Cooling setting unit system for corona film production and control method

Abstract

The invention relates to the technical field of film production, in particular to a cooling setting unit system for corona film production and a control method. Comprising a cooling roller, a compressor, a condenser, a drying filter, a thermostatic expansion valve, a dry type evaporator, a water pump, a water tank, a freezing water return port, a freezing water outlet, a water supplementing port and a water discharging port. A waterway output end of the dry-type evaporator is connected to a water inlet connector of the cooling roller, a medium outlet end of the dry-type evaporator is connected with the compressor, the compressor is connected with the condenser, the condenser is connected with the drying filter, the drying filter is connected with the thermostatic expansion valve, and the thermostatic expansion valve is connected with a medium inlet of the dry-type evaporator to form circulation. According to the invention, the problems of bubbles and shrinkage are eliminated by realizing efficient shaping.

Description

Technical Field

[0001] This invention relates to the technical field of thin film production, and specifically to a cooling and shaping unit system and control method for corona thin film production. Background Technology

[0002] In the field of plastic film processing, corona treatment, as a core process for enhancing film surface energy, is widely used in packaging, electronics, new energy, and medical industries. It uses high-voltage discharge to oxidize the molecules on the film surface, forming active groups such as hydroxyl and carbonyl groups, thereby enhancing the adhesion of inks, adhesives, and the film. However, the high temperatures generated during corona treatment (reaching 150-200℃) can easily lead to film deformation, adhesion, or surface performance degradation. Especially in the production of multilayer co-extruded films, issues such as bubbles and shrinkage directly affect product yield and performance. Traditional cooling methods using fans or circulating air have the following technical drawbacks:

[0003] Insufficient cooling efficiency: Air cooling systems dissipate heat through air convection, but the heat exchange coefficient between the film surface and the air is low, resulting in slow cooling speed and easy uneven film shrinkage; Water cooling systems have high heat conduction efficiency, but direct contact can easily lead to moisture residue on the film surface, causing delamination problems in subsequent printing or lamination processes.

[0004] Poor temperature control accuracy: Traditional cooling devices lack a dynamic temperature feedback mechanism and cannot adjust cooling parameters in real time according to the film material (such as PP, PE, PI) or thickness (5-200μm), resulting in large fluctuations in film surface tension, which affects printing clarity and composite strength. Summary of the Invention

[0005] In order to solve the technical problems and shortcomings in the prior art, the present invention provides a cooling and shaping unit system and control method for the production of corona films, which can overcome the technical problems of…

[0006] To achieve the above and other related objectives, the present invention adopts the following technical solution:

[0007] A cooling and setting unit system for corona-treated film production includes a frame, a separating roller, a corona treatment device, a guide roller, a cooling and setting machine, and a take-up roller. The film passes sequentially through the separating roller, the corona treatment device, the guide roller, the cooling and setting machine, and the take-up roller. Two sets of these components are symmetrically arranged. The cooling and setting machine includes a cooling roller, a compressor, a condenser, a dry filter, a thermal expansion valve, a dry evaporator, a water pump, a water tank, an axial flow fan, a chilled water return port, a chilled water outlet, a water inlet, and a drain port. The cooling roller cools and sets the film while transporting it. The water outlet of the cooling roller is connected to the water tank, the water inlet is connected above the water tank, and the drain port is connected below the water tank. The water pump, mounted on the water tank, delivers water to the dry evaporator. The water output of the dry evaporator is connected to the water inlet of the cooling roller.

[0008] The medium outlet of the dry evaporator is connected to a compressor, the compressor is connected to a condenser, the condenser is connected to a drying filter, the drying filter is connected to a thermal expansion valve, and the thermal expansion valve is connected to the medium inlet of the dry evaporator to form a circulation. An axial flow fan blows air onto the condenser.

[0009] Preferably, the cooling roller is mounted on a frame, and temperature sensors and air outlet ducts are arranged along the length of the cooling roller on the frame. The temperature sensors and air outlet ducts correspond one-to-one and monitor the temperature at the outlet of the air outlet duct in real time. Each air outlet duct is equipped with a wind temperature controller, which is connected to the temperature sensor and the central controller to output the set wind speed and wind temperature.

[0010] Preferably, the frame is divided into multiple control areas, each of which is equipped with a temperature sensor and an air outlet duct to form a zone control unit, which performs temperature compensation and airflow control for the control area.

[0011] Preferably, an image recognition unit is provided on the frame. The image recognition unit acquires images of the film and cooling roller after contact, during initial cooling, during initial shaping, and during separation. It obtains the separation boundary between the film and cooling roller and transmits the separation boundary to the central controller as a control variable for the area control unit.

[0012] Preferably, the central controller divides the separation boundary lines according to the control area division method and forms unit boundaries, determines the coordinate system based on the separation boundary lines, and proposes a target straight line, and determines the adjustment parameters based on the difference between the unit boundary lines and the target straight line.

[0013] Preferably, the central controller records a certain moment, the unit boundary variable c(t), and the control variable r(t) output by the central controller; constructs a variable function as: deviation e(t) = r(t) - c(t); sets parameters a0, a1, and a2 to form the control increment, Δu(t) = a0e(t) + a1e(t-1)a2e(t-2); and stores Δu(t); shifts the deviation function in time to prepare for the next moment: that is, changes e(t-1) to e(t-2), changes e(t) to e(t-1), and finally returns.

[0014] Preferably, the central controller calculates the deviation function e(t), the coarse adjustment term, and the fine adjustment term, and determines the output function u(t-1) of the previous moment and the maximum control quantity u. max And the sign of the deviation e(t):

[0015] Case 1: If u(t-1) ≥ u max And e(t) > 0, or u(t-1) ≤ u min If e(t) < 0, then the cumulative error term is not acquired;

[0016] Scenario 2: If u min <u(t-1)<u max Then calculate the cumulative error;

[0017] Finally, the coarse adjustment term, the cumulative error term, and the fine adjustment term are added to the control variable to form the control output at this moment.

[0018] On the other hand, a control method is also provided. According to the cooling and shaping unit system for corona film production described above, the wind force, wind temperature and unit boundary in the area control unit are formed into a dataset based on the sampling time and transmitted to the cloud server. The cloud server performs data fitting based on historical data and infers the wind force and wind temperature output of the optimal unit boundary.

[0019] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0020] 1. This invention uses a separating roller to split the film, a corona treatment device to corona treat one side of the film, and a guide roller to guide the film into a cooling and setting machine. The cooling and setting machine uses its water cooling technology to cool and set the film. The film is cooled by contacting the surface of the cooling roller. This equipment is symmetrically set in two sets, which can be used to manufacture packaging bags or perform multi-layer processing of bag bodies, and can improve work efficiency. The cooling and setting machine can quickly cool down the film, set the film, and accurately control the temperature to make the film set stable.

[0021] 2. In this invention, not only is the film cooled by the cooling and setting machine, but the ambient temperature and wind force are also controlled by combining the air outlet duct and temperature sensor. The wind force with a specific temperature can play an auxiliary role in the removal of the film from the cooling roller after it has been set.

[0022] 3. Based on the structure of the cooling roller, multiple control zones are set up to improve the control range and accuracy, which can more accurately improve the film forming quality. Image recognition is used to determine the separation boundary, and through data processing and parameter adjustment, the separation boundary can be made to tend to a straight line, maintaining reliable forming quality.

[0023] Other additional advantages and benefits of this application will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of this application. Attached Figure Description

[0024] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used in conjunction with embodiments of the invention to explain the invention and do not constitute a limitation thereof. In the drawings:

[0025] Figure 1 This is a simplified schematic diagram of the overall structure of an embodiment of this application;

[0026] Figure 2 This is a partial schematic diagram illustrating the operation of an embodiment of this application;

[0027] Figure 3 This is a schematic diagram illustrating the principle of this application;

[0028] Figure 4 This is a schematic diagram of a cooling and setting machine.

[0029] Explanation of reference numerals for major components:

[0030] 1. Compressor; 2. Condenser; 3. Dryer filter; 4. Thermal expansion valve; 5. Dry evaporator; 6. Water pump; 7. Water tank; 8. Axial flow fan; 9. Chilled water return port; 10. Chilled water outlet; 11. Water inlet; 12. Drain port; 13. Frame; 14. Separating roller; 15. Corona discharge device; 16. Guide roller; 17. Take-up roller; 18. Film; 19. Cooling roller; 20. Temperature sensor; 21. Air outlet duct; 22. Control area; 23. Area control unit; 24. Image recognition unit; 25. Separation boundary line; 26. Unit boundary line; 27. Target straight line. Detailed Implementation

[0031] The specific embodiments of the present invention will be further described below with reference to the accompanying drawings. The following specific examples illustrate the embodiments of the present invention, and those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments, and the details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of the present invention. It should be noted that, unless otherwise specified, the following embodiments and features in the embodiments can be combined with each other.

[0032] It should be noted that the illustrations provided in the following embodiments are only schematic representations of the basic concept of the present invention. The illustrations only show the components related to the present invention and are not drawn according to the number, shape and size of the components in actual implementation. In actual implementation, the form, quantity and proportion of each component can be changed at will, and the layout of the components may also be more complex.

[0033] It should be noted that in the description of this application, the terms "upper," "lower," "left," "right," "inner," and "outer," etc., indicating directional or positional relationships, are based on the directional or positional relationships shown in the accompanying drawings. These are merely for ease of description and do not indicate or imply that the device or element must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting the invention. Furthermore, it should be noted that in the description of this application, unless otherwise explicitly specified and limited, the terms "installed," "connected," "linked," 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 communication between two elements. Those skilled in the art can understand the specific meaning of the above terms in the invention based on the specific circumstances.

[0034] Example:

[0035] This invention discloses a cooling and shaping unit system for the production of corona thin films 18, with reference to... Figure 1 As shown, the assembly includes a frame 13, a separating roller 14, a corona treatment device 15, a guide roller 16, a cooling and setting machine, and a take-up roller 17. The film 18 passes sequentially through the separating roller 14, the corona treatment device 15, the guide roller 16, the cooling and setting machine, and the take-up roller 17. Two sets of the separating roller 14, the corona treatment device 15, the guide roller 16, the cooling and setting machine, and the take-up roller 17 are symmetrically arranged. This allows the film 18 to be split, and each split film 18 undergoes corona treatment on one side before being directly cooled and set.

[0036] Combination Figure 1 , Figure 2 and Figure 4 Understandably, the cooling and setting machine includes a cooling roller 19, a compressor 1, a condenser 2, a dryer filter 3, a thermal expansion valve 4, a dry evaporator 5, a water pump 6, a water tank 7, an axial flow fan 8, a chilled water return port 9, a chilled water outlet 10, a water inlet 11, and a drain port 12. Figure 4 The load in the cooling roller 19 is the cooling roller 19. The cooling roller 19 cools and shapes the film 18 while transporting it. The water outlet of the cooling roller 19 is connected to the water tank 7. The water tank 7 is connected to the water inlet 11 above and the water outlet 12 below. The water tank 7 is equipped with a water pump 6 to transport water to the dry evaporator 5. The water output end of the dry evaporator 5 is connected to the water inlet of the cooling roller 19.

[0037] The medium outlet of the dry evaporator 5 is connected to the compressor 1, the compressor 1 is connected to the condenser 2, the condenser 2 is connected to the dry filter 3, the dry filter 3 is connected to the thermal expansion valve 4, and the thermal expansion valve 4 is connected to the medium inlet of the dry evaporator 5 to form a circulation. The axial flow fan 8 blows air onto the condenser 2.

[0038] The cooling system operates on the following principle: chilled water is supplied to the load, i.e., the cooling roller 19, through a water circulation system. The cooling roller 19 absorbs the temperature of the thin film 18, raising the temperature of the chilled water, which is then discharged into the water tank 7. The water tank 7 is then pumped by the water pump 6 to the dry evaporator 5 for cooling, producing new chilled water which is then supplied to the cooling system, thus forming a cycle. The water tank 7 can be used for water replacement or water level adjustment via the water inlet 11 and the drain 12. The operating principle of the refrigerant's circulation piping is the same as that of an air conditioner. It should be noted that the core function of the dryer filter 3 is to protect the refrigeration system from moisture and impurities.

[0039] Specifically, the process includes: Drying: Adsorbing moisture from the refrigerant using molecular sieves and activated alumina to prevent ice blockage. Filtration: Using a metal mesh to intercept solid impurities, preventing clogging of the throttling element or damage to compressor 1. Neutralization: Some models can neutralize acidic substances to prevent metal corrosion. Installation location: Typically located on the high-pressure liquid line between the condenser 2 outlet and the expansion valve inlet.

[0040] Thermostatic expansion valve has four core functions: 1. Regulating refrigerant flow to maintain stable system operation. 2. Throttling and pressure reduction: Converting high-pressure liquid into a low-temperature, low-pressure vapor-liquid mixture. 3. Flow regulation: Automatically adjusting the opening based on the temperature sensor signal to adapt to changes in refrigeration load. 4. Superheat control: Ensuring the evaporator has appropriate superheat to prevent liquid slugging and abnormal overheating. It also controls the flow and pressure of the refrigeration system.

[0041] Based on the above scheme, further preferred options are as follows: Figure 3The cooling roller 19 is mounted on the frame 13. Temperature sensors 20 and air outlet ducts 21 are arranged along the length of the cooling roller 19 on the frame 13. The temperature sensors 20 and air outlet ducts 21 are one-to-one and monitor the temperature at the outlet of the air outlet duct 21 in real time. Each air outlet duct 21 is equipped with a temperature controller, which is connected to the temperature sensor 20 and the central controller to output the set airflow and temperature. The frame 13 is divided into multiple control areas 22. Each control area 22 is equipped with a temperature sensor 20 and an air outlet duct 21, forming an area control unit 23, which performs temperature compensation and airflow control for this control area 22.

[0042] An image recognition unit 24 is installed on the frame 13. The image recognition unit 24 captures images of the film 18 and the cooling roller 19 after contact, during initial cooling, during initial shaping, and during separation. It obtains the separation boundary 25 between the film 18 and the cooling roller 19 and transmits the separation boundary 25 to the central controller as a control variable for the area control unit 23. The hardware of the image recognition unit 24 can be a camera.

[0043] The central controller divides the separation boundary 25 according to the division method of the control area 22, forming unit boundaries 26. Based on the separation boundary 25, a coordinate system is determined, and a target straight line 27 is proposed. The adjustment parameters are determined based on the difference between the unit boundary 26 and the target straight line 27. The central controller records a certain moment, the unit boundary variable c(t), and the control variable r(t) output by the central controller; constructs a variable function as: deviation e(t) = r(t) - c(t); sets parameters a0, a1, and a2 to form the control increment, Δu(t) = a0e(t) + a1e(t-1)a2e(t-2); and stores Δu(t); shifts the deviation function in time to prepare for the next moment: that is, changing e(t-1) to e(t-2), changing e(t) to e(t-1), and finally returning. In this scheme, since the increment is only related to the most recent deviation sampling values ​​and does not need to be accumulated, it is relatively easy to generate accumulated errors. At the same time, the false triggering is small, the control of air pressure (blowing force) in the jet system is more precise, and it is easy to respond quickly during the start-up process.

[0044] The central controller calculates the deviation function e(t), the coarse adjustment term, and the fine adjustment term, and compares the output function u(t-1) of the previous moment with the maximum control quantity u. max And the sign of the deviation e(t):

[0045] Case 1: If u(t-1) ≥ u max And e(t) > 0, or u(t-1) ≤ u min If e(t) < 0, then the cumulative error term is not acquired;

[0046] Scenario 2: If u min <u(t-1)<u max Then calculate the cumulative error;

[0047] Finally, the coarse adjustment term, the cumulative error term, and the fine adjustment term are added to the control variable to form the control output at this moment.

[0048] It can effectively suppress the saturation phenomenon of control quantity. In actual operation, due to the limitation or saturation of parameters such as maximum air pressure of the air pump and other blowing equipment, the control quantity and its rate of change are often limited to a maximum and minimum range, which can easily increase the overshoot and settling time of the system. By judging whether the system has entered the saturation state, the cumulative error term is not calculated after entering the saturation range, which can also be said to weaken the accumulation of the cumulative error term, thereby effectively overcoming the problem of cumulative error saturation.

[0049] Example 2:

[0050] Based on the above embodiment 1, a control method is provided. According to the cooling and shaping unit system for the production of corona film 18 described above, the wind force, wind temperature and unit boundary 26 in the area control unit 23 are formed into a dataset according to the sampling time and transmitted to the cloud server. The cloud server performs data fitting based on historical data and infers the optimal wind force and wind temperature output of the unit boundary 26.

[0051] Based on the structure of the cooling roller 19, multiple control areas 22 are set to improve the control range and accuracy, which can more accurately improve the forming quality of the film 18. Image recognition is used to determine the separation boundary 25, and through data processing and parameter adjustment, the separation boundary 25 can be made to tend to a straight line, maintaining reliable forming quality.

[0052] The technical solution of the present invention has been described above with reference to the preferred embodiments shown in the accompanying drawings. The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. For those skilled in the art, the present invention can have various modifications and variations. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A cooling and setting unit system for the production of corona-treated film (18), comprising a frame (13), a separating roller (14), a corona treatment device (15), a guide roller (16), a cooling and setting machine, and a take-up roller (17), wherein the film (18) passes sequentially through the separating roller (14), the corona treatment device (15), the guide roller (16), the cooling and setting machine, and the take-up roller (17), wherein the separating roller (14), the corona treatment device (15), the guide roller (16), the cooling and setting machine, and the take-up roller (17) are symmetrically arranged in two sets, characterized in that, The cooling and shaping machine includes a cooling roller (19), a compressor (1), a condenser (2), a dry filter (3), a thermal expansion valve (4), a dry evaporator (5), a water pump (6), a water tank (7), an axial flow fan (8), a chilled water return port (9), a chilled water outlet (10), a water inlet (11), and a drain port (12). The cooling roller (19) cools and shapes the film (18) while transporting it. The water outlet of the cooling roller (19) is connected to the water tank (7). The water inlet (11) is connected to the top of the water tank (7), and the drain port (12) is connected to the bottom of the water tank (7). The water pump (6) is mounted on the water tank (7) to transport water to the dry evaporator (5). The water output end of the dry evaporator (5) is connected to the water inlet of the cooling roller (19). The medium outlet end of the dry evaporator (5) is connected to the compressor (1), the compressor (1) is connected to the condenser (2), the condenser (2) is connected to the dryer filter (3), the dryer filter (3) is connected to the thermal expansion valve (4), the thermal expansion valve (4) is connected to the medium inlet of the dry evaporator (5) to form a circulation, and the axial flow fan (8) blows air onto the condenser (2).

2. The cooling and shaping unit system for the production of corona films (18) according to claim 1, characterized in that, The cooling roller (19) is mounted on the frame (13). Temperature sensors (20) and air outlet pipes (21) are arranged along the length of the cooling roller (19) on the frame (13). The temperature sensors (20) and air outlet pipes (21) correspond one-to-one and monitor the temperature at the outlet of the air outlet pipe (21) in real time. Each air outlet pipe (21) is equipped with a wind temperature controller. The wind temperature controller is connected to the temperature sensor (20) and the central controller and outputs the set wind force and wind temperature.

3. The cooling and shaping unit system for the production of corona films (18) according to claim 2, characterized in that, The frame (13) is divided into multiple control areas (22). Each control area (22) is equipped with a temperature sensor (20) and an air outlet duct (21) to form a regional control unit (23), which performs temperature compensation and airflow control on this control area (22).

4. The cooling and shaping unit system for the production of corona films (18) according to claim 3, characterized in that, An image recognition unit (24) is provided on the frame (13). The image recognition unit (24) collects images of the film (18) and the cooling roller (19) after contact, during initial cooling, during initial shaping, and during separation. It obtains the separation boundary (25) between the film (18) and the cooling roller (19) and transmits the separation boundary (25) to the central controller as a control variable for the area control unit (23).

5. The cooling and shaping unit system for the production of corona films (18) according to claim 4, characterized in that, The central controller divides the separation boundary (25) according to the division method of the control area (22) and forms a unit boundary (26). It determines the coordinate system based on the separation boundary (25) and proposes the target straight line (27). It determines the adjustment parameters based on the difference between the unit boundary (26) and the target straight line (27).

6. The cooling and shaping unit system for corona film production according to claim 5, characterized in that, The central controller records a certain moment, the unit boundary variable c(t), and the control variable r(t) of the wind force output by the central controller; constructs a variable function as: deviation e(t) = r(t) - c(t); sets parameters a0, a1, a2 to form the control increment, Δu(t) = a0e(t) + a1e(t-1)a2e(t-2); and stores Δu(t). The deviation function is shifted in time to prepare for the next moment: that is, e(t-1) is changed to e(t-2), e(t) is changed to e(t-1), and finally the result is returned.

7. The cooling and shaping unit system for corona film production according to claim 6, characterized in that, The central controller calculates the deviation function e(t), the coarse adjustment term, and the fine adjustment term, and determines the output function u(t-1) of the previous moment and the maximum control quantity u. max And the sign of the deviation e(t): Case 1: If u(t-1) ≥ u max And e(t) > 0, or u(t-1) ≤ u min If e(t) < 0, then the cumulative error term is not acquired; Scenario 2: If u min <u(t-1)<u max Then calculate the cumulative error; Finally, the coarse adjustment term, the cumulative error term, and the fine adjustment term are added to the control variable to form the control output at this moment.

8. A control method, comprising a cooling and shaping unit system for the production of corona films (18) according to any one of claims 1-7, characterized in that, The wind force, wind temperature and unit boundary (26) in the area control unit (23) are formed into a dataset according to the sampling time and transmitted to the cloud server. The cloud server performs data fitting based on historical data and infers the wind force and wind temperature output of the optimal unit boundary (26).

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