An aluminum foil high-precision intelligent slitting method and device based on online tension and roll diameter cooperative control

Abstract

This invention relates to the field of aluminum foil slitting technology, and discloses a high-precision intelligent slitting method and device for aluminum foil based on online tension and roll diameter coordinated control. This invention aims to solve the problems of strip breakage, burrs at the cut, and winding defects caused by large tension fluctuations, lag in roll diameter calculation, and passive shearing in existing aluminum foil slitting technologies. This invention achieves high-precision digital control throughout the entire process, effectively eliminating the impact of system disturbances on ultra-thin aluminum foil, and significantly improving slitting speed, cut smoothness, and structural stability of the finished roll. Its core lies in constructing a precise tension model through laser scanning and inertia identification during the startup phase, and using a dual-loop strategy to achieve constant tension control under dynamic roll diameter during operation; innovatively introducing vacuum adsorption isolation technology to cut off tension coupling, and cooperating with high-speed active shearing by the cutter to optimize the edge cutting quality; the winding end adopts a tapered tension and flattening strategy with coordinated adjustment of roll diameter and speed.

Description

Technical Field

[0001] This invention relates to the field of aluminum foil slitting technology, and more specifically, to a high-precision intelligent slitting method and apparatus for aluminum foil based on online tension and roll diameter coordinated control. Background Technology

[0002] Aluminum foil, as an important industrial material, is widely used in high-end manufacturing fields such as current collectors for new energy batteries, electronic capacitors, high-barrier flexible packaging, and aerospace thermal insulation due to its excellent barrier properties, thermal conductivity, electromagnetic shielding, and lightweight characteristics. Especially in the power battery and precision electronics industries, ultra-thinness (such as double-zero foil and battery aluminum foil) has become the mainstream trend. These aluminum foils not only require extremely high thickness uniformity and surface cleanliness, but also have extremely stringent standards for maintaining mechanical properties during subsequent processing, making them an indispensable key link in the modern precision industrial chain.

[0003] However, in the slitting and rewinding process of aluminum foil production, existing slitting equipment generally faces the bottleneck of insufficient control precision. Because aluminum foil is extremely thin and has very low ductility, it is exceptionally sensitive to tension fluctuations. Traditional equipment, relying solely on sensor feedback or simple open-loop control, often struggles to cope with the nonlinear rotational inertia changes caused by variations in roll diameter. This can easily lead to the aluminum foil being instantly torn or undergoing irreversible plastic deformation during high-speed operation. Furthermore, existing passive mechanical shearing methods easily produce burrs, flanging, and even aluminum powder accumulation at the cut, severely affecting the electrochemical or sealing performance of downstream products. In the winding stage, relying solely on experience-based constant pressure or single taper control often fails to adapt to the aerodynamic effects of high-speed winding, resulting in quality defects such as air pockets, end-face misalignment, or internal stress collapse in the finished roll, making it difficult to meet the precision manufacturing requirements of high-end aluminum foil products. Summary of the Invention

[0004] In view of the aforementioned existing problems, the present invention is proposed.

[0005] Therefore, this invention provides a high-precision intelligent slitting method and device for aluminum foil based on online tension and roll diameter coordinated control, which solves the problems of strip breakage, cut burrs and winding defects caused by large tension fluctuations, lag in roll diameter calculation and passive shearing in existing aluminum foil slitting technologies.

[0006] To solve the above-mentioned technical problems, the present invention provides the following technical solution:

[0007] This invention provides a high-precision intelligent slitting method for aluminum foil based on online tension and roll diameter coordinated control, which includes the following steps:

[0008] S1: In response to the slitting start command, the initial geometric parameters of the aluminum master coil are obtained through the laser detection component, the drive motor performs a small-amplitude trial action to back-calculate the initial moment of inertia, a global tension control model is constructed based on the geometric parameters and the moment of inertia, and a static pre-tensioning operation is performed to eliminate aluminum foil slack.

[0009] S2: During the unwinding process, the traction line speed and motor angular velocity are continuously collected, the current dynamic winding diameter value is calculated cyclically, a feedforward torque command is generated based on the dynamic winding diameter value, and closed-loop correction is performed in combination with the online feedback data of the tension sensor to maintain constant tension output on the unwinding side.

[0010] S3: The output aluminum foil is introduced into the vacuum adsorption buffer unit. The negative pressure adsorption force locks the aluminum foil on the speed-stabilizing roller surface to isolate the tension fluctuations on the unwinding side and the winding side. In the isolated state, the slitting knife group is driven to perform active shearing on the aluminum foil at a preset overspeed synchronous ratio.

[0011] S4: Based on the continuously updated winding diameter, a nonlinear taper tension control strategy is executed to adjust the winding torque. According to the winding diameter and the current linear speed, the contact pressure of the flattening roller is dynamically adjusted in coordination to remove interlayer air until the task completion signal is detected.

[0012] As a preferred embodiment of the high-precision intelligent aluminum foil slitting method based on online tension and roll diameter coordinated control described in this invention, the process of back-calculating the initial moment of inertia in step S1 specifically includes:

[0013] The controller sends a set of test pulse commands containing acceleration and deceleration sections to the unwinding motor, driving the unwinding motor to perform reciprocating micro-motions of the aluminum master coil within a range that does not produce actual unwinding displacement; the output torque current value and the corresponding angular acceleration response value of the unwinding motor are collected at high frequency during the micro-motion process;

[0014] The collected torque current value is subtracted from the known no-load friction loss torque of the system to obtain the effective net torque for driving the load; the effective net torque is compared and analyzed with the angular acceleration response value, and the proportional coefficient between the two is extracted as the value of the initial rotational inertia of the current aluminum mother coil.

[0015] As a preferred embodiment of the high-precision intelligent aluminum foil slitting method based on online tension and roll diameter coordinated control described in this invention, the process of constructing the global tension control model in step S1 specifically includes:

[0016] The controller first reads the material property parameters of the aluminum foil, and combines the initial moment of inertia with the initial geometric parameters to establish a dynamic mapping table that associates the change in roll diameter, the decay of moment of inertia and the target tension. Based on the dynamic mapping table, an unwinding tension reference curve is generated that dynamically adjusts as the roll diameter decreases and sets the basic tension value that the unwinding motor should output at different roll diameter nodes.

[0017] The allowable range of tension deviation is determined based on the allowable tensile strength of the aluminum foil material and the precision requirements of the slitting process. The allowable range of tension deviation is defined as the error threshold band that triggers closed-loop feedback adjustment.

[0018] As a preferred embodiment of the high-precision intelligent aluminum foil slitting method based on online tension and roll diameter coordinated control described in this invention, the process of cyclically calculating the dynamic roll diameter value in step S2 specifically includes:

[0019] During the rotation of the unwinding shaft, the number of pulses fed back by the traction roller encoder and the number of pulses fed back by the unwinding motor encoder are synchronously accumulated within the time sampling period.

[0020] The number of pulses of the traction roller is converted into the linear displacement increment of the aluminum foil, and the number of pulses of the unwinding motor is converted into the angular displacement increment of the unwinding shaft; the ratio of the linear displacement increment to the angular displacement increment is calculated as the original value of the original roll diameter for the current sampling period.

[0021] The original roll diameter values ​​from multiple consecutive sampling periods are smoothed to remove abnormal data caused by aluminum foil fluctuations, resulting in an effective dynamic roll diameter value for control calculations.

[0022] As a preferred embodiment of the high-precision intelligent aluminum foil slitting method based on online tension and roll diameter coordinated control described in this invention, the process of generating feedforward torque commands and performing closed-loop correction in step S2 specifically includes:

[0023] Based on the real-time updated effective dynamic roll diameter value and the tension reference curve, the open-loop base torque required to overcome the current rotational inertia and mechanical friction is calculated and sent directly to the unwinding motor as a feedforward torque command; the actual tension value fed back by the tension sensor is monitored simultaneously, and the deviation between the actual tension value and the target tension value is calculated.

[0024] After detecting that the deviation exceeds the error threshold band, a compensation torque command is generated based on the magnitude and direction of the deviation; the compensation torque command is superimposed on the feedforward torque command, and the output torque of the unwinding motor is dynamically adjusted until the deviation returns to within the error threshold band.

[0025] As a preferred embodiment of the high-precision intelligent aluminum foil slitting method based on online tension and roll diameter coordinated control described in this invention, the process of isolating tension fluctuations using a vacuum adsorption buffer unit in step S3 specifically includes:

[0026] Activate the negative pressure generating device connected inside the buffer roller to detect the adsorption pressure value at the micropores on the roller surface;

[0027] After confirming that the adsorption pressure value has reached a locking threshold sufficient to overcome the tangential slip force of the aluminum foil, the aluminum foil is tightly adsorbed onto the surface of the buffer roller.

[0028] The rotational linear speed of the buffer roller is set as the main speed reference for the entire slitting system, which forces the aluminum foil input from the unwinding side and the aluminum foil output from the winding side to maintain speed synchronization when passing through the buffer roller. By setting a vacuum adsorption node, the transmission of tension fluctuations from the unwinding side to the winding side can be blocked.

[0029] As a preferred embodiment of the high-precision intelligent aluminum foil slitting method based on online tension and roll diameter coordinated control described in this invention, the process of driving the slitting blade group to perform active shearing in step S3 specifically includes:

[0030] Based on the linear speed of the aluminum foil passing through the buffer roller, the target linear speed of the slitting tool is calculated according to the preset overspeed ratio coefficient.

[0031] The slitting blade shaft drive motor is controlled to rotate continuously at the target linear velocity, so that the linear velocity of the cutting edge of the slitting blade is always higher than the moving speed of the aluminum foil throughout the entire shearing operation.

[0032] By utilizing the continuous speed difference, a tension effect is created on the aluminum foil in the shearing zone, so that the aluminum foil is cut under tension, avoiding tearing or folding of the cut edge due to material relaxation.

[0033] As a preferred embodiment of the high-precision intelligent aluminum foil slitting method based on online tension and roll diameter coordinated control described in this invention, the process of adjusting the contact pressure of the flattening roller in step S4 specifically includes:

[0034] During the winding process, the controller continuously monitors the current winding roll diameter and the aluminum foil travel line speed, and dynamically adjusts the opening of the pneumatic proportional valve according to the winding roll diameter and the travel line speed.

[0035] After detecting an increase in the winding diameter, the pneumatic proportional valve is driven to perform a pressure reduction action, so that the contact pressure of the flattening roller on the surface of the aluminum foil roll decreases non-linearly with the increase of the roll diameter, in order to avoid damaging the inner aluminum foil.

[0036] After detecting an increase in the travel line speed, the pneumatic proportional valve is driven to perform a pressure boosting compensation action, so that the contact pressure of the flattening roller increases accordingly with the increase in speed, in order to squeeze out the air that tries to enter the interlayer due to high-speed winding.

[0037] The controller superimposes pressure reduction adjustment based on roll diameter and pressure increase compensation based on speed in real time, and outputs the final pressure control command to ensure that the finished roll maintains consistent hardness throughout the process.

[0038] This invention also provides a high-precision intelligent aluminum foil slitting system based on online tension and roll diameter coordinated control, used to perform the above method, specifically including the following modules:

[0039] The physical parameter acquisition module is used to drive the laser detection component to scan the aluminum mother coil during the startup phase and acquire the initial geometric parameters;

[0040] The inertia dynamic identification module is used to control the unwinding motor to perform micro-motion tests and collect torque and acceleration data to calculate the initial moment of inertia.

[0041] The tension model construction module is used to establish a dynamic mapping table and reference curve relating the roll diameter and tension based on the initial geometric parameters and the moment of inertia.

[0042] The dynamic roll diameter calculation module is used to cyclically collect speed and position signals during unwinding operation, calculate and output the effective dynamic roll diameter value after filtering.

[0043] The dual-ring tension adjustment module is used to generate feedforward commands by combining the effective dynamic roll diameter value, and to generate closed-loop compensation commands using tension feedback to control the unwinding motor.

[0044] The vacuum adsorption isolation module is used to monitor the negative pressure status of the buffer unit and set the speed of the buffer roller as the system speed reference after establishing adsorption lock.

[0045] The synchronous active shearing module is used to calculate the target overspeed value based on the system speed reference and drive the slitting blade group to perform active stretching and shearing on the aluminum foil;

[0046] The taper tension generation module is used to control the output torque of the winding motor according to a non-linear decreasing strategy based on the real-time winding diameter;

[0047] The pressure compensation module is used to dynamically adjust the contact pressure of the flattening roller based on changes in the winding diameter and travel line speed.

[0048] This invention also provides a high-precision intelligent aluminum foil slitting device based on online tension and roll diameter coordinated control. This device slits aluminum foil using multiple rollers mounted on a base, performs the aforementioned method, and serves as a carrier for the aforementioned system. Specifically, it includes:

[0049] The slitting unit includes an unwinding roller, a traction roller, an adsorption roller, a slitting roller, and a take-up roller, which are fixedly installed on the top of the base in sequence. The adsorption roller has a cavity coaxially arranged inside, and an adsorption hole communicating with the cavity is opened on the surface of the adsorption roller. An air extraction pipe is arranged through the adsorption roller and coaxially with the cavity, and an air extraction pipe is provided on the air extraction pipe.

[0050] The detection unit includes a negative pressure sensor disposed on the top of the adsorption roller for detecting the adsorption intensity, a pressure-sensitive thin film capacitor integrated on the surface of the traction roller for measuring the pressure of the aluminum foil to calculate the tension, and an angle sensor for measuring the rotation angle of the roller body disposed at the shaft connection between the unwinding roller and the base.

[0051] Below the unwinding roller and on the base, a reference distance sensor for measuring the distance between the rollers and an unwinding distance sensor for measuring the distance between the aluminum master coils are fixedly installed. The diameter of the aluminum master coil can be obtained by subtracting the distance measurement results of the two and adding the roller radius.

[0052] Below the winding roller and on the base, a reference distance sensor for measuring the distance between the rollers and a winding distance sensor for measuring the distance between the slit aluminum coils are fixedly installed. The winding diameter of the slit aluminum coils can be obtained by subtracting the distance measurement results of the two sensors and adding the roller radius.

[0053] The beneficial effects of this invention are as follows: by using physical parameter measurement modeling, dynamic roll diameter real-time reconstruction, and feedforward and feedback dual-loop control strategies, the technical problems of aluminum foil being extremely thin, easily broken, and sensitive to tension fluctuations are solved. At the same time, by using vacuum adsorption isolation and high-speed active shearing technology, edge quality defects caused by traditional passive cutting are eliminated, achieving high precision, high efficiency, and high yield in aluminum foil cutting.

[0054] During startup, laser scanning and motor micro-motion inverse inertia calculations replace traditional estimation or manual input methods, ensuring the physical accuracy of the initial tension model and effectively preventing aluminum foil breakage or wrinkling due to model mismatch at startup. During operation, a dual-loop control strategy utilizes roll diameter feedforward to ensure rapid tension response and closed-loop correction to eliminate interference from material unevenness, achieving constant tension output across the entire speed range. In particular, the introduction of a vacuum adsorption buffer unit physically constructs a tension isolation wall, completely severing tension coupling interference between unwinding and rewinding. Combined with the active overspeed shearing of the slitting blade, the tensile effect generated by a slight speed difference ensures smooth, burr-free cut edges. Furthermore, the dual-dimensional coordinated flattening control of roll diameter and speed during rewinding dynamically adjusts the contact pressure according to the roll diameter and rotation speed, ensuring a tight core while effectively eliminating high-speed air intake, preventing air pockets and uneven end faces, and significantly improving the rewinding quality of the finished aluminum foil roll. Attached Figure Description

[0055] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the following description of the embodiments will be briefly introduced. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0056] Figure 1 This is a flowchart of a high-precision intelligent slitting method for aluminum foil based on online tension and roll diameter coordinated control.

[0057] Figure 2 To initialize and refine the flowchart.

[0058] Figure 3 A detailed flowchart for dual-loop control.

[0059] Figure 4 This is a data flow diagram for system modules.

[0060] Figure 5 This is an overall diagram of a high-precision intelligent aluminum foil slitting device based on online tension and roll diameter coordinated control.

[0061] Figure 6 This is a rear view of a high-precision intelligent aluminum foil slitting device based on online tension and roll diameter coordinated control.

[0062] Figure 7 This is a cross-sectional view of the adsorption roller. Detailed Implementation

[0063] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

[0064] Many specific details are set forth in the following description in order to provide a full understanding of the invention. However, the invention may also be practiced in other ways different from those described herein, and those skilled in the art can make similar extensions without departing from the spirit of the invention. Therefore, the invention is not limited to the specific embodiments disclosed below.

[0065] Secondly, the term "one embodiment" or "example" as used herein refers to a specific feature, structure, or characteristic that may be included in at least one implementation of the invention. The appearance of an embodiment in different places in this specification does not necessarily refer to the same embodiment, nor is it a single or selective embodiment that mutually excludes other embodiments.

[0066] Example 1

[0067] Reference Figures 1-3This is one embodiment of the present invention, which provides a high-precision intelligent slitting method for aluminum foil based on online tension and roll diameter coordinated control, including the following steps:

[0068] S1. In response to the slitting start command, the initial geometric parameters of the aluminum master coil are obtained through the laser detection component. The drive motor performs a micro-amplitude trial action to back-calculate the initial moment of inertia. Based on the geometric parameters and the moment of inertia, a global tension control model is constructed, and a static pre-tensioning operation is performed to eliminate aluminum foil slack.

[0069] The initial moment of inertia is calculated in reverse. The controller sends a set of test pulse commands containing acceleration and deceleration sections to the unwinding motor, driving the unwinding motor to perform reciprocating micro-motion within a range that does not produce actual unwinding displacement. The output torque current value and the corresponding angular acceleration response value of the unwinding motor are collected at high frequency during the micro-motion process.

[0070] Subtract the known no-load friction loss torque from the collected torque current value to obtain the effective net torque for driving the load; compare and analyze the effective net torque with the angular acceleration response value, and extract the proportional coefficient between the two as the value of the initial rotational inertia of the current aluminum mother coil.

[0071] A global tension control model is constructed. The controller first reads the material property parameters of the aluminum foil and, combined with the initial moment of inertia and the initial geometric parameters, establishes a dynamic mapping table that associates the change in roll diameter, the decay of moment of inertia, and the target tension. Based on the dynamic mapping table, an unwinding tension reference curve is generated that dynamically adjusts as the roll diameter decreases and sets the basic tension value that the unwinding motor should output at different roll diameter nodes.

[0072] The allowable range of tension deviation is determined based on the allowable tensile strength of the aluminum foil material and the precision requirements of the slitting process. The allowable range of tension deviation is defined as the error threshold band that triggers closed-loop feedback adjustment.

[0073] Upon receiving the slitting start command, a laser rangefinder sensor installed at a fixed position on the unwinding frame emits a measuring beam towards the surface of the stationary aluminum master coil and the surface of the roller, reading the straight-line distance from the sensor probe to the surface of the aluminum master coil and the surface of the roller. Subtracting the two values ​​yields the actual thickness of the aluminum coil, and adding the pre-stored roller radius gives the current physical radius value of the aluminum master coil, which serves as the starting base for subsequent coil diameter calculations.

[0074] The controller sends a very short-duration, constant-amplitude drive torque command to the unwinding motor, driving the aluminum master coil to produce a small, strictly limited angular acceleration motion that does not produce an effective unwinding displacement. During this period, the controller calculates the rate of change of the aluminum master coil's rotational speed per unit time, i.e., angular acceleration, by acquiring the pulse signal fed back by the motor encoder. Simultaneously, it reads the actual current value output by the motor driver at this moment and converts it into electromagnetic torque. Subtracting the inherent mechanical friction torque measured and stored by the system under no-load conditions from this electromagnetic torque, the net drive torque actually acting on the aluminum master coil to overcome inertia is obtained. The ratio of the net drive torque to the measured angular acceleration is calculated as the current initial moment of inertia of the aluminum master coil.

[0075]

[0076] in, This represents the initial moment of inertia of the aluminum mother coil; This represents the electromagnetic torque output by the motor driver; This represents the inherent mechanical friction torque of the system under no-load conditions; This indicates the angular acceleration generated by the aluminum mother coil during the measurement.

[0077] The controller reads the pre-stored aluminum foil material density and width parameters, and combines them with the measured initial radius and initial moment of inertia to derive the numerical correspondence between the change in roll diameter and the decrease in the total moment of inertia of the system. Based on this correspondence, the theoretical basic torque required by the unwinding motor to maintain constant tension at each roll diameter node is pre-calculated as the roll diameter gradually decreases from the current initial value to the core diameter. This series of corresponding torque value points is then linked into an unwinding tension reference curve that varies with the roll diameter.

[0078] Based on the allowable tensile strength of the aluminum foil material and the precision requirements of the slitting process, a fixed numerical range is set above and below the target value of the unwinding tension reference curve as an error threshold band. This threshold band will serve as the logical criterion for determining whether to intervene in the feedback adjustment mechanism based on the deviation ratio, integral and derivative during subsequent operation. Subsequently, the controller drives the unwinding motor and the winding motor to work together to slowly apply tension to tighten the aluminum foil. When the value fed back by the tension sensor rises to the target value and remains stably within the error threshold band within the preset time window, it is determined that the pre-tensioning is completed and the aluminum foil slack is eliminated.

[0079] S2. During the unwinding process, the traction line speed and motor angular velocity are continuously collected, the current dynamic winding diameter value is calculated cyclically, a feedforward torque command is generated based on the dynamic winding diameter value, and closed-loop correction is performed in combination with the online feedback data of the tension sensor to maintain constant tension output on the unwinding side.

[0080] The dynamic roll diameter value is calculated cyclically, and the number of pulses fed back by the traction roller encoder and the number of pulses fed back by the unwinding motor encoder are synchronously accumulated within the time sampling period during the rotation of the unwinding shaft.

[0081] The number of pulses of the traction roller is converted into the linear displacement increment of the aluminum foil, and the number of pulses of the unwinding motor is converted into the angular displacement increment of the unwinding shaft; the ratio of the linear displacement increment to the angular displacement increment is calculated as the original value of the original roll diameter for the current sampling period.

[0082] The original roll diameter values ​​of multiple consecutive sampling periods are smoothed to remove abnormal data caused by aluminum foil jumping, and the effective dynamic roll diameter value used for control calculation is obtained.

[0083] A feedforward torque command is generated and closed-loop correction is performed. Based on the real-time updated effective dynamic roll diameter value and the tension reference curve, the open-loop base torque required to overcome the current rotational inertia and mechanical friction is calculated and sent directly to the unwinding motor as a feedforward torque command. The actual tension value fed back by the tension sensor is monitored simultaneously, and the deviation between the actual tension value and the target tension value is calculated.

[0084] After detecting that the deviation exceeds the error threshold band, a compensation torque command is generated based on the magnitude and direction of the deviation; the compensation torque command is superimposed on the feedforward torque command, and the output torque of the unwinding motor is dynamically adjusted until the deviation returns to within the error threshold band.

[0085] As the slitting process begins, the diameter of the aluminum coil gradually decreases as material is continuously output, which means that the physical properties of the system are constantly changing.

[0086] A very short time window is set as the sampling period during the continuous rotation of the unwinding shaft. At the end of each such period, the controller reads the cumulative number of pulses from the traction roller encoder and the cumulative number of pulses from the unwinding motor encoder.

[0087] Using the known diameter parameters of the traction roller, the number of pulses on the traction roller is converted into the actual length traveled by the aluminum foil during this time, i.e., the linear displacement increment; the number of pulses on the unwinding motor is converted into the angle rotated by the unwinding shaft, i.e., the angular displacement increment. By calculating the ratio of these two increments, the actual radius of the aluminum master coil under the current condition can be calculated.

[0088]

[0089] in, This represents the instantaneous roll diameter at the current sampling moment; This represents the linear displacement increment within the sampling period; This represents the increment of angular displacement within the sampling period; This indicates the cumulative number of pulses from the traction roller encoder. Indicates the diameter of the traction roller; Indicates the resolution (number of lines) of the traction roller encoder. This indicates the cumulative number of pulses from the unwinding motor encoder. This indicates the resolution of the unwinding motor encoder.

[0090] To prevent the calculated value from fluctuating due to equipment vibration or minor unevenness on the aluminum foil surface, it is necessary to combine several consecutive calculated values, remove the largest and smallest values, and take the average value in the middle to obtain a smooth, stable, and effective dynamic roll diameter value. This value will serve as the core basis for subsequent control.

[0091] After calculating the real-time updated effective dynamic roll diameter, the system immediately consults the previously established tension model. Based on the current roll diameter, it calculates the remaining inertia of the aluminum master roll at this moment. Combining this with the current rotational speed and friction, it calculates the theoretical force the motor should exert to maintain tension. This calculated force is then sent directly to the unwinding motor as a feedforward torque command, ensuring that the tension is generally accurate under conditions of no interference.

[0092] However, interference always occurs in actual production (such as slight variations in aluminum foil thickness). Therefore, it is necessary to monitor the real-time data transmitted by the tension sensor and continuously calculate the difference between the actual tension and the target tension. If this difference is within the set error threshold range, no further intervention is required. Once the difference is found to have exceeded this range, closed-loop correction needs to be initiated. Based on the magnitude and direction of the difference, a compensation torque is calculated. This compensation torque is then directly added to the theoretical force, causing the motor to exert more or less force until the tension is pulled back within the error threshold range.

[0093] S3. The output aluminum foil is introduced into the vacuum adsorption buffer unit. The negative pressure adsorption force locks the aluminum foil on the speed-stabilizing roller surface to isolate the tension fluctuations on the unwinding side and the winding side. In the isolated state, the slitting knife group is driven to perform active shearing on the aluminum foil at a preset overspeed synchronization ratio.

[0094] The vacuum adsorption buffer unit is used to isolate tension fluctuations, and the negative pressure generating device connected inside the buffer roller is activated to detect the adsorption pressure value at the micropores on the roller surface.

[0095] After confirming that the adsorption pressure value has reached a locking threshold sufficient to overcome the tangential slip force of the aluminum foil, the aluminum foil is tightly adsorbed onto the surface of the buffer roller.

[0096] The rotational linear speed of the buffer roller is set as the main speed reference of the entire slitting system, which forces the aluminum foil input on the unwinding side and the aluminum foil output on the winding side to maintain speed synchronization when passing through the buffer roller. By setting a vacuum adsorption node, the transmission of tension fluctuations on the unwinding side to the winding side can be blocked.

[0097] The drive slitting blade assembly performs active shearing. Based on the linear speed of the aluminum foil passing through the buffer roller, the target linear speed of the slitting blade is calculated according to the preset overspeed ratio coefficient.

[0098] The slitting blade shaft drive motor is controlled to rotate continuously at the target linear velocity, so that the linear velocity of the cutting edge of the slitting blade is always higher than the moving speed of the aluminum foil throughout the entire shearing operation.

[0099] By utilizing the continuous speed difference, a tension effect is created on the aluminum foil in the shearing zone, so that the aluminum foil is cut under tension, avoiding tearing or folding of the cut edge due to material relaxation.

[0100] In this process, after the aluminum foil is output from the unwinding side at a constant tension, it must first pass through a crucial stage of tension isolation and speed synchronization before entering the precision slitting area. A high-pressure centrifugal fan or vacuum pump connected to the internal air passage of the vacuum adsorption buffer roller is activated, rapidly establishing a negative pressure environment within the roller's internal chamber. The precision micropores distributed on the roller surface generate a strong centripetal adsorption force under the pressure difference. A pressure sensor monitors the adsorption pressure at the micropores in real time and compares it to a preset locking threshold. This locking threshold is calculated based on the aluminum foil's coefficient of friction and maximum operating tension, aiming to ensure that the adsorption force is sufficient to completely overcome the tendency for the aluminum foil to slide relative to the roller surface or tangentially shift.

[0101] When the monitored adsorption pressure value stably exceeds the locking threshold, the aluminum foil is firmly locked onto the surface of the buffer roller. At this point, the movement of the aluminum foil is no longer affected by tension fluctuations on the unwinding side, but is completely controlled by the physical rotation of the buffer roller. Then, all other axes in the entire production line (including traction, slitting, and winding) must follow the real-time rotational speed of this buffer roller. This forced synchronization mechanism based on physical adsorption prevents any residual tension fluctuations on the unwinding side from being transmitted to the high-precision slitting area, ensuring absolute smoothness when the aluminum foil enters the cutting edge.

[0102] Under the premise of ensuring absolute stability and no micro-vibration in the aluminum foil feed speed, the travel line speed of the buffer roller, which serves as the main reference, is collected in real time, and a preset overspeed ratio coefficient greater than 1 is introduced (usually set between 1.03 and 1.05). The controller multiplies the current travel line speed by this coefficient to calculate the target line speed that the slitting tool should theoretically possess.

[0103] Then, a speed command is sent to the servo motor that independently drives the slitting cutter axis, controlling the axis to rotate continuously at the target linear velocity. This ensures that the cutting edge of the slitting cutter maintains a slightly higher linear velocity than the aluminum foil itself when it contacts and cuts into the foil. This persistent speed difference creates an additional pulling force along the direction of travel on the aluminum foil in front of the shear point at a microscopic level, forming a localized tension effect. Under this tension, the aluminum foil is cleanly and crisply cut, effectively overcoming the stretching and springback that easily occur when extremely thin aluminum foil is subjected to force. This avoids quality defects such as tearing at the cut, edge curling, and aluminum powder accumulation caused by material relaxation or speed lag.

[0104] S4. Based on the continuously updated winding diameter, a nonlinear taper tension control strategy is executed to adjust the winding torque. According to the winding diameter and the current linear speed, the contact pressure of the flattening roller is dynamically adjusted in coordination to remove interlayer air until the task completion signal is detected.

[0105] Adjusting the contact pressure of the flattening roller, during the winding process, the controller continuously monitors the current winding roll diameter and aluminum foil travel line speed, and dynamically adjusts the opening of the pneumatic proportional valve according to the winding roll diameter and travel line speed.

[0106] After detecting an increase in the winding diameter, the pneumatic proportional valve is driven to perform a pressure reduction action, so that the contact pressure of the flattening roller on the surface of the aluminum foil roll decreases non-linearly with the increase of the roll diameter, in order to avoid damaging the inner aluminum foil.

[0107] After detecting an increase in the travel line speed, the pneumatic proportional valve is driven to perform a pressure boosting compensation action, so that the contact pressure of the flattening roller increases accordingly with the increase in speed, in order to squeeze out the air that tries to enter the interlayer due to high-speed winding.

[0108] The controller superimposes pressure reduction adjustment based on roll diameter and pressure increase compensation based on speed in real time, and outputs the final pressure control command to ensure that the finished roll maintains consistent hardness throughout the process.

[0109] The narrow aluminum foil after slitting enters the final winding and forming stage. The control objective of this stage is to construct a finished roll material with a stable structure and no internal stress damage during the dynamic process of continuously increasing roll diameter.

[0110] As the number of aluminum foil layers on the winding shaft increases, the roll diameter continues to grow. If a constant winding tension is maintained, the taut outer aluminum foil will exert enormous radial pressure on the inner layer, causing the inner foil to wrinkle and even deforming the core (commonly known as the "vegetable heart phenomenon"). The controller calculates the current winding diameter in real time and inputs it into a preset nonlinear attenuation model. This model stipulates that as the roll diameter increases, the torque output by the winding motor does not increase nonlinearly, but rather gradually decreases its unit tension value according to a specific curvature. This control method ensures an ideal stress distribution of tight inside and loose outside in the finished roll, guaranteeing the core's compactness while preventing excessive compression of the inner layer by the outer layer.

[0111]

[0112] in, Indicates the current volume diameter The target winding tension is below; This indicates the initial winding tension set. This represents the tension reduction rate coefficient (usually ranging from 0.1 to 0.3). Indicates the diameter of the winding core; This indicates the maximum winding diameter.

[0113] While controlling the tension, it is also necessary to coordinate the adjustment of the contact pressure of the flattening roller to solve the air entrainment problem during high-speed winding. Adjusting the contact pressure of the flattening roller is a dynamic balancing process affected by two variables. The controller needs to continuously monitor the current winding diameter and the linear speed of the aluminum foil, and adjust the opening of the pneumatic proportional valve connected to the flattening roller cylinder in real time based on these two parameters.

[0114] As the winding diameter gradually increases over time, the controller drives the pneumatic proportional valve to perform a pressure reduction action, causing the contact pressure applied by the flattening roller to the surface of the aluminum foil roll to decrease non-linearly with the increase of the roll diameter. This logic corresponds to the taper tension control, preventing the pressure from the flattening roller combined with the winding tension from causing excessive internal stress in the roll material as the roll diameter increases, which could damage the aluminum foil surface or cause interlayer adhesion.

[0115] When the production line speed is increased, the high-speed airflow forms an air film on the aluminum foil surface, attempting to be drawn into the interlayer to form air pockets or cause the coil to deviate. To counteract this air buoyancy effect, the controller drives the pneumatic proportional valve to perform a pressure compensation action, so that the contact pressure of the flattening roller increases accordingly with the speed, using greater mechanical pressure to force out the air attempting to enter the interlayer.

[0116] The controller performs real-time superposition calculations of the pressure reduction adjustment calculated based on the roll diameter and the pressure increase compensation calculated based on the speed, and outputs the final pressure control command.

[0117]

[0118] in, This indicates the final contact pressure command value for the flattening roller; Indicates the initial base pressure; This represents the pressure attenuation coefficient based on the roll diameter; This is the current winding diameter; Indicates the diameter of the winding core; This represents the pressure compensation coefficient based on linear velocity; This represents the current aluminum foil travel line speed.

[0119] Throughout the entire winding process, the drive flattening roller adheres to the surface of the roll material with optimal pressure, ensuring that the finished roll maintains uniform hardness and a flat end face regardless of the roll diameter or speed, until the set roll length or diameter is detected to have reached the target value, at which point a task completion signal is issued.

[0120] Example 2

[0121] Reference Figure 1 and Figure 4 These are two embodiments of the present invention. This embodiment provides a high-precision intelligent slitting system for aluminum foil based on online tension and roll diameter coordinated control. This system is typically deployed on a high-performance computing server to execute the steps described in Embodiment 1.

[0122] The system's software architecture consists of a set of highly collaborative functional modules, specifically including:

[0123] The physical parameter acquisition module is used to drive the laser detection component to scan the aluminum mother coil during the startup phase and acquire the initial geometric parameters;

[0124] The inertia dynamic identification module is used to control the unwinding motor to perform micro-motion tests and collect torque and acceleration data to calculate the initial moment of inertia.

[0125] The tension model construction module is used to establish a dynamic mapping table and reference curve relating the roll diameter and tension based on the initial geometric parameters and the moment of inertia.

[0126] The dynamic roll diameter calculation module is used to cyclically collect speed and position signals during unwinding operation, calculate and output the effective dynamic roll diameter value after filtering.

[0127] The dual-ring tension adjustment module is used to generate feedforward commands by combining the effective dynamic roll diameter value, and to generate closed-loop compensation commands using tension feedback to control the unwinding motor.

[0128] The vacuum adsorption isolation module is used to monitor the negative pressure status of the buffer unit and set the speed of the buffer roller as the system speed reference after establishing adsorption lock.

[0129] The synchronous active shearing module is used to calculate the target overspeed value based on the system speed reference and drive the slitting blade group to perform active stretching and shearing on the aluminum foil;

[0130] The taper tension generation module is used to control the output torque of the winding motor according to a non-linear decreasing strategy based on the real-time winding diameter;

[0131] The pressure compensation module is used to dynamically adjust the contact pressure of the flattening roller based on changes in the winding diameter and travel line speed.

[0132] During system startup, the physical parameter acquisition module drives a laser rangefinder to measure the distance to a stationary aluminum master coil, obtaining a precise initial physical radius through geometric calculation. Next, the inertia dynamic identification module controls the unwinding motor to perform a micro-torque excitation test, collecting angular acceleration and current torque data during the micro-motion process, and using dynamic principles to calculate the system's initial rotational inertia. Based on these two measured physical benchmarks, the tension model construction module establishes a dynamic mapping table relating coil diameter changes, inertia decay, and target tension, and generates a complete unwinding tension benchmark curve, laying the data foundation for subsequent control.

[0133] Once in operation, the dynamic roll diameter calculation module periodically collects the linear displacement of the traction roller and the angular displacement of the unwinding motor at high frequency. Through comparison, calculation, and filtering, it outputs a smooth and effective dynamic roll diameter value in real time. This value is sent to the dual-loop tension adjustment module to generate an open-loop feedforward torque command by looking up a table. Simultaneously, this module also monitors the feedback deviation of the tension sensor in real time and generates a closed-loop compensation command by adjusting the proportional, integral, and derivative values ​​based on the deviation. The feedforward and feedback commands are then superimposed to drive the unwinding motor, maintaining a constant tension output.

[0134] During the slitting process, the vacuum adsorption isolation module monitors the negative pressure state of the buffer roller in real time. Once a stable adsorption lock is established, the speed of the buffer roller is set as the main speed reference for the entire line, physically blocking the transmission of tension fluctuations. The synchronous active shearing module follows this speed reference, calculates and drives the slitting blade assembly to rotate at a slightly overspeed, actively stretching and shearing the aluminum foil to ensure a clean cut.

[0135] Finally, at the take-up end, the taper tension generation module executes a non-linear decreasing strategy based on the real-time increase in the take-up roll diameter to adjust the output torque of the take-up motor, preventing the inner layers from deforming under pressure. Simultaneously, the pressure coordination compensation module comprehensively considers the dual effects of increased roll diameter and speed, dynamically calculates and outputs pressure commands to adjust the pneumatic proportional valve, controlling the flattening roller to always adhere to the roll material with optimal pressure, effectively eliminating interlayer air and ensuring the hardness and flatness of the finished roll.

[0136] Example 3

[0137] Reference Figure 5 and Figure 7 These are three embodiments of the present invention. This embodiment provides a high-precision intelligent aluminum foil slitting device based on online tension and roll diameter coordinated control. The device slits aluminum foil 302 by multiple rollers installed on the base 301. The device is used to execute the method described in Embodiment 1 and serves as the slitting carrier of the system described in Embodiment 2.

[0138] Specifically, it includes:

[0139] The slitting unit 100 includes an unwinding roller 101, a traction roller 102, an adsorption roller 103, a slitting roller 104, and a take-up roller 105, which are sequentially fixedly installed on the top of the base 301. The adsorption roller 103 has a coaxially arranged cavity 106 inside, and an adsorption hole 107 communicating with the cavity 106 is opened on the surface of the adsorption roller 103. An air extraction pipe 108 is arranged through the adsorption roller 103 and coaxially with the cavity 106, and an air extraction pipe 109 is provided on the air extraction pipe 108.

[0140] The detection unit 200 includes a negative pressure sensor 201 disposed on the top of the adsorption roller 103 for detecting the adsorption intensity, a pressure-sensitive thin film capacitor 202 integrated on the surface of the traction roller 102 for measuring the pressure of the aluminum foil 302 to calculate the tension, and an angle sensor 203 for measuring the rotation angle of the roller body disposed at the shaft connection between the unwinding roller 101 and the base 301.

[0141] Below the unwinding roller 101 and on the base 301, a reference distance measuring sensor 204a for measuring the distance between the rollers and an unwinding distance measuring sensor 204b for measuring the distance between the aluminum master coils are fixedly installed. The diameter of the aluminum master coil can be obtained by subtracting the distance measurement results of the two and adding the roller radius.

[0142] Below the take-up roller 105 and on the base 301, a reference distance sensor 204a for measuring the distance between the rollers and a take-up distance sensor 204c for measuring the distance between the slit aluminum coils are fixedly installed. The take-up diameter of the slit aluminum coils can be obtained by subtracting the distance measurement results of the two sensors and adding the roller radius.

[0143] The unwinding roller 101 is rotatably mounted on top of the base 301, and a high-precision angle sensor 203 is integrated at its shaft joint for real-time feedback of the rotation angle and angular velocity of the unwinding shaft. To obtain the initial roll diameter, a set of differential ranging components is installed on the base 301 below the unwinding roller 101. One is a reference ranging sensor 204a that directly measures the distance to the unwinding roller itself, and the other is an unwinding ranging sensor 204b that measures the distance to the surface of the aluminum master coil. Upon startup, by subtracting the distance measurements from the two sensors and adding the known roller radius, the initial physical roll diameter of the aluminum master coil, eliminating installation errors, can be calculated.

[0144] After being drawn out from the unwinding roller 101, the aluminum foil 302 first passes through the traction roller 102. The pressure-sensitive film capacitor 202 integrated on its surface can directly sense the contact pressure of the aluminum foil 302 against the roller surface, thereby calculating the online tension value of the aluminum foil 302 in real time, providing a sensitive feedback signal for dual-loop control. Subsequently, the aluminum foil 302 adheres tightly to the adsorption roller 103. Its interior is designed with a hollow containment cavity 106, and its surface is densely covered with adsorption holes 107 connecting to this cavity. A coaxially penetrating suction pipe 108, in conjunction with the installed suction pipe 109, establishes a negative pressure environment inside the pipe body through a negative pressure generating device. The negative pressure sensor 201 located at the top of the adsorption roller 103 monitors the adsorption intensity in real time. Once a locked state is confirmed, the adsorption roller 103 uses a strong air pressure difference to firmly adsorb the aluminum foil 302, not only establishing the system's speed benchmark but also physically isolating tension fluctuations on the unwinding side.

[0145] The aluminum foil 302, after being stably isolated, is fed into the slitting roller 104. Driven by an independent motor, this roller assembly actively stretches and shears the aluminum foil 302 at a slight overspeed. The slit strips of narrow aluminum foil eventually reach the winding roller 105. To precisely control the quality of the coil, a range measuring assembly is also configured below the winding roller 105, consisting of a reference range measuring sensor 204a and a winding range measuring sensor 204c. These two work together to monitor the change in diameter of the aluminum coil after slitting (i.e., the winding diameter) in real time. Based on this real-time diameter data, the system can not only perform taper tension control but also coordinate the adjustment of the pneumatic flattening roller located above the winding roller, dynamically changing its contact pressure. This ensures the compactness and end-face flatness of the finished coil as the diameter increases.

[0146] Preferably, the ranging sensor can be a commercially available laser triangulation sensor, spectral confocal displacement sensor, or laser phase ranging sensor.

[0147] Preferably, the negative pressure sensor can be a commercially available silicon piezoresistive negative pressure sensor, a ceramic capacitive negative pressure sensor, or a diffused silicon negative pressure transmitter.

[0148] Preferably, the angle sensor can be of models such as IP54 BRT50, WDD35D4, and EL-WDA.

[0149] In summary, this invention solves the technical challenges of extremely thin and easily broken aluminum foil and its sensitivity to tension fluctuations by using physical parameter measurement modeling, dynamic roll diameter real-time reconstruction, and a dual-loop control strategy of feedforward and feedback. At the same time, it eliminates edge quality defects caused by traditional passive cutting by using vacuum adsorption isolation and high-speed active shearing technology, thus achieving high precision, high efficiency, and high yield in aluminum foil cutting.

[0150] During startup, laser scanning and motor micro-motion inverse inertia calculations replace traditional estimation or manual input methods, ensuring the physical accuracy of the initial tension model and effectively preventing aluminum foil breakage or wrinkling due to model mismatch at startup. During operation, a dual-loop control strategy utilizes roll diameter feedforward to ensure rapid tension response and closed-loop correction to eliminate interference from material unevenness, achieving constant tension output across the entire speed range. In particular, the introduction of a vacuum adsorption buffer unit physically constructs a tension isolation wall, completely severing tension coupling interference between unwinding and rewinding. Combined with the active overspeed shearing of the slitting blade, the tensile effect generated by a slight speed difference ensures smooth, burr-free cut edges. Furthermore, the dual-dimensional coordinated flattening control of roll diameter and speed during rewinding dynamically adjusts the contact pressure according to the roll diameter and rotation speed, ensuring a tight core while effectively eliminating high-speed air intake, preventing air pockets and uneven end faces, and significantly improving the rewinding quality of the finished aluminum foil roll.

[0151] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A high-precision intelligent slitting method for aluminum foil based on online tension and roll diameter coordinated control, characterized in that, Performed by the controller, the process includes the following steps: S1: In response to the slitting start command, the initial geometric parameters of the aluminum master coil are obtained through the laser detection component, the drive motor performs a micro-amplitude exploratory action to back-calculate the initial moment of inertia, a global tension control model is constructed based on the initial geometric parameters and the initial moment of inertia, and a static pre-tensioning operation is performed to eliminate aluminum foil slack. S2: During the unwinding process, the traction line speed and motor angular velocity are continuously collected, the current dynamic winding diameter value is calculated cyclically, a feedforward torque command is generated based on the dynamic winding diameter value, and closed-loop correction is performed in combination with the online feedback data of the tension sensor to maintain constant tension output on the unwinding side. S3: The output aluminum foil is introduced into the vacuum adsorption buffer unit. The negative pressure adsorption force locks the aluminum foil on the speed-stabilizing roller surface to isolate the tension fluctuations on the unwinding side and the winding side. In the isolated state, the slitting knife group is driven to perform active shearing on the aluminum foil at a preset overspeed synchronous ratio. S4: Based on the continuously updated winding diameter, a nonlinear taper tension control strategy is executed to adjust the winding torque. According to the winding diameter and the traction line speed, the contact pressure of the flattening roller is dynamically adjusted in coordination to remove interlayer air until the task completion signal is detected. The process of back-calculating the initial moment of inertia in step S1 specifically includes: The controller sends a set of test pulse commands containing acceleration and deceleration sections to the unwinding motor, driving the unwinding motor to perform reciprocating micro-motions of the aluminum master coil within a range that does not produce actual unwinding displacement; the output torque current value and the corresponding angular acceleration response value of the unwinding motor are collected at high frequency during the micro-motion process; Subtract the known no-load friction loss torque from the collected torque current value to obtain the effective net torque for driving the load; compare and analyze the effective net torque with the angular acceleration response value, and extract the proportional coefficient between the two as the value of the initial rotational inertia of the current aluminum mother coil. The process of constructing the global tension control model in step S1 specifically includes: The controller first reads the material property parameters of the aluminum foil, and combines the initial moment of inertia with the initial geometric parameters to establish a dynamic mapping table that associates the change in roll diameter, the decay of moment of inertia and the target tension value. Based on the dynamic mapping table, an unwinding tension reference curve is generated that dynamically adjusts as the roll diameter decreases and sets the basic tension value that the unwinding motor should output at different roll diameter nodes. The allowable range of tension deviation is determined based on the allowable tensile strength of aluminum foil material and the precision requirements of the slitting process. The allowable range of tension deviation is defined as the error threshold band that triggers closed-loop feedback adjustment. The process of iteratively calculating the dynamic roll diameter value in step S2 specifically includes: During the rotation of the unwinding shaft, the number of pulses fed back by the traction roller encoder and the number of pulses fed back by the unwinding motor encoder are synchronously accumulated within the time sampling period. The number of pulses of the traction roller is converted into the linear displacement increment of the aluminum foil, and the number of pulses of the unwinding motor is converted into the angular displacement increment of the unwinding shaft; the ratio of the linear displacement increment to the angular displacement increment is calculated as the original roll diameter value of the current sampling period. The original roll diameter values ​​of multiple consecutive sampling periods are smoothed to remove abnormal data caused by aluminum foil jumping, and the effective dynamic roll diameter value used for control calculation is obtained. The process of isolating tension fluctuations using a vacuum adsorption buffer unit in step S3 specifically includes: Activate the negative pressure generating device connected inside the buffer roller to detect the adsorption pressure value at the micropores on the roller surface; After confirming that the adsorption pressure value has reached a locking threshold sufficient to overcome the tangential slip force of the aluminum foil, the aluminum foil is tightly adsorbed onto the surface of the buffer roller. The rotational linear speed of the buffer roller is set as the main speed reference for the entire slitting system, which forces the aluminum foil input from the unwinding side and the aluminum foil output from the winding side to maintain speed synchronization when passing through the buffer roller. By setting a vacuum adsorption node, the transmission of tension fluctuations from the unwinding side to the winding side can be blocked.

2. The high-precision intelligent aluminum foil slitting method based on online tension and roll diameter coordinated control according to claim 1, characterized in that, The process of generating the feedforward torque command and performing closed-loop correction in step S2 specifically includes: Based on the real-time updated effective dynamic roll diameter value and the unwinding tension reference curve, the open-loop base torque required to overcome the current rotational inertia and mechanical friction is calculated and sent directly to the unwinding motor as a feedforward torque command; the actual tension value fed back by the tension sensor is monitored simultaneously, and the deviation between the actual tension value and the target tension value is calculated. After detecting that the deviation exceeds the error threshold band, a compensation torque command is generated based on the magnitude and direction of the deviation; the compensation torque command is superimposed on the feedforward torque command, and the output torque of the unwinding motor is dynamically adjusted until the deviation returns to within the error threshold band.

3. The high-precision intelligent aluminum foil slitting method based on online tension and roll diameter coordinated control according to claim 1, characterized in that, The process of driving the slitting blade assembly to perform active shearing in step S3 specifically includes: Based on the linear speed of the aluminum foil passing through the buffer roller, the target linear speed of the slitting tool is calculated according to the preset overspeed ratio coefficient. The slitting blade shaft drive motor is controlled to rotate continuously at the target linear speed, so that the target linear speed of the cutting edge of the slitting blade is always higher than the traveling linear speed of the aluminum foil throughout the entire shearing operation. By utilizing the continuous speed difference, a tension effect is created on the aluminum foil in the shearing zone, so that the aluminum foil is cut under tension, avoiding tearing or folding of the cut edge due to material relaxation.

4. The high-precision intelligent aluminum foil slitting method based on online tension and roll diameter coordinated control according to claim 1, characterized in that, The process of adjusting the contact pressure of the flattening roller in step S4 specifically includes: During the winding process, the controller continuously monitors the current winding roll diameter and the aluminum foil travel line speed, and dynamically adjusts the opening of the pneumatic proportional valve according to the winding roll diameter and the travel line speed. After detecting an increase in the winding diameter, the pneumatic proportional valve is driven to perform a pressure reduction action, so that the contact pressure of the flattening roller on the surface of the aluminum foil roll decreases non-linearly as the winding diameter increases, in order to avoid damaging the inner aluminum foil. After detecting an increase in the travel line speed, the pneumatic proportional valve is driven to perform a pressure boosting compensation action, so that the contact pressure of the flattening roller increases accordingly with the increase in speed, in order to squeeze out the air that tries to enter the interlayer due to high-speed winding. The controller superimposes the pressure reduction adjustment based on the winding diameter and the pressure increase compensation based on the speed in real time, and outputs the final contact pressure control command to ensure that the finished roll maintains consistent hardness throughout the process.

5. A high-precision intelligent aluminum foil slitting system based on online tension and roll diameter coordinated control, characterized in that, The system is used to perform the method according to any one of claims 1 to 4, specifically including: The physical parameter acquisition module is used to drive the laser detection component to scan the aluminum mother coil during the startup phase and acquire the initial geometric parameters; The inertia dynamic identification module is used to control the unwinding motor to perform micro-motion tests and collect torque and acceleration data to calculate the initial moment of inertia. The tension model construction module is used to establish a dynamic mapping table and reference curve relating the unwinding diameter and tension based on the initial geometric parameters and the initial moment of inertia. The dynamic roll diameter calculation module is used to cyclically collect speed and position signals during unwinding operation, calculate and output the effective dynamic roll diameter value after filtering. The dual-ring tension adjustment module is used to generate feedforward commands by combining the effective dynamic roll diameter value, and to generate closed-loop compensation commands using tension feedback to control the unwinding motor. The vacuum adsorption isolation module is used to monitor the negative pressure status of the buffer unit and set the rotational linear speed of the buffer roller as the main speed reference for the entire slitting system after establishing adsorption lock. The synchronous active shearing module is used to calculate the target overspeed value based on the main speed reference and drive the slitting blade group to perform active stretching and shearing on the aluminum foil; The taper tension generation module is used to control the output torque of the winding motor according to a non-linear decreasing strategy based on the real-time winding diameter; The pressure compensation module is used to dynamically adjust the contact pressure of the flattening roller based on changes in the winding diameter and travel line speed.

6. A high-precision intelligent aluminum foil slitting device based on online tension and roll diameter coordinated control, which slits aluminum foil (302) using multiple rollers mounted on a base (301), characterized in that, The device is used as a slitting carrier for the system of claim 5, specifically comprising: The slitting unit (100) includes an unwinding roller (101), a traction roller (102), an adsorption roller (103), a slitting roller (104), and a take-up roller (105) which are sequentially fixedly installed on the top of the base (301). The adsorption roller (103) has a coaxially arranged cavity (106) inside. The adsorption roller (103) has an adsorption hole (107) that communicates with the cavity (106) on its surface. An air extraction pipe (108) is arranged through the adsorption roller (103) and coaxially with the cavity (106). An air extraction pipe (109) is provided on the air extraction pipe (108). The detection unit (200) includes a negative pressure sensor (201) disposed on the top of the adsorption roller (103) for detecting the adsorption intensity, a pressure-sensitive thin film capacitor (202) integrated on the surface of the traction roller (102) for measuring the pressure of the aluminum foil (302) to calculate the tension, and an angle sensor (203) for measuring the rotation angle of the roller body is disposed at the shaft connection between the unwinding roller (101) and the base (301). Below the unwinding roller (101) and on the base (301), a reference distance sensor (204a) for measuring the distance between the rollers and an unwinding distance sensor (204b) for measuring the distance between the aluminum master coils are fixedly installed. The unwinding diameter of the aluminum master coil can be obtained by subtracting the distance measurement results of the two and adding the roller radius. Below the take-up roller (105) and on the base (301), a reference distance sensor (204a) for measuring the distance between the rollers and a take-up distance sensor (204c) for measuring the distance between the slit aluminum coils are fixedly installed. The take-up diameter of the slit aluminum coils can be obtained by subtracting the distance measurement results of the two and adding the roller radius.

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