A digital control system for a strip coiling apparatus

Abstract

The application belongs to the technical field of automation control, and particularly relates to a digital control system of a strip coiling equipment, which first combines a tension sensing assembly and an image acquisition device to comprehensively acquire strip tension data and state characteristic information, dynamically adjusts braking torque parameters, then takes the line speed of a coiler as a target signal, realizes speed synchronization alignment of an uncoiler and a traction roller through a following strategy, immediately adopts a taper tension control mode, dynamically adjusts a tension value in combination with real-time coiling diameter parameters, ensures the stability of the tension and the regularity of the coiling shape in the coiling process, and finally detects and processes strip deviation problems in real time according to a closed-loop deviation correction mechanism. The equipment control strategy of the strip coiling process of the application is deeply bound with uncoiling control, synchronous coordination, coiling control, and deviation correction core modules, has integrated control capability of multivariable cooperation and self-adaptive optimization, and thus effectively improves the automation and intelligent level of the strip coiling process.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of automation control, and particularly relates to a digital control system of a strip winding equipment. BACKGROUND

[0002] With the wide application of the strip winding process in the manufacturing field of basic materials such as metal foil, polymer film and composite material, the control precision and stability have become the key factors affecting the product quality and production efficiency in the electronic, new energy, automobile and packaging industries. The strip winding process involves multiple links such as unwinding, traction and winding, and needs to realize stable tension output, accurate speed synchronization, dynamic winding diameter adaptation and real-time deviation correction. The control mismatch in any link may cause the strip to wrinkle, stretch and even break, which seriously affects the quality of finished products.

[0003] At present, the existing winding equipment control system in this field mostly adopts a decentralized control architecture and relies on traditional sensor feedback and static control model, which is difficult to cope with the complex control requirements brought by material property changes, working condition disturbances and equipment dynamic response delays, especially in high-speed and high-precision winding scenes. The following significant defects are shown: 1. The existing device control strategy for the strip winding process is in an island distribution, and lacks integrated control ability of multivariable coordination and adaptive optimization: in terms of tension control, the existing system usually only relies on tension sensor detection signal for feedback adjustment, without introducing visual perception information of the actual physical state of the strip, which causes the system to be unable to identify and compensate the abnormal shape of the strip caused by non-tension factors in real time, resulting in tension control lag, overshoot or oscillation, and making it difficult to realize the smoothness and adaptive adjustment of the unwinding process.

[0004] In terms of speed coordination, most existing systems do not establish a unified master speed reference and follow-up control mechanism, and the unwinder, traction roller and winder often run independently or adopt a simple master-slave control strategy, which lacks high-precision linear speed dynamic matching capability, resulting in speed cumulative error between multiple devices, which easily causes strip tension fluctuation or quality defects such as material stacking, stretching, etc.

[0005] In terms of winding control, the existing technology usually adopts a constant tension setting strategy, without considering the significant influence of the continuously increasing winding diameter on the actual tension distribution in the winding process, and lacks the ability to calculate and dynamically adjust the taper tension according to the real-time winding diameter, which causes uneven stress distribution between the layers of the wound material, and problems such as loose inside and tight outside, irregular winding shape or core collapse.

[0006] 2. The existing deviation correction system for the strip winding equipment mostly relies on threshold triggered on-off control, lacks closed-loop feedback and multi-stage response mechanism, and is easy to cause the strip deviation to be aggravated or the equipment to be frequently started and stopped due to response delay or overshoot. SUMMARY

[0007] In order to overcome the shortcomings in the background art, the embodiment of the present application provides a strip coiling equipment digital control system, which can effectively solve the problems involved in the above background art.

[0008] The purpose of the present application can be achieved by the following technical solutions: a strip coiling equipment digital control system, comprising: an uncoiling control module, a synchronous coordination module, a coiling control module and a deviation correction module.

[0009] The uncoiling control module is connected with the synchronous coordination module, the synchronous coordination module is connected with the coiling control module, and the coiling control module is connected with the deviation correction module.

[0010] The uncoiling control module: configure the frequency converter output reverse torque of the uncoiler, obtain the tension data of each monitoring point through the tension sensor assembly, synchronously collect the state characteristic information of the uncoiled strip, dynamically adjust the braking torque based on the matching degree of the tension data and the state characteristic information, and maintain the stable unwinding tension.

[0011] The synchronous coordination module: set the coiler as the speed master device, control the uncoiler and the traction roller to track the coiling line speed through the following control strategy, and realize the synchronous alignment of the running speeds of multiple devices.

[0012] The coiling control module: adopts a taper tension control mode, obtains the current roll diameter parameter in real time, calculates the real-time tension value in combination with the initial tension parameter and the preset maximum roll diameter parameter, and the real-time tension value is determined based on the correlation between the initial tension value and the proportion of the current roll diameter in the maximum roll diameter.

[0013] The deviation correction module: detects the deviation amount parameter of the strip, starts the closed-loop deviation correction control mechanism, and executes the corresponding deviation correction operation according to the comparison result of the deviation amount parameter and the preset warning threshold.

[0014] Compared with the prior art, the embodiment of the present application has at least the following advantages or beneficial effects: (1) The present application breaks through the existing single control mode which depends on tension data, realizes dynamic adjustment of braking torque by fusing tension sensing and visual state recognition, combines tension data and strip state characteristic information, and improves the accuracy and adaptive ability of tension control through multi-modal perception of the strip.

[0015] (2) The present application clearly sets the coiler as the speed master device, uses its line speed as the only following reference of the uncoiler and the traction roller, eliminates the speed adaptation conflict caused by the lack of unified reference of multiple devices from the source, and still monitors the speed deviation after synchronization is completed. When the speed deviation exceeds the allowed range, the adjustment is automatically restarted without manual intervention, which can maintain long-term stable operation of the equipment, reduce operation and maintenance cost and fault risk.

[0016] (3) The present application determines the coiling tension in real time based on the correlation between the initial tension value and the proportion of the current roll diameter to the maximum roll diameter in the conical control mode, so that the strip is always fitted to the roll with a tension suitable for the current roll diameter during the coiling process, avoiding the misregistration and uneven stacking of the strip caused by tension fluctuation, effectively ensuring the neatness of the final coiled strip, reducing the arrangement cost during subsequent uncoiling use, and improving the finished product qualification rate.

[0017] (4) The present application realizes the rapid suppression of deviation and stable operation of the system through offset closed-loop detection and multi-threshold grading correction strategy, avoiding both the scrap of the strip caused by the failure of single correction method and the over-adjustment and frequent start-stop. BRIEF DESCRIPTION OF DRAWINGS

[0018] The present application will be further described with the aid of the accompanying drawings, but the embodiments in the drawings do not constitute any limitation on the present application, and other drawings can be obtained by those of ordinary skill in the art without creative labor on the basis of the following drawings.

[0019] Figure 1 It is a schematic diagram of the module connection of the present application.

[0020] Figure 2 It is an implementation flowchart of the uncoiling control module of the present application.

[0021] Figure 3 It is an implementation flowchart of the coiling control module of the present application. DETAILED DESCRIPTION

[0022] The technical solutions in the embodiments of the present application will be described clearly and completely below with the aid of the drawings in the embodiments of the present application. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative labor fall within the scope of protection of the present application.

[0023] Referring to Figure 1 The present application provides a strip coiling equipment digital control system, which comprises an uncoiling control module, a synchronous coordination module, a coiling control module and a deviation correction module.

[0024] The uncoiling control module is connected with the synchronous coordination module, the synchronous coordination module is connected with the coiling control module, and the coiling control module is connected with the deviation correction module.

[0025] The uncoiling control module: The frequency converter output reverse torque of the uncoiler is configured, the tension data of each monitoring point is obtained through the tension sensing assembly, the state characteristic information of the uncoiled strip is synchronously collected, the braking torque is dynamically adjusted based on the matching degree of the tension data and the state characteristic information, and the uncoiling tension is maintained stable.

[0026] Referring to Figure 2 As shown in the preferred embodiment of the present application, the unwinding control module is implemented as follows: in the initial unwinding stage, the unwinding machine frequency converter outputs a reverse torque according to the preset initial torque parameter to establish an initial braking torque.

[0027] During the unwinding of the strip, the tension data of each monitoring point is continuously collected by the tension sensing assembly.

[0028] The state feature information of the unwound strip is captured by the image acquisition device, including the slackness, wrinkle state and edge flatness of the strip.

[0029] The matching standard of the preset tension data and the state feature information is that when the tension data is within the preset range and the state feature information is normal, it is determined to be matched.

[0030] If it is determined to be matched, the current braking torque is maintained.

[0031] If it is determined to be not matched, the adjustment amount of the braking torque is calculated according to the deviation direction of the tension data and the abnormal type of the state feature information.

[0032] It should be noted that the abnormal type of the state feature information includes abnormal slack type, abnormal wrinkle type and abnormal edge type, and the determination method of each type of abnormality is: the quantitative parameters of the real-time calculated slackness, wrinkle state and edge flatness are compared with their respective preset qualified threshold intervals, and if any quantitative parameter exceeds its corresponding qualified threshold interval, it is determined that the corresponding type of abnormality occurs.

[0033] The output torque of the unwinding machine frequency converter is adjusted according to the adjustment amount until the tension data and the state feature information return to the matching state.

[0034] In a preferred embodiment of the present application, the state feature information of the unwound strip is captured as follows: image acquisition devices are arranged on the outlet side of the unwinding machine to continuously acquire images of the strip surface and edge, generating an image sequence.

[0035] Real-time image processing and feature extraction are performed on the image sequence, including: I. Calculate the displacement vector field of the specific texture on the strip surface between consecutive frames, and quantify the strain distribution of the longitudinal and transverse directions of the strip surface, and use the mean value and fluctuation degree of the strain distribution as the quantitative parameters representing the slackness of the strip.

[0036] II. Identify the wrinkle area on the strip surface and generate a pixel-level mask of the wrinkle area, and use the area ratio and number of the wrinkle area as the quantitative parameters representing the wrinkle state.

[0037] III. Extracting the strip edge pixel points, and fitting the extracted edge pixel points to an ideal reference straight line by using the least square method, calculating the average deviation and the maximum deviation value of the strip edge pixel points from the ideal reference straight line, taking the average deviation and the maximum deviation value as the quantitative parameters for characterizing the edge flatness.

[0038] Taking the extracted quantitative parameters as the basis for judging the running state of the strip to capture the state characteristic information of the uncoiling strip.

[0039] In a preferred embodiment of the present application, the adjustment amount of the braking torque is implemented as follows: the deviation value of the tension data from its matching standard is subjected to time series incremental operation to obtain a basic adjustment amount of the braking torque, and the positive and negative directions of the basic adjustment amount of the braking torque are determined according to the deviation direction of the tension data relative to its matching standard.

[0040] It should be noted that the specific process of determining the positive and negative directions of the basic adjustment amount of the braking torque is as follows: if the tension data is less than the lower limit value of the preset range of the matching standard, it is determined that the deviation direction is negative, and the basic adjustment amount of the braking torque is determined to be in the negative direction, which is used to reduce the output torque of the uncoiler frequency converter, reduce the reverse resistance torque applied by the uncoiler, make the traction roll and the coiler more easily pull the strip, and then increase the actual tension through the tightening of the strip.

[0041] If the tension data is greater than the upper limit value of the preset range of the matching standard, it is determined that the deviation direction is positive, and the basic adjustment amount of the braking torque is determined to be in the positive direction, which is used to increase the output torque of the uncoiler frequency converter, enhance the reverse resistance torque applied by the uncoiler, increase the resistance of the traction roll and the coiler to pull the strip, and thus reduce the actual tension.

[0042] It should be noted that the time series incremental operation process is as follows: the tension deviation data at the current and historical time is obtained in real time to construct a time series deviation sequence, wherein the calculation method of the tension deviation data is determined by the deviation direction: when the deviation direction is positive, the difference between the actual tension data and the upper limit value of the preset range is taken as the tension deviation data, and when the deviation direction is negative, the absolute value of the difference between the actual tension data and the lower limit value of the preset range is taken as the tension deviation data.

[0043] Based on the time series deviation sequence, the first and second difference quantities reflecting the deviation trend are calculated.

[0044] The deviation value, the first difference quantity and the second difference quantity at the current time are respectively subjected to weighted operation with predefined proportional, integral and differential coefficients, and the sum is obtained to obtain the basic adjustment amount.

[0045] Wherein the action mechanism of each predefined coefficient is: the proportional coefficient is used to regulate the response strength to the current deviation size.

[0046] The integral coefficient is used to regulate the response strength of the historical deviation accumulation amount, so as to eliminate the steady-state error.

[0047] The differential coefficient is used to regulate the suppression strength of the deviation change trend, so as to predict the system state and suppress the oscillation.

[0048] In addition, each predefined coefficient can be generated by a systematic parameter self-tuning mechanism, specifically including two ways: a. Automatic tuning path: enable the parameter self-tuning module during the system debugging stage, actively apply characteristic disturbance signals such as step signals, specific frequency pulses, etc. to the controlled object through a preset program, synchronously collect the system dynamic response curve, analyze the system characteristic parameters based on built-in algorithms such as step response identification method, relay feedback oscillation method, etc., and then automatically generate an optimized coefficient set adapted to the current hardware configuration.

[0049] b. Working condition adaptation path: based on the working condition adaptation test of multiple groups of different material, thickness specifications of the strip during the system development stage, the optimal coefficient set verified by actual measurement is stored according to the strip characteristic parameters, and a strip-coefficient mapping database is constructed. In actual operation, the matching pre-stored coefficient set can be automatically called according to the physical parameters of the current processing strip.

[0050] According to the abnormal type of the state characteristic information, the corresponding compensation adjustment amount is obtained by querying the predefined compensation strategy table.

[0051] It should be noted that the compensation strategy table defines the compensation adjustment amount and direction corresponding to different abnormal types and their severity levels, and the severity level is quantified by the deviation ratio of the abnormal type corresponding parameter relative to its qualified threshold. Taking the abnormal relaxation type as an example, the deviation ratios of the strain distribution mean and fluctuation degree relative to their respective qualified thresholds are calculated, and the maximum value is taken. According to the maximum value in the predefined interval range, the severity level is determined.

[0052] The specific value and direction of the compensation adjustment amount stored in the compensation strategy table are calibrated based on the experimental data of different materials and specifications of the strip during the equipment debugging stage. The core principle is that the compensation amount provided should effectively suppress or eliminate the abnormal state of this category and this level. The following is an example table of compensation adjustment amount direction for three abnormal types.

[0053] Table 1: Example table of compensation adjustment amount direction for each abnormal type

[0054]

[0055] Based on the significant degree of the state characteristic information abnormality, the visual confidence weight is calculated, which is used as the weight allocation for the compensation adjustment amount and the basic adjustment amount. The final brake torque adjustment amount is calculated by linear weighted fusion calculation.

[0056] It should be noted that the calculation process of the visual confidence weight is: the maximum deviation ratio of each abnormal type quantization parameter relative to its qualified threshold is extracted, and the significant degree of state feature information abnormality is obtained by accumulating, the significant degree is input into a preset monotonically increasing function, and the output value is normalized to in the interval, to obtain the visual confidence weight.

[0057] Wherein the preset monotonically increasing function can be exemplified as , the significant degree of state feature information abnormality, is a natural constant, is a preset significant degree threshold corresponding to the visual confidence weight of 1, is a preset control factor, used to control the transition speed of the function, the function curve is smooth, and has sensitive nonlinear characteristics near the threshold , which is very suitable for converting abnormal degree into confidence.

[0058] It should be particularly noted that the compensation adjustment amount used in the linear weighted fusion calculation process is the algebraic sum of the compensation adjustment amounts corresponding to all triggered abnormal types in their corresponding directions, and the value is a comprehensive compensation result, and the weight of the basic adjustment amount is the difference between 1 and the visual confidence weight.

[0059] It should be noted that the introduction of the visual confidence weight realizes the adaptive intelligent decision of multi-source information fusion in the control system, and the technical effect is that: on the one hand, the dynamic allocation of control authority is realized: the system is no longer mechanically executing fixed rules, but can intelligently perform smooth and seamless authority transition between feedback control based on traditional PID model and feedforward compensation control based on machine vision rules according to the severity of abnormal state. When there is no abnormality or the abnormality is slight, the PID control is mainly used to ensure the response speed, and when the abnormality is serious, the visual compensation is mainly used to solve the core contradiction.

[0060] On the other hand, the robustness and fault tolerance of the system are improved: the mechanism gives the system the ability to diagnose and treat, that is, even if the tension sensor reading is normal, as long as the visual detection detects significant abnormalities, the system will give high weight to the visual information and execute the correction operation. This reduces the absolute dependence on a single sensor and enhances the ability to respond to complex working conditions and potential sensor misalignment.

[0061] The embodiment of the application breaks through the existing single control mode depending on tension data, realizes dynamic adjustment of braking torque by fusing tension sensing and visual state recognition, combining tension data and strip state feature information, and improves the accuracy and adaptive ability of tension control through multi-modal perception of the strip.

[0062] Synchronization and Coordination Module: The winding machine is set as the speed master device, and the unwinding machine and traction roller are controlled to track the winding line speed through a follow control strategy to achieve synchronous alignment of the operating speeds of multiple devices.

[0063] In a preferred embodiment of the present invention, the synchronization and coordination module is implemented as follows: the operating speed of the winding machine is set as the reference speed, and the linear speed parameters of the winding machine are collected in real time; the operating linear speed parameters of the uncoiler and traction roller are compared with the linear speed parameters of the winding machine, and the speed deviation value is calculated.

[0064] Based on the speed deviation value, a follow-up control strategy is adopted to adjust the drive parameters of the uncoiler and traction roller, so that their running speed converges to the coiler's linear speed.

[0065] Continuously monitor the speed deviation between multiple devices, and maintain the current control parameters when the speed deviation is within the preset allowable range.

[0066] When the speed deviation exceeds the preset allowable range, the speed adjustment process is restarted.

[0067] In a preferred embodiment of the present invention, the following control strategy is implemented as follows: the linear speed parameter of the winding machine is used as the target speed signal and sent to the control units of the uncoiler and the traction roller respectively.

[0068] The control unit of the uncoiler and traction roller generates an adjustment signal based on the difference between the target speed signal and its own actual speed parameters.

[0069] The driving parameters are corrected in real time based on the adjustment signal, so that the running speed of the uncoiler and traction roller gradually approaches the target speed signal.

[0070] It should be noted that the above drive parameters specifically refer to the speed setpoint or torque setpoint of the frequency converter.

[0071] During speed adjustment, the speed deviation value is continuously monitored. When the speed deviation value is less than the preset threshold, it is determined that synchronization is completed.

[0072] It should be noted that the preset allowable range and preset threshold for the speed deviation value mentioned above are determined comprehensively based on the transmission accuracy of the equipment, the process requirements of the strip material, and the system response characteristics, and are calibrated through on-site debugging experiments. The preset threshold is equal to the upper limit of the preset allowable range.

[0073] This invention clearly defines the winding machine as the speed-controlling device, using its linear speed as the sole reference for the unwinding machine and traction roller. This eliminates speed adaptation conflicts caused by multiple devices lacking a unified reference from the source. After synchronization is completed, the speed deviation is still monitored, and the machine automatically restarts and adjusts when it exceeds the allowable range. This allows the equipment to maintain long-term stable operation without manual intervention, reducing maintenance costs and failure risks.

[0074] The winding control module adopts a taper tension control mode, acquires a current winding diameter parameter in real time, calculates a real-time tension value in combination with an initial tension parameter and a preset maximum winding diameter parameter, and determines the real-time tension value based on an associated relationship between the initial tension value and a proportion of the current winding diameter to the maximum winding diameter.

[0075] Referring to Figure 3 In a preferred embodiment of the present application, the winding control module is implemented as follows: in an initial winding stage, an initial tension parameter and a maximum winding diameter parameter are set, and a taper coefficient is configured.

[0076] The winding diameter detection assembly acquires a current winding diameter parameter in real time.

[0077] Based on a proportional relationship among the initial tension parameter, the current winding diameter parameter and the maximum winding diameter parameter and the taper coefficient, a real-time tension value is calculated.

[0078] It should be noted that the real-time tension value can be calculated according to an exemplary formula wherein is an effective taper coefficient, which is not a fixed value but is acquired from a preset process parameter table according to a material code and a thickness parameter of the strip, and the smaller the value is, the greater the attenuation amplitude of the tension is as the winding diameter increases, is a calculated real-time tension set value, are respectively an initial tension parameter and a maximum winding diameter parameter set, is a current winding diameter parameter acquired in real time, is a fixed empty winding diameter of a winding reel of the winding machine.

[0079] The real-time tension value is converted into a control signal of the winding machine, the winding driving force is adjusted, and the actual winding tension is kept consistent with the calculated real-time tension value.

[0080] It should be noted that the control signal of the winding machine is specifically a torque instruction value required by a winding motor, and the conversion process is as follows: the real-time tension value is multiplied by the current winding diameter parameter, the product is further subjected to a ratio operation with a total speed ratio of a preset mechanical transmission system, and half of the ratio operation result is taken as the torque instruction value.

[0081] The adjustment of the winding driving force is specifically as follows: the torque instruction value is sent to a winding machine frequency converter as a given value in a torque mode, the winding motor outputs a corresponding electromagnetic torque, and thus the required winding tension is generated.

[0082] When the winding diameter parameter reaches the maximum winding diameter parameter, the winding operation is stopped.

[0083] In a preferred embodiment of the present application, the roll diameter detection component is implemented as follows: a displacement detection device is arranged beside the coiler to monitor the distance between the coiler roll and the detection point in real time.

[0084] According to the distance parameter and the structural size of the coiler, the current roll diameter parameter is calculated.

[0085] It should be noted that the current roll diameter parameter conversion process is as follows: a fixed distance from the installation position of the displacement detection device to the center of the coiler roll is preset, the fixed distance is subtracted from the distance from the displacement detection device to the surface of the coiled material measured in real time, and the double difference value is taken as the current roll diameter parameter.

[0086] The current roll diameter parameter is compared with the preset maximum roll diameter parameter, and when the current roll diameter parameter reaches a preset proportion of the maximum roll diameter parameter, a roll diameter warning signal is issued.

[0087] It should be noted that the preset proportion is used to reserve the operation time for deceleration or roll change, which can be exemplarily 0.9.

[0088] The embodiment of the present application adopts a conical control mode, determines the coiling tension in real time based on the correlation between the initial tension value and the proportion of the current roll diameter to the maximum roll diameter, so that the strip is always attached to the roll with a tension suitable for the current roll diameter during the coiling process, avoiding the misregistration and uneven stacking of the strip caused by tension fluctuations, effectively ensuring the neatness of the final coiled material, reducing the arrangement cost during subsequent uncoiling use, and improving the finished product qualification rate.

[0089] The deviation correction module detects the deviation amount parameter of the strip, starts a closed-loop deviation correction control mechanism, and performs corresponding deviation correction operation according to the comparison result of the deviation amount parameter and the preset warning threshold.

[0090] In a preferred embodiment of the present application, the deviation correction module is implemented as follows: the deviation detection component is used to collect the deviation amount parameter of the strip in real time.

[0091] It should be noted that the deviation detection component includes a photoelectric sensor or a CCD vision sensor, a signal conditioning circuit, and a microprocessor unit, which collects the deviation amount parameter of the strip in real time as follows: the photoelectric sensor or the CCD vision sensor emits a detection light beam or collects an image by aligning with the edge feature points of the strip, and converts it into a corresponding electrical signal.

[0092] The signal conditioning circuit is used to filter and amplify the electrical signal to suppress field interference.

[0093] The microprocessor unit calculates the actual position coordinates of the edge of the strip according to the processed signal.

[0094] The actual position coordinates are compared with preset reference position coordinates, and the difference is the real-time offset parameter.

[0095] The offset parameter is compared with preset first and second warning thresholds.

[0096] If the offset parameter is less than the first warning threshold, the current running state is maintained.

[0097] If the offset parameter is greater than the first warning threshold and less than the second warning threshold, a hydraulic cylinder is started to perform a rapid correction operation.

[0098] It should be noted that the above-mentioned starting of the hydraulic cylinder to perform the rapid correction operation is specifically: inputting the offset parameter into a proportional-integral controller to generate a control signal.

[0099] The control signal is sent to an electro-hydraulic servo threshold or a proportional threshold to drive the hydraulic cylinder piston rod to extend and retract, thereby driving the correction roller to translate to reduce the offset.

[0100] If the offset parameter is greater than the second warning threshold, a speed reduction instruction and an alarm signal are simultaneously started until the offset parameter returns to below the first warning threshold.

[0101] It should be noted that the first and second warning thresholds are preset according to the width and material characteristics of the strip, and the first warning threshold can be exemplarily 1%-3% of the width of the strip, and the second warning threshold can be exemplarily 3%-5% of the width of the strip, and the first warning threshold is strictly less than the second warning threshold, and the specific values are finally determined through experiments after observing the running stability of the strip and the response state of the correction system under different thresholds in the system debugging stage, and are stored in the system cloud database for direct calling.

[0102] In a preferred embodiment of the present application, the closed-loop correction control mechanism is implemented as follows: during the execution of the rapid correction operation of the hydraulic cylinder, the offset detection assembly feeds back the offset parameter of the strip in real time.

[0103] The feedback offset parameter is compared with the target offset to calculate a correction deviation value.

[0104] The extension and retraction amount of the hydraulic cylinder is adjusted according to the correction deviation value until the offset parameter is less than the first warning threshold.

[0105] If the offset parameter does not return to below the first warning threshold within a preset time, a secondary correction measure is started, including enhancing the driving force of the hydraulic cylinder or adjusting the speed difference of the traction roller.

[0106] The embodiment of the application realizes rapid suppression of deviation and stable operation of the system through offset closed-loop detection and multi-threshold grading deviation correction strategy, avoids single deviation correction method failure leading to strip deviation scrap, and effectively avoids over-adjustment and frequent start-stop.

[0107] The above formulas are dimensionless values calculated, the formula is obtained by collecting a large amount of data to simulate a formula of the nearest real situation, and the preset parameters in the formula are set by a person skilled in the art according to the actual situation.

[0108] The above embodiments can be realized wholly or partially by software, hardware, firmware or any combination thereof. When realized by software, the above embodiments can be realized wholly or partially in the form of a computer program product.

[0109] Those skilled in the art can realize that the modules and algorithm steps of the examples described in combination with the embodiments disclosed herein can be realized by electronic hardware or a combination of computer software and electronic hardware. Whether the functions are realized in hardware or software depends on the specific application and design constraints of the technical solution. A person skilled in the art can use different methods to realize the described functions for each specific application, but such implementation should not be considered beyond the scope of the present application.

[0110] In addition, the functional modules in each embodiment of the present application can be integrated in one processing module, or each module can exist physically alone, or two or more modules can be integrated in one module.

[0111] The above is merely specific embodiments of the present application, but the protection scope of the present application is not limited thereto, any person skilled in the art can easily think of changes or replacements within the technical range disclosed in the present application, which should be covered in the protection scope of the present application. Therefore, the protection scope of the present application should be subject to the protection scope of the claims.

[0112] Finally, the above is only the preferred embodiment of the present application, and is not used to limit the present application, any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application should be included in the protection scope of the present application.

Claims

1. A digital control system for a strip coiling apparatus, characterized by, The application relates to a strip unwinding control system, which comprises the following modules: An unwinding control module: configuring the frequency converter output reverse torque of the unwinder, acquiring the tension data of each monitoring point through the tension sensor assembly, synchronously collecting the state characteristic information of the unwound strip, dynamically adjusting the braking torque based on the matching degree of the tension data and the state characteristic information, and maintaining the unwinding tension stable; In the initial unwinding stage, the frequency converter of the unwinder outputs the reverse torque according to the preset initial torque parameters to establish the initial braking torque; in the unwinding process of the strip, the tension data of each monitoring point are continuously collected through the tension sensor assembly; the state characteristic information of the unwound strip is captured through the image acquisition equipment, and the state characteristic information comprises the slackness, wrinkle state and edge flatness of the strip; a preset matching standard of the tension data and the state characteristic information is that the tension data is within the preset range and the state characteristic information is normal; if it is determined that the tension data and the state characteristic information are matched, the current braking torque is maintained; if it is determined that the tension data and the state characteristic information are not matched, the adjustment amount of the braking torque is calculated according to the deviation direction of the tension data and the abnormal type of the state characteristic information; the output torque of the frequency converter of the unwinder is adjusted according to the adjustment amount until the tension data and the state characteristic information return to the matching state; A synchronous coordination module: setting the coiler as the speed master equipment, controlling the unwinder and the traction roller to track the coiling line speed through the following control strategy, and realizing the synchronous alignment of the running speeds of the multiple equipment; The synchronous coordination module is implemented as follows: the running speed of the coiler is set as the reference speed, and the line speed parameters of the coiler are collected in real time; The running line speed parameters of the unwinder and the traction roller are compared with the line speed parameters of the coiler, and the speed deviation value is calculated; The driving parameters of the unwinder and the traction roller are adjusted based on the speed deviation value and the following control strategy, so that the running speeds of the unwinder and the traction roller converge to the line speed of the coiler; The speed deviation value among the multiple equipment is continuously monitored, and when the speed deviation value is within the preset allowable range, the current control parameters are maintained; otherwise, the speed adjustment process is restarted; A coiling control module: adopting a taper tension control mode, acquiring the current coiling diameter parameters in real time, calculating the real-time tension value in combination with the initial tension parameters and the preset maximum coiling diameter parameters, and determining the real-time tension value based on the correlation between the initial tension value and the proportion of the current coiling diameter in the maximum coiling diameter; The real-time tension value is converted into the control signal of the coiler, the coiling driving force is adjusted, and the actual coiling tension is kept consistent with the calculated real-time tension value; A deviation rectification module: detecting the deviation amount parameters of the strip, starting the closed-loop rectification control mechanism, and executing corresponding rectification operations according to the comparison result of the deviation amount parameters and the preset early warning threshold value; The deviation rectification module is implemented as follows: The deviation amount parameters of the strip are collected in real time through the deviation detection assembly; The deviation amount parameters are compared with the preset first early warning threshold value and second early warning threshold value; If the deviation amount parameters are smaller than the first early warning threshold value, the current running state is maintained; If the deviation amount parameters are greater than the first early warning threshold value and smaller than the second early warning threshold value, the hydraulic cylinder is started to execute the rapid rectification operation; If the deviation amount parameters are greater than the second early warning threshold value, the speed reduction instruction and the alarm signal are simultaneously started until the deviation amount parameters return to below the first early warning threshold value.

2. A digital control system for a strip coiling apparatus as claimed in claim 1, wherein, The state characteristic information of the unwound strip is captured as follows: An image acquisition device is arranged at the outlet side of the uncoiler to continuously acquire images of the strip surface and edges to generate an image sequence; Real-time image processing and feature extraction are performed on the image sequence, including: I. Calculating the displacement vector field of specific textures on the strip surface between consecutive frames to quantify the longitudinal and transverse strain distribution of the strip surface, and using the mean value and fluctuation degree of the strain distribution as quantitative parameters to represent the strip relaxation; II. Identifying the wrinkle regions on the strip surface and generating a pixel-level mask for the wrinkle regions, and using the area ratio and number of the wrinkle regions as quantitative parameters to represent the wrinkle state; III. Extracting the edge pixels of the strip, fitting the extracted edge pixels into an ideal reference straight line using the least squares method, and calculating the average deviation and maximum deviation of the edge pixels from the ideal reference straight line as quantitative parameters to represent the edge flatness; The extracted quantitative parameters are used as the basis for judging the running state of the strip to capture the state feature information of the uncoiled strip.

3. A digital control system for a strip coiling apparatus as defined in claim 1, wherein The adjustment amount of the braking torque is implemented as follows: By performing time-series incremental operation on the deviation value of the tension data from its matching standard, the basic adjustment amount of the braking torque is obtained, and according to the deviation direction of the tension data from its matching standard, the positive or negative direction of the basic adjustment amount of the braking torque is determined; According to the abnormal type of the state feature information, the corresponding compensation adjustment amount is obtained by querying the pre-defined compensation strategy table; The visual confidence weight is calculated based on the significance of the state feature information anomaly, and the compensation adjustment amount and the basic adjustment amount are weighted and allocated, and the final braking torque adjustment amount is calculated by linear weighted fusion.

4. The digital control system for a strip coiling apparatus of claim 1 wherein, The following implementation is followed for the following control strategy: The linear speed parameter of the coiler is used as the target speed signal, which is sent to the control units of the uncoiler and the traction roller respectively; The control units of the uncoiler and the traction roller generate adjustment signals according to the difference between the target speed signal and the actual speed parameter; Based on the adjustment signal, the driving parameters are corrected in real time to gradually approach the target speed signal; During the speed adjustment process, the speed deviation value is continuously monitored, and when the speed deviation value is less than the preset threshold, it is determined that the synchronization is completed.

5. The digital control system for a strip coiling apparatus of claim 1 wherein, The following implementation is followed for the coiling control module: In the initial stage of coiling, the initial tension parameter and the maximum coil diameter parameter are set, and the taper coefficient is configured; The current coil diameter parameter during coiling is obtained in real time by the coil diameter detection component; Based on the proportional relationship among the initial tension parameter, the current coil diameter parameter and the maximum coil diameter parameter, and the taper coefficient, the real-time tension value is calculated; The real-time tension value is converted into a control signal of the coiler to adjust the coiling driving force, so that the actual coiling tension remains consistent with the calculated real-time tension value; When the coil diameter parameter reaches the maximum coil diameter parameter, the coiling operation is stopped.

6. A digital control system for a strip coiling apparatus as defined in claim 5, wherein The following implementation is followed for the coil diameter detection component: A displacement detection device is arranged beside the coiler to monitor the distance parameter between the coiling shaft and the detection point in real time; According to the distance parameter and the structural size of the coiler, the current coil diameter parameter is calculated. The current roll diameter parameter is compared with a preset maximum roll diameter parameter, and when the current roll diameter parameter reaches a preset proportion of the maximum roll diameter parameter, a roll diameter early warning signal is sent out.

7. The digital control system for a strip coiling apparatus of claim 1 wherein, The closed-loop deviation correction control mechanism is implemented as follows: During the fast deviation correction operation of the hydraulic cylinder, the offset detection assembly feeds back the strip offset parameter in real time; The feedback offset parameter is compared with the target offset to calculate a deviation correction deviation value; The extension amount of the hydraulic cylinder is adjusted according to the deviation correction deviation value until the offset parameter is less than the first early warning threshold; If the offset parameter does not return below the first early warning threshold within a preset time, a secondary deviation correction measure is started, including enhancing the driving force of the hydraulic cylinder or adjusting the speed difference of the traction rollers.

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