism clearance or compensation error.

5. The adaptive cutting method for misaligned two-segment pre-compressed aluminum-plastic film according to claim 3, characterized in that, The crank angle at which the pressure block first contacts the membrane surface is defined as the starting angle of the pre-compression section. The crank angle at which the punch completely penetrates the aluminum-plastic film is defined as the end angle of the cutting segment. ;Will and Write the parameters to the machine parameter page and automatically generate a two-segment stroke reference table. The first stroke segment corresponds to the pre-compression segment, and the second stroke segment corresponds to the shearing segment. Based on the obtained parameter conditions, perform a single-pass test punch with material, check the cut edges, and mark them to solidify the current status. Value and Configuration.

6. The adaptive cutting method for misaligned two-segment pre-compressed aluminum-plastic film according to claim 3, characterized in that, The obtained displacement curves of the pressure block and the punch are imported into the controller. Two displacement data points are retrieved degree by degree for a preset angle interval after the top dead center of the crank, and the degree difference within this interval is searched. The maximum difference point identification method is used to determine the first contact angle of the pressure block entering the film surface. Combined with the total thickness of the aluminum-plastic film and the overtravel distance reserved after the punch penetrates. Regarding the first antennae Move backward by a fixed angular distance to generate the preload end angle. ; Set the preload end angle Write the control parameters to the page so that the machine completes the preload section convergence at that angle.

7. The adaptive cutting method for misaligned two-segment pre-compressed aluminum-plastic film according to claim 6, characterized in that, For the preload end angle Archive the data and switch the control system to segmented control mode; when the crank angle reaches... The automatic switching of the punch downward speed to the preset low speed will be activated. Simultaneously, the pressure block is locked in its current position to prevent it from sliding with the punch; through speed steps, the aluminum layer and the two plastic layers on both sides are fully pressed together before shearing, blocking the interlayer slippage channel during the subsequent shearing; at the same time, , Write the data in association with the device model number; Under the condition that segmented control is in effect, the control system schedules the punch displacement sensor and pressure sensor to output angle and force comparison tables within the same sampling time; subsequently, the crank angle is... From the preload end angle From The process of traversing step by step is stopped, and the termination determination method of the monotonically increasing segment is used to capture the shear force of the punch. The peak position is determined, and the angle corresponding to this position is recorded as the maximum shear force angle. ;right Leave a safety angle distance forward Then, the minimum separation angle of the pre-compression shear section is superimposed. Based on this, the endpoint angle of the shear segment is generated. : in, The end angle of the sheared segment; This represents the maximum shear force angle. For safety angular distance; This is the preload end angle; This is the minimum separation angle of the pre-compression shear section.

8. The adaptive cutting method for misaligned two-segment pre-compressed aluminum-plastic film according to claim 7, characterized in that, For the obtained Write to the controller parameter page, then call the controller's internal timer to... and The angular distance is the numerator, and the rated crank speed is the denominator. The system automatically calculates the pre-compression time ratio and the shearing time ratio, and simultaneously corrects the feeding wait pulse to ensure the feeding cycle time matches the two strokes in integer multiples. After writing the data, a single-cycle verification is performed on the number of strokes: when the punch is in... The cutting endpoint is considered complete when the blade stops cutting and just penetrates the membrane without overshooting; if undercutting occurs, the process is automatically adjusted. Decrease and recalculate Continue cutting until the cut is complete and there are no aluminum layer dents. Will and After writing the two angle parameters, start the no-load segment verification program to stop the pressure block and punch at the respective positions. , Position and hold stationary; after confirming smooth mechanism operation, load the aluminum-plastic film and perform three trial cuts, inspecting the cut edges before proceeding. , And the corresponding speed is used to solidify into a fixed formula.

9. The adaptive cutting method for misaligned two-segment pre-compressed aluminum-plastic film according to claim 3, characterized in that, Step S3 includes: S31. Roll the aluminum-plastic film of the preset length. Load the feeder into the feeding mechanism and set the tension of the guide rollers to the standard tension for room temperature. Perform zero-point calibration on the pressure block displacement sensor and the punch force sensor; after the hydraulic oil temperature rises to the normal operating range, record the no-load output of the force sensor as the baseline pressure. ; S32. Switch the control mode to manual single-stroke while keeping the two-stage stroke parameters unchanged. After each feeding cycle, jog the punch to complete one full downward stroke; at the end of the pre-compression section... The force sensor output is captured in real time to record peak pressure. At least five consecutive cuts must be made within a three-second timeframe. S33, regarding the information obtained in step S32 Fill in the pressure test record sheet in order, arranged from highest to lowest; take the arithmetic mean of the three highest groups to obtain the reference pressure for this batch of pre-loading sections. The average of the remaining two groups is taken to obtain the initial low pressure value. ; S34. Adjust the stroke pressure knob in increments. Adjust downwards while maintaining the angle of travel. and feeding step distance Perform a single punching operation under unchanged conditions; if the cut edge is intact and without indentations, adjust the speed again. Repeat the punching process; if edge warping or interlayer loosening occurs, immediately revert to the previous pressure setting and record the peak value measured at that setting as the minimum sealing pressure. ; S35, apply the minimum sealing pressure The three membrane samples cut under the given conditions were numbered sequentially, removed, and examined. S36. The minimum sealing pressure verified in S35. The numerical input control system pressure setting page is set and read-only locking is enabled; simultaneously, a new entry is created in the production formula management module, binding the current two-stage stroke angle. and feeding pitch .

10. The adaptive cutting method for a staggered two-segment pre-compressed aluminum-plastic film according to claim 9, characterized in that, Step S4 includes: S41. Switch the sampling mode of the preload section force sensor to single-stroke trigger, so that the sensor detects the force when the punch reaches the preload end point. And stop at the moment of peak output; for this impulse sequence number and the current opening degree of the servo valve port Synchronous writing to the temporary storage area; using a fixed-length first-in-first-out queue. Item management: when the queue is full, the oldest record is overwritten in chronological order to ensure that the temporary storage area always reflects the most recent working conditions; S42, store the latest peak pressure in the temporary storage area. Minimum sealing pressure for curing in step S36 Perform a one-to-one difference operation and write the result to the deviation register: in, The unit is kN, representing the current pressure deviation; The unit is kN, representing the current peak pressure; The unit is kN, representing the minimum sealing pressure; Set tolerance window width ,like If so, the control panel will prompt you to hold and will directly jump to the next pulse monitoring; if If the valve port is not corrected, the sealing layer will be prevented from failing due to batch differences in the membrane material or temperature rise drift. S43, Display the deviation register as The number of times This was determined to be an underpressure surge; a boost command was immediately injected into the servo valve control word, causing the valve core to shift in the opening direction; to avoid excessive pressure replenishment at once causing instantaneous pressure on the diaphragm, a single-stage incremental method was used, amplifying only one single-stage opening increment. And calculate the new valve opening degree in real time: in, Indicates the valve opening degree before the next stroke; This indicates the valve opening at the end of the current stroke; Indicates the increment of single-level opening; This indicates the maximum opening degree allowed by the hydraulic station hardware; Complete the calculation, Along with the sequence number Write the parameters to the parameter stack and send update pulses to the hydraulic actuator; feed back the valve spool displacement to the target. A one-time matching verification is performed. Only after the verification passes can the punch interlock be released, allowing the next punch to proceed. S44, When the deviation register displays That is, the pressure is higher than At this time, the servo valve control command is set to valve-off mode; according to the same Decrease valve opening by step and write Pause the feeding cycle for half a beat to allow the system oil pressure to drop fully; S45. Update the valve opening. After writing to the hydraulic actuator register, the punch interlock is released and the next punching operation begins; the punch reaches the preload endpoint. At that time, the force sensor captured the peak pressure. The system then automatically completes the serial processing.

11. The adaptive cutting method for misaligned two-segment pre-compressed aluminum-plastic film according to claim 10, characterized in that, The serial processing in step S45 includes: S451, will OP sequence number and valve opening Write The queue is used to discard the oldest entry when it overflows. S452, Calculate the punch force deviation And then transfer to the deviation register; S453, Update the continuous stability counter The following formula can be used for recursion: in, This represents the cumulative number of strokes that have reached the tolerance window. This indicates the count value of the previous stroke; Indicates the first Pressure deviation during punching; Indicates the width of the tolerance window; when If necessary, jump to S42 to perform the next round of deviation judgment; If the counter is cleared, the system will return to S42 to start a new round of valve port correction. When continuous Second punching all showed If the cutting edge is visually inspected and shows no delamination or warping, adjust the current valve opening. Lock this as the final operating value for this batch and write a pressure stabilization marker into the production formula; if any subsequent stroke results in... It will automatically return to S42 to restart the valve port correction process to ensure that the seal quality remains under control throughout the entire mass production period.

12. The adaptive cutting method for misaligned two-segment pre-compressed aluminum-plastic film according to claim 1, characterized in that, Step S5 includes: S51. Set the pre-pressure stabilization signal as the starting condition for the roll feeder to unload the material, driving the roll feeder motor to keep the aluminum-plastic film under constant tension. The die passes through the guide roller and enters the feed roller; the spatial distance from the center of the die to the leading edge of the pressure block is measured and recorded using a photoelectric tool setting line detection method. In the Control Panel Edge allowance around the superimposed cutting edge The input is the theoretical step size. ; After completing the input, lock the tension controller and fix the position of the guide roller to establish the geometric reference for continuous feeding, and set the theoretical step distance in the task setting table. The record is set to the default value for the current model. S52, Regarding the theoretical step size After confirmation, the step distance signal is bound to the servo feed motor pulse counter, and a no-step test is performed using a single-stroke trigger method; the actual step distance obtained from the test is then... Perform visual size measurement, if Less than or equal to the allowable error Then immediately the corresponding pulse number The energy is stored in the counter; then the system switches to automatic mode, instructing the servo motor to press the button the instant each pressure block is lifted. Promote the use of aluminum-plastic film to achieve a smooth transition from intermittent feeding to continuous feeding; S53. When continuous feeding enters the stable operation stage, the angle output of the crank stroke encoder will be... Pulse feedback with servo feed motor Simultaneously, data is written to the comparison register to monitor the step distance maintenance between each stroke in real time; if the register calculates the step distance offset... Exceeding the threshold If this happens, the pulse will automatically pause for one beat, and a single-stage correction pulse will be applied to the counter. This ensures that the next stroke enters the preload zone in the correct position; once the correction is completed, the pause is lifted, and subsequent strokes are monitored.

13. The adaptive cutting method for misaligned two-segment pre-compressed aluminum-plastic film according to claim 1, characterized in that, Step S6 includes: S61. Fix the optical edge sensor to the side of the punching exit, and use the positioning fixture to fine-tune the probe focal length and tilt angle in micrometer increments so that the detection spot can completely cover the newly generated cutting edge; after completing the physical fixation, perform step-by-step amplification calibration on the sensor sensitivity knob, and when the cutting edge burr height reaches the preset reference, the sensor outputs a reference level. ; Will Write the quality comparison register of the controller as a reference value; Connect the sensor signal line to the high-speed acquisition port of the controller, and use the rising edge of the punching completion as the trigger condition in the program to ensure that a frame of the cut feature is captured immediately after each punching. S62, The controller acquires the current cutting level. The reference level cured in step S61 Perform a difference calculation and write it to a temporary storage register; use a counter to record the difference trend, and when the difference increases three consecutive times and exceeds the allowable threshold... When the speed control module is activated, a deceleration trigger bit is immediately written to it, and a prompt to start speed fine-tuning appears on the operation screen when the cutting edge deviation increases. If the difference does not exceed the threshold, the counter is reset and the current punching speed is maintained to avoid affecting the production cycle. S63. Map the received deceleration trigger bit to the frequency of the second servo drive. Decrease command; by fixed increment The frequency was lowered once, and the speed and pressure of the pre-compression section were locked to ensure that the sealing operation was not disturbed. After the speed adjustment was completed, the edge cutting level of the subsequent three strokes was monitored. If all return If the frequency falls within the specified range, a new frequency will be automatically frozen; if the frequency still exceeds the limit, it will be reduced again. Repeat the monitoring until the cutting edge quality returns to the target range; S64. When the cutting edge of 20 consecutive punches is stable within the target range and the feeding step distance is... When there is no offset, the current minimum sealing pressure will be used. The frequency of the corrected second-stage servo drive and stride Write the production formula for this model in read-only format; then start the automatic stacking mechanism so that the finished film sheets fall into the receiving box in sequence via vacuum suction cups.

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