Cooperative leapfrogging control method for multiple rolls of alumite of gilding press

Abstract

The invention discloses a collaborative leapfrogging control method for multiple rolls of alumite of a stamping machine. The collaborative leapfrogging control method comprises the following steps: step 1), configuring a collaborative control hardware system; step 2), establishing joint position mapping; 3) calculating key parameters in real time; (4) dynamic tension compensation and leapfrogging control are carried out; and (5) in the normal conveying process of the alumite, the tension of each coil of alumite is maintained to be stabilized within a preset range. Through core designs such as multi-roll cooperative control and dynamic tension compensation, the multi-roll synchronous hot stamping scene is adapted, the limitation of single-roll control in the prior art is broken through, the problem of tension sudden change during high-speed leapfrogging is solved, the phenomena of alumite stretching, wrinkling and breaking are reduced, and the hot stamping quality stability is guaranteed.

Description

Technical Field

[0001] This invention relates to a collaborative step-jumping control method for multiple rolls of electroplated aluminum foil in a hot stamping machine. Background Technology

[0002] Hot stamping is a post-printing process that uses the principle of heat transfer to transfer the aluminum layer of gold foil (electroplated aluminum) onto the surface of a substrate to create a metallic effect. Gold foil is usually used in rolls wound into continuous strips. Due to the need for customized lengths of gold foil, joints are prone to appear on a single roll of gold foil. These joints cannot be used for hot stamping and must be avoided before hot stamping.

[0003] In existing technologies, early methods involved manually monitoring the joint position. When the gold foil was about to be used at the joint, the machine was manually stopped and the joint removed. This method was inefficient and prone to producing defective products due to human error. To address this issue, Chinese Patent No. CN2021106887432 discloses an automatic gold foil joint avoidance structure and method. This method uses a detection unit to obtain joint position information and calculates the real-time distance between the joint and the hot stamping plate. When the distance does not meet the foil feeding requirements, the foil feeding unit and foil pulling unit are controlled to run rapidly to achieve a skip step.

[0004] However, the existing technology has obvious drawbacks: on the one hand, during the high-speed step-by-step process, the gold foil tension changes abruptly, which can easily lead to the gold foil being stretched, wrinkled, or even broken, affecting the hot stamping quality and production continuity; on the other hand, it is only designed for single rolls of gold foil and cannot be adapted to the scenario of simultaneous hot stamping of multiple rolls of electroplated aluminum foil. Simultaneous hot stamping of multiple rolls is widely used in scenarios such as mass production and hot stamping of complex patterns, and the existing technology is difficult to meet the actual production needs. Summary of the Invention

[0005] To address the aforementioned problems, this invention provides a collaborative step-jump control method for multiple rolls of electroplated aluminum foil in a hot stamping machine, effectively solving the problems mentioned in the background art.

[0006] The technical solution adopted in this invention is:

[0007] A method for coordinated step skipping control of multiple rolls of electroplated aluminum foil in a hot stamping machine includes the following steps:

[0008] Step 1) Configure the collaborative control hardware system: Set up a controller and multiple single-roll skipping mechanisms that are communicatively connected to the controller. Each single-roll skipping mechanism corresponds to one roll of electroplated aluminum, and each single-roll skipping mechanism includes:

[0009] Foil feeding unit: Independently configured with foil feeding roller, foil feeding roller and foil passing roller, the drive motor of all foil feeding rollers is connected to the controller, and the controller realizes synchronous speed adjustment;

[0010] Foil pulling unit: Independently configured with foil pulling roller and drive motor (servo motor of the same source as foil feeding unit). The foil pulling roller drive motor is connected to the controller to achieve speed synchronization and linkage control with the foil feeding unit motor;

[0011] Detection Unit: Independently configured with a dual detection component of "color sensor + vision probe" and an independent foil support plate. The dual detection component is used to detect the joint position of the corresponding roll of electroplated aluminum. The detection signal is uploaded to the controller. The independent foil support plate is used to ensure the flatness of the electroplated aluminum during the conveying process and to avoid the recognition accuracy of the dual detection component being affected by the wrinkles or offset of the electroplated aluminum.

[0012] Measurement unit: Independently configured with a dynamic electronic distance measuring device, which monitors the distance between the color sensor of the corresponding roll and the hot stamping plate in real time, and uploads the distance data to the controller;

[0013] Tension compensation unit: Tension sensors are installed on the conveying path of each roll of electroplated aluminum to collect the tension data of the electroplated aluminum in real time and feed it back to the controller;

[0014] Step 2) Establish joint position mapping: The controller receives the detection signals from each detection unit, associates them with the roll number of the corresponding single roll skipping mechanism, and establishes and updates the "roll number-joint position" mapping library;

[0015] Step 3) Real-time calculation of key parameters: Based on the spacing data uploaded by each measurement unit, the controller calculates the real-time distance between each roll of gold foil joint and the corresponding hot stamping plate by combining the number of foil feeds after detecting the joint information and the length of each foil feed.

[0016] Step 4) Dynamic Tension Compensation and Skip Control: When the real-time distance of the joint of any roll of electroplated aluminum does not meet the foil feeding distance (the foil feeding distance here refers to the minimum safe distance between the joint and the hot stamping plate when the joint needs to trigger a skip, which is preset according to the length of the hot stamping plate, the joint length, and the foil feeding accuracy, and is usually 30-80mm), the foil pulling length of the roll of electroplated aluminum is calculated and skipped according to the foil pulling length. The foil pulling length = hot stamping plate length + joint length + reserved safety length (the reserved safety length is 5-10mm, determined according to the foil feeding accuracy). Before skipping, the controller calculates and adjusts the skipping speed increase of its foil feeding unit and foil pulling unit based on the tension data fed back by the tension sensor corresponding to the roll of electroplated aluminum, and simultaneously adjusts the other rolls of aluminum. The operating speed of the foil unit enables all rolls of electroplated aluminum to perform a skipping operation in coordination until the joint of the roll of electroplated aluminum moves to the hot stamping plate outlet. When the real-time distance between the joints of at least two rolls of electroplated aluminum does not meet the foil feeding distance, the foil pulling length of the at least two rolls of electroplated aluminum is calculated and skipping is performed according to the maximum foil pulling length. Before skipping, the controller selects the maximum tension data from the tension sensors corresponding to the at least two rolls of electroplated aluminum to calculate the increase in the skipping operating speed of the foil feeding unit and foil pulling unit corresponding to the at least two rolls of electroplated aluminum and adjusts it accordingly. At the same time, the operating speed of other foil feeding units is adjusted synchronously so that all rolls of electroplated aluminum can perform a skipping operation in coordination until the joints of the at least two rolls of electroplated aluminum have all moved to the hot stamping plate outlet.

[0017] Step 5) During the normal conveying of electroplated aluminum, maintain the tension of each roll of electroplated aluminum within the preset range.

[0018] Preferably, the drive motor of the foil feeding unit is a servo motor, and the controller realizes closed-loop speed synchronization control of each servo motor through pulse signals.

[0019] Preferably, the dual detection component of the detection unit operates as follows: the color sensor performs preliminary joint identification, and the vision probe verifies the identification result. When the two detection results are consistent, a valid joint signal is sent to the controller; if the detection results are inconsistent, an alarm is triggered and the disputed data is retained for review.

[0020] Preferably, the dynamic electronic ranging device uses a laser ranging sensor with a measurement accuracy of ≤±0.1mm and a measurement frequency of ≥100Hz.

[0021] Preferably, the calculation formula for the target operating speed increase of the foil feeding unit and the foil pulling unit in step 4) is: target operating speed increase = a * current operating speed of the foil feeding unit and the foil pulling unit, where 0 < a < 1, and a is a speed adjustment coefficient, which is determined according to the thickness of the electroplated aluminum: 0.3-0.5 for thin electroplated aluminum (thickness ≤ 12μm), 0.5-0.8 for medium thickness (12-25μm), and 0.8-0.9 for thick electroplated aluminum (> 25μm), to ensure that the tension fluctuation during the jump step is ≤ ±2N.

[0022] Preferably, in step 4), when the controller detects that the tension value of any roll of electroplated aluminum reaches the maximum tension warning value, it controls all rolls of electroplated aluminum to skip steps according to the running speed corresponding to the maximum tension warning value.

[0023] Preferably, the specific control logic of step 5) is as follows: The controller compares the real-time collected tension data with a preset tension threshold. When the tension value of any roll of electroplated aluminum is higher than the upper limit of the preset tension threshold, the controller reduces the running speed of all rolls of electroplated aluminum according to a preset calculation formula until the tension value of all rolls of electroplated aluminum is within the preset tension threshold. The speed reduction value is calculated as (current tension - upper limit of preset tension threshold) × k (k is a speed adjustment coefficient, with a value of 1-3 mm / s·N⁻¹, determined according to the thickness of the electroplated aluminum). When the tension value is lower than the lower limit of the preset tension threshold, the controller increases the running speed of all rolls of electroplated aluminum according to a preset calculation formula until the tension value of all rolls of electroplated aluminum is within the preset tension threshold. The speed increase value is calculated as (lower limit of preset tension threshold - current tension) × k (k is a speed adjustment coefficient, with a value of 1-3 mm / s·N⁻¹, determined according to the thickness of the electroplated aluminum). The preset tension threshold range depends on the material of the electroplated aluminum (such as PET base film, PVC). The base film and hot stamping temperature are determined, usually 10-30N; the maximum tension warning value is 1.2-1.5 times the upper limit of the preset tension threshold.

[0024] Preferably, the controller is also equipped with a fault self-diagnosis module, which monitors the working status of the foil feeding unit, detection unit, measurement unit and tension compensation unit of each single roll skipping mechanism in real time. When a component fault is detected, the machine stops immediately and a fault alarm signal is issued.

[0025] The innovative aspects of this invention are as follows:

[0026] (i) Multi-roll electroplated aluminum collaborative step-jump control logic, breaking through the limitations of single-roll adaptation.

[0027] Existing technologies only design skip-step solutions for single rolls of electroplated aluminum foil, which cannot meet the needs of mass production and complex pattern hot stamping scenarios for simultaneous hot stamping of multiple rolls. This solution innovatively proposes a "multi-roll collaborative skip-step" control strategy, which connects all single-roll skip-step mechanisms through a controller to build a unified control system:

[0028] 1. When a single roll has a joint, the controller calculates the foil pulling length and speed adjustment value of that roll, and synchronously adjusts the speed of all foil feeding units to ensure that multiple rolls of electroplated aluminum jump synchronously, avoiding misalignment of multiple rolls and mismatch of hot stamping patterns caused by independent jumps of a single roll.

[0029] 2. When multiple rolls have joints at the same time, the principle of "maximum foil length priority" is adopted. The skip step is uniformly performed according to the longest foil length among the multiple rolls. At the same time, the speed increase value is calculated based on the maximum tension data among the multiple rolls to ensure that all roll joints can avoid the hot stamping plate and the tension is stable.

[0030] (ii) Dynamic tension compensation mechanism to solve the problem of sudden tension changes during jump steps.

[0031] To address the problem of tension abrupt changes during high-speed stepping in existing technologies, which cause stretching, wrinkling, and breakage of electroplated aluminum, this solution designs a full-process tension control system covering "before stepping - during stepping - normal conveying":

[0032] 1. Before skipping steps, the controller collects data from the tension sensors of each roll in real time and dynamically calculates the speed increase of the foil feeding / pulling unit based on the tension value (formula: target running speed increase = a × current running speed, 0 < a < 1), avoiding tension impact caused by skipping steps at a fixed speed;

[0033] 2. During the skipping process, if the tension of any roll reaches the maximum warning value, the speed of the entire roll will be adjusted in a coordinated manner immediately to ensure the integrity of the electroplated aluminum with tension safety as the priority.

[0034] 3. During normal conveying, the "tension threshold comparison - speed linkage adjustment" logic is used to reduce the speed of the entire roll when the tension is higher than the upper limit and increase the speed of the entire roll when it is lower than the lower limit, so as to keep the tension of all rolls stable within the preset range.

[0035] (III) "Dual detection + abnormal alarm" component to improve the accuracy of connector identification

[0036] To avoid misjudgments caused by a single detection method, an innovative dual detection component of "color sensor + vision probe" is adopted, coupled with an independent foil support plate to ensure detection stability.

[0037] 1. Layered working logic: The color sensor quickly and initially identifies the connector, and the vision probe accurately verifies the identification result. Only when the detection results of the two are consistent is a valid connector signal sent to the controller, thus ensuring the identification accuracy.

[0038] 2. Abnormal handling mechanism: If the results of the two tests are inconsistent, an alarm will be triggered immediately, and the disputed data will be retained for manual review. This will not only avoid material waste caused by skipping steps, but also prevent defective products from being generated by missed joints.

[0039] (iv) End-to-end fault self-diagnosis and protection design to ensure production continuity.

[0040] A fault self-diagnosis module is added to the controller to monitor the working status of the foil feeding unit, detection unit, measurement unit, and tension compensation unit of each single roll skipping mechanism in real time.

[0041] 1. Fault response mechanism: When a component fault is detected (such as sensor malfunction or motor abnormality), the machine will be stopped immediately;

[0042] 2. Alarm and Traceability: Simultaneously issue fault alarm signals and retain tension data, joint position data, etc. at the time of the fault, so as to facilitate staff to quickly locate the problem and troubleshoot the fault, and reduce downtime;

[0043] (V) High-precision measurement and synchronous control hardware configuration to solidify the technical foundation

[0044] 1. The measuring unit uses a laser rangefinder sensor with a measurement accuracy of ≤±0.1mm and a measurement frequency of ≥100Hz, ensuring the real-time and accuracy of the distance data between the color sensor and the hot stamping plate. This provides precise support for joint distance calculation. Compared with the method of determining the "distance between the detection unit and the hot stamping plate" only during equipment initialization, this method takes into account the dynamic offset during machine operation (such as mechanical wear after long-term operation, body deformation caused by temperature changes, and loosening of the hot stamping plate).

[0045] 2. The foil feeding unit drive motor is a servo motor. The controller realizes closed-loop control of the speed of each servo motor through pulse signals to ensure the consistency of the conveying speed of multiple rolls of electroplated aluminum and avoid speed deviation during synchronous skipping.

[0046] Corresponding technical effects:

[0047] (i) Adapt to multi-roll production scenarios, improving production efficiency and scope of application.

[0048] 1. Successfully overcomes the limitations of existing single-roll control technology, can meet the needs of simultaneous hot stamping of 2-6 rolls of electroplated aluminum, and is suitable for mainstream application scenarios such as mass production and multi-roll hot stamping of complex patterns, thus expanding the scope of application.

[0049] 2. Multi-roll collaborative skip-step printing eliminates the need for manual intervention in switching, greatly improving production efficiency compared to traditional single-roll hot stamping, especially in batch order production, which can shorten the delivery cycle;

[0050] (ii) Reduce scrap rate and save material costs

[0051] 1. The dynamic tension compensation mechanism effectively suppresses sudden tension changes during skipping steps, greatly reducing the stretching, wrinkling, and breakage rates of electroplated aluminum.

[0052] 2. The dual detection components enable connector identification accuracy of ≥99%, reducing the missed detection and false detection rate to below 1%, thus avoiding the generation of defective products due to connectors not being avoided or skipping steps.

[0053] (III) Ensure the stability of hot stamping quality

[0054] 1. The combination of multi-roll speed synchronization control and tension stability control ensures precise alignment of the multi-roll electroplated aluminum transfer positions, with a hot stamping pattern registration error of ≤±0.2mm, greatly improving the consistency and aesthetics of hot stamping complex patterns;

[0055] 2. During normal conveying, the tension remains stable within the preset range, avoiding problems such as print peeling and uneven gloss caused by tension fluctuations, thus increasing the product qualification rate from 85%-90% to 97%-98%.

[0056] (iv) Improve production continuity and reduce downtime losses

[0057] 1. The fault self-diagnosis module responds quickly to faults, locks the faulty volume, and reduces downtime by more than 60%;

[0058] 2. The alarm signal and fault data traceability function reduces the fault troubleshooting time from an average of 30 minutes / time to 10 minutes / time, reducing production capacity loss caused by faults;

[0059] (v) Improved ease of operation and reduced reliance on manual labor

[0060] 1. Fully automated control of the process, eliminating the need for manual monitoring of joints and manual shutdown to clean joints, reducing labor intensity and minimizing human error;

[0061] 2. The abnormal alarm and data retention functions eliminate the need for staff to monitor the production process in real time. They only need to conduct periodic inspections and handle alarm information, reducing labor costs by 20%-30%.

[0062] This invention, through core designs such as multi-roll collaborative control and dynamic tension compensation, is adapted to multi-roll synchronous hot stamping scenarios, breaks through the limitations of single-roll control in existing technologies, solves the problem of sudden tension changes during high-speed skipping steps, reduces the stretching, wrinkling, and breakage of electroplated aluminum, and ensures the stability of hot stamping quality. Attached Figure Description

[0063] Figure 1 This is a flowchart of the control method of the present invention. Detailed Implementation

[0064] It should be noted that the following detailed descriptions are illustrative and intended to provide further explanation of this application. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains.

[0065] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0066] Furthermore, in the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "clockwise," and "counterclockwise," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0067] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, unless otherwise stated, "a plurality of" means two or more, unless explicitly defined otherwise.

[0068] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0069] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0070] The present invention will now be described in further detail with reference to specific embodiments and accompanying drawings.

[0071] Example 1

[0072] This embodiment takes the production scenario of simultaneous hot stamping of 3 rolls of electroplated aluminum foil as an example. The width of a single roll of electroplated aluminum foil in the hot stamping machine is 50mm, the length of a single foil feeding is 10mm, the running speed of the foil feeding unit during normal production is 100mm / s, the preset tension threshold range is 15N-25N, the maximum tension warning value is 30N, the dynamic electronic ranging device uses a laser ranging sensor, the drive motor of the foil feeding unit uses a servo motor, the controller is a PLC controller (model: Siemens S7-1500), the color sensor is Omron E3Z-R61, the vision probe is Cognex In-Sight 2000, and the tension sensor is HBM U9C.

[0073] like Figure 1 As shown, the present invention provides a collaborative step-jump control method for multiple rolls of electroplated aluminum foil in a hot stamping machine, as detailed below:

[0074] I. Configuration of Collaborative Control Hardware System

[0075] Complete the hardware system setup according to the requirements in step 1). The specific configuration is as follows:

[0076] 1. Controller: The controller adopts a Siemens S7-1500 PLC controller, which has the ability to acquire and control signals in multiple channels. It can simultaneously receive detection signals, spacing data and tension data from three single-roll skipping mechanisms, and output pulse signals to control the operation of each servo motor.

[0077] 2. Single-coil skipping mechanism (3 sets, corresponding to No. 1, No. 2, and No. 3 electroplated aluminum coils respectively)

[0078] Foil feeding unit: Each group is independently configured with a foil feeding roller (30mm in diameter), a foil feeding roller (50mm in diameter), and a foil conveying roller (20mm in diameter). The drive motor of the foil feeding roller is a Mitsubishi HG-KN23J-S100 servo motor. All three servo motors are connected to the PLC controller via PROFINET bus. The controller realizes speed synchronization closed-loop control through pulse signals, and the speed control accuracy can reach ±1mm / s.

[0079] Detection Unit: Each unit is independently configured with an "Omron E3Z-R61 color sensor + Cognex In-Sight2000 vision probe" dual detection component, and is equipped with an independent acrylic foil support plate (5mm thick, smooth surface treatment). The dual detection component is installed 10mm above the foil feeding path, and the detection signal is uploaded to the PLC controller through a digital input module.

[0080] Measurement Unit: Each group is independently equipped with a laser rangefinder sensor (model: Keyence IL-100), with a measurement accuracy of ≤±0.1mm and a measurement frequency of ≥100Hz. It is installed next to the color sensor to monitor the distance between the color sensor and the hot stamping plate in real time. The distance data is uploaded to the PLC controller through the analog input module. The measurement range is 50mm-200mm.

[0081] Tension compensation unit: An HBM U9C tension sensor is installed in the middle of the conveying path of each roll of electroplated aluminum to collect tension data of the electroplated aluminum in real time. The acquisition frequency is 50Hz, and the data is fed back to the PLC controller through a 4-20mA current signal.

[0082] II. Specific Control Process Execution

[0083] Step 2): Establish connector location mapping

[0084] The PLC controller receives detection signals uploaded by three detection units in real time and establishes and updates the "reel number - connector position" mapping library according to the following logic:

[0085] 1. The color sensor scans the surface of the electroplated aluminum. When a sudden color change is detected (the electroplated aluminum joint has a color difference due to splicing), it is initially determined to be the joint location, and the number of foil feeds at the current detection time is recorded.

[0086] 2. The vision probe simultaneously acquires images of this location, extracts joint features (such as splicing gaps and thickness variations) from the images, and verifies the preliminary identification results of the color sensor;

[0087] 3. When the detection results of the color sensor and the vision probe are consistent, the PLC controller associates and stores the roll number (1#, 2#, or 3#), the current foil feeding count, and the real-time spacing detected by the laser rangefinder, establishing a "roll number - joint position" mapping library; if the two detection results are inconsistent, the controller triggers a buzzer alarm (alarm frequency 2Hz) and displays the disputed data (including roll number, detection time, color sensor signal value, and vision probe image) on the touch screen, which is then manually reviewed to confirm whether it is a valid joint;

[0088] In this embodiment, when roll #1 has been fed 100 times, both detection components detect a joint. At this time, the distance detected by the laser rangefinder is 80mm, and the controller stores the information "Roll #1 - 100 foil feeds - 80mm distance" into the mapping library. When roll #2 has been fed 150 times, a valid joint is detected with a distance of 75mm. When roll #3 has been fed 200 times, a valid joint is detected with a distance of 90mm.

[0089] Step 3): Real-time calculation of key parameters

[0090] Based on the spacing data uploaded by each measurement unit, combined with the number of foil feeds after detecting the joint information and the length of a single foil feed, the PLC controller calculates the real-time distance between each roll of electroplated aluminum joint and the corresponding hot stamping plate using the following formula: Real-time distance = Initial spacing - (Number of foil feeds after detecting the joint × Length of a single foil feed) Wherein, the initial spacing is the spacing value measured by the laser rangefinder when a valid joint is detected.

[0091] In this embodiment:

[0092] The number of foil feeds after the joint is detected in roll #1 starts to accumulate from 0. When the cumulative number of foil feeds is 20, the real-time distance = 80mm - (20 × 10mm) = 60mm;

[0093] When the cumulative number of foil feeds after the joint detection of roll #2 is 15, the real-time distance = 75mm - (15 × 10mm) = 60mm;

[0094] When the cumulative number of foil feeds after the joint is detected in roll #3 is 10, the real-time distance is 90mm - (10 × 10mm) = 80mm. The preset foil feed distance threshold is 50mm. When the real-time distance is ≤ 50mm, the skip step control is triggered.

[0095] Step 4): Dynamic tension compensation and skip control

[0096] This embodiment demonstrates the step control process in two scenarios:

[0097] Scenario 1: Single roll connector triggers step skip (taking roll #1 as an example)

[0098] When the cumulative foil feeding count after the joint is detected in roll #1 reaches 30, the real-time distance = 80mm - (30 × 10mm) = 50mm, reaching the foil feeding distance threshold, triggering the jump step control:

[0099] 1. Calculate the foil pulling length: Based on the length of the hot stamping plate (100mm) and the joint length (20mm), determine the foil pulling length of roll #1 to be 120mm;

[0100] 2. Tension data acquisition: The PLC controller receives a real-time tension value of 22N from the tension sensor of roll #1;

[0101] 3. Calculate the speed increase: According to the formula "target running speed increase = a × current running speed", where a is 0.5 (because the thickness of the electroplated aluminum in this embodiment is 15μm, which is a medium thickness, and the tension stability is best when a=0.5 after experimental verification), the target running speed increase = 0.5×100mm / s=50mm / s. The target running speed of the foil feeding unit and the foil pulling unit during the jump step is 100mm / s+50mm / s=150mm / s;

[0102] 4. Coordinated skip-step execution: The PLC controller simultaneously sends speed control signals to the servo motors of the three foil feeding units, adjusting the foil feeding / pulling unit speed of roll #1 to 150mm / s, and synchronously adjusting the foil feeding units speed of rolls #2 and #3 to 150mm / s, thus coordinating the skip-step operation. Skip-step time = foil pulling length ÷ target running speed = 120mm ÷ 150mm / s = 0.8s;

[0103] 5. Skip Step End Judgment: When the joint of roll #1 moves to the hot stamping plate outlet, the controller determines that the skip step has ended, and the speed of all roll foil feeding units returns to 100mm / s.

[0104] Scenario 2: Multi-roll connector triggers step skipping (taking roll #1 and roll #2 as an example)

[0105] When the cumulative foil feeding count of roll #1 reaches 30 times (real-time distance 50mm) and the cumulative foil feeding count of roll #2 reaches 25 times (real-time distance = 75mm - (25 × 10mm) = 50mm), both rolls simultaneously reach the foil feeding distance threshold, triggering the skip step control.

[0106] 1. Calculate the foil pulling length: The foil pulling length of roll #1 is 120mm, and the foil pulling length of roll #2 is 130mm (because the joint length of roll #2 is 25mm). Select the maximum foil pulling length of 130mm as the uniform step length;

[0107] 2. Tension data acquisition: The PLC controller receives the tension value of 22N for roll #1 and the tension value of 24N for roll #2, and selects the maximum tension value of 24N as the basis for calculation;

[0108] 3. Calculate the speed increase: 'a' remains at 0.5, so the target speed increase = 0.5 × 100 mm / s = 50 mm / s, and the target speed is 150 mm / s.

[0109] 4. Coordinated skip step execution: The controller controls the servo motors of the three foil feeding units to run at a speed of 150mm / s, performing a 130mm foil pulling skip step. The skip step time = 130mm ÷ 150mm / s ≈ 0.87s.

[0110] 5. Skip Step End Judgment: When the joints of rolls #1 and #2 both move to the hot stamping plate outlet, the skip step is judged to be over, and all rolls resume normal foil feeding speed;

[0111] During the above-mentioned step skipping process, if the controller detects that the tension value of any roll reaches 30N (maximum tension warning value), it will immediately control all roll foil feeding units and foil pulling units to reduce the running speed to 80mm / s (the preset speed corresponding to the maximum tension warning value) until the tension value falls back to the preset range, and then resume the normal step skipping speed.

[0112] Step 5): Tension stabilization control during normal conveying process

[0113] During normal aluminum electroplating (without triggering a step skip), the PLC controller maintains stable tension according to the following logic:

[0114] 1. Real-time acquisition of tension data from 3 rolls of electroplated aluminum foil, with data comparison performed every 50ms;

[0115] 2. When the tension value of roll #2 is detected to be 26N (higher than the preset tension threshold upper limit of 25N), the controller calculates the reduction speed value = (26-25)×2=2mm / s according to the preset calculation formula (reduction speed value = (current tension - upper limit of threshold) × 2mm / s・N⁻¹), and uniformly reduces the running speed of the three rolls of electroplated aluminum to 98mm / s. The tension data is continuously monitored. When the tension value of roll #2 drops back to 24N (within the preset range), the speed adjustment is stopped.

[0116] 3. When the tension value of roll #3 is detected to be 14N (lower than the preset tension threshold of 15N), the speed increase value is calculated according to the preset calculation formula (increase speed value = (threshold lower limit - current tension) × 2mm / s·N⁻¹) = (15-14) × 2 = 2mm / s. The running speed of roll #3 of electroplated aluminum is uniformly increased to 102mm / s until the tension value of roll #3 rises to 16N, and the normal speed operation is restored.

[0117] III. Execution of Fault Self-Diagnosis Function

[0118] The controller's fault self-diagnosis module monitors the working status of the foil feeding unit, detection unit, measurement unit, and tension compensation unit of each single-roll skipping mechanism in real time.

[0119] 1. If the laser rangefinder sensor of roll #1 is found to be not uploading data (determined to be a sensor failure), the controller will immediately stop the unit, trigger the red alarm light to stay on, and display "Laser rangefinder sensor failure of roll #1" on the touch screen. The tension data and foil feeding number at the time of the failure will be retained to facilitate the staff to troubleshoot.

[0120] 2. If an abnormal feedback signal from the servo motor of roll #2 is detected (indicating a motor failure), the controller will also immediately stop the unit and trigger an alarm.

[0121] IV. Implementation Results Verification

[0122] Through the control method of this embodiment, during the simultaneous hot stamping process of 3 rolls of electroplated aluminum foil:

[0123] 1. The connector identification accuracy rate reached 99.5%, and no defective products were found due to missed detections or false detections;

[0124] 2. During the step-by-step process, the tension fluctuation of the electroplated aluminum is controlled within ±2N, with no stretching, wrinkling or breakage, and the registration error of the hot stamping pattern is ≤±0.2mm;

[0125] 3. Multi-roll collaborative skip response time ≤ 0.1s, improving production continuity by more than 35%.

[0126] Finally, it should be noted that the above examples are merely specific embodiments of the present invention. Obviously, the present invention is not limited to the above embodiments and many variations are possible. All variations that can be directly derived or conceived by those skilled in the art from the disclosure of this invention should be considered within the scope of protection of this invention.

Claims

1. A method for coordinated step control of multiple rolls of electrochemical aluminum for a gilder, characterized in that, The method comprises the following steps: Step 1), configuring a cooperative control hardware system: setting a controller and a plurality of single-roll jump mechanisms connected in communication with the controller, each single-roll jump mechanism corresponding to a roll of electrochemical aluminum, and each single-roll jump mechanism comprising: a foil feeding unit: independently configuring a foil feeding rubber roller, a foil feeding roller and a foil passing roller, the drive motors of all the foil feeding rollers being connected to the controller, and the speed of the drive motors being synchronously adjusted by the controller; a foil pulling unit: independently configuring a foil pulling roller and a drive motor, the foil pulling roller drive motor being connected to the controller and being synchronously controlled in speed with the foil feeding unit motor; a detection unit: independently configuring a "color sensor + visual probe" double detection assembly and an independent foil supporting plate, the double detection assembly being used to detect the joint position of the corresponding roll of electrochemical aluminum, and the detection signal being transmitted to the controller; a measurement unit: independently configuring a dynamic electronic distance measuring device, which is used to monitor the distance between the color sensor of the corresponding roll and the gilding plate in real time, and the distance data being transmitted to the controller; a tension compensation unit: setting a tension sensor on the conveying path of each roll of electrochemical aluminum, collecting the electrochemical aluminum tension data in real time and feeding back to the controller; Step 2), establishing a joint position mapping: the controller receives the detection signals of each detection unit, associates the roll number of the corresponding single-roll jump mechanism, and establishes and updates a "roll number-joint position" mapping library; Step 3), real-time calculation of key parameters: the controller calculates the real-time distance between the joint of each roll of gold foil and the corresponding gilding plate based on the distance data transmitted by each measurement unit, in combination with the number of times of feeding foil after detecting the joint information and the length of single foil feeding; Step 4), dynamic tension compensation and jump control: when the real-time distance of the joint of any roll of electrochemical aluminum does not meet the foil feeding distance, the foil pulling length of the roll of electrochemical aluminum is calculated and the jump is performed according to the foil pulling length, before the jump, the controller calculates the jump running speed increase value of the foil feeding unit and the foil pulling unit of the roll of electrochemical aluminum according to the tension data fed back by the corresponding tension sensor of the roll of electrochemical aluminum, and adjusts the speed, while synchronously adjusting the running speed of the foil feeding units of other rolls, so that all the rolls of electrochemical aluminum cooperatively perform the jump operation until the joint of the roll of electrochemical aluminum moves to the discharge end of the gilding plate; when the real-time distance of the joint of at least two rolls of electrochemical aluminum does not meet the foil feeding distance, the foil pulling length of the at least two rolls of electrochemical aluminum is calculated and the jump is performed according to the maximum foil pulling length, before the jump, the controller selects the maximum tension data from the tension data fed back by the corresponding tension sensors of the at least two rolls of electrochemical aluminum to calculate the jump running speed increase value of the corresponding foil feeding unit and the foil pulling unit of the at least two rolls of electrochemical aluminum, and adjusts the speed, while synchronously adjusting the running speed of the foil feeding units of other rolls, so that all the rolls of electrochemical aluminum cooperatively perform the jump operation until the joints of the at least two rolls of electrochemical aluminum all move to the discharge end of the gilding plate; Step 5), during the normal conveying process of the electrochemical aluminum, the tension of each roll of electrochemical aluminum is maintained stable within a preset range.

2. A method for the coordinated step control of multiple rolls of electrochemical aluminum for a gilder according to claim 1, characterized in that, The drive motors of the foil feeding unit are servo motors, and the controller realizes synchronous closed-loop control of the speed of each servo motor through pulse signals.

3. A method for the coordinated step control of multiple rolls of electrochemical aluminum for a gilder according to claim 2, characterized in that, The working logic of the double detection assembly of the detection unit is that the color sensor performs preliminary joint identification, the visual probe verifies the identification result, when the detection results of the two are consistent, an effective joint signal is sent to the controller, if the detection results are inconsistent, an alarm is triggered and the controversial data is reserved for review.

4. A method for the coordinated step control of multiple rolls of electrochemical aluminum for a gilder according to claim 3, characterized in that, The dynamic electronic distance measuring device adopts a laser distance measuring sensor, and the measurement accuracy is less than or equal to 0.1mm, and the measurement frequency is greater than or equal to 100Hz.

5. A method for coordinated step control of multiple rolls of electrochemical aluminum for a gilder according to claim 4, characterized in that, The calculation formula of the target running speed increase value of the foil feeding unit and the foil pulling unit in the step 4) is: target running speed increase value = a * current running speed of the foil feeding unit and the foil pulling unit, wherein 0 < a < 1.

6. A method for coordinated step control of multiple rolls of electrochemical aluminum for a gilder according to claim 4, characterized in that, When the controller detects that the tension value of any one of the volumes of the electrochromic aluminum reaches the maximum tension warning value, the controller controls the foil feeding unit and the foil pulling unit of all the volumes of the electrochromic aluminum to perform step running according to the running speed corresponding to the maximum tension warning value.

7. A method for coordinated step control of multiple rolls of electrochemical aluminum for a gilder according to claim 6, characterized in that, The specific control logic of the step 5) is that the controller compares the real-time collected tension data with the preset tension threshold value, when the tension value of any one of the volumes of the electrochromic aluminum is higher than the upper limit of the preset tension threshold value, the running speed of all the volumes of the electrochromic aluminum is reduced according to a preset calculation formula until the tension value of all the volumes of the electrochromic aluminum is within the preset tension threshold value, when the tension value is lower than the lower limit of the preset tension threshold value, the running speed of all the volumes of the electrochromic aluminum is increased according to the preset calculation formula until the tension value of all the volumes of the electrochromic aluminum is within the preset tension threshold value.

8. A method for coordinated step control of multiple rolls of electrochemical aluminum for a gilder according to claim 7, characterized in that, The controller is also configured with a fault self-diagnosis module, which monitors the working state of the foil feeding unit, the detection unit, the measuring unit and the tension compensation unit of each single-volume step mechanism in real time, and when a component fault is detected, the machine is immediately stopped, and a fault alarm signal is sent.

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