Coil diameter detection method, detection device, equipment and medium

Abstract

The invention discloses a rolling diameter detection method, a detection device, equipment and a medium. The rolling diameter detection method comprises the following steps: firstly, recording a sensing signal at a preset sensing position sensed by a U-shaped switch sensor in real time; an analog quantity signal corresponding to an ultrasonic signal received by the ultrasonic sensor is recorded in real time, then the rolling diameter of the detected coiled material is detected according to a sensing signal at a preset sensing position sensed by the U-shaped switch sensor and is defined as a first rolling diameter, and the rolling diameter of the detected coiled material is defined as a second rolling diameter according to the analog quantity signal corresponding to the ultrasonic signal received by the ultrasonic sensor. And detecting the rolling diameter of the detected coiled material, defining the rolling diameter as a second rolling diameter, and finally determining the first rolling diameter as a target rolling diameter value of the detected coiled material when the difference value between the first rolling diameter and the second rolling diameter meets a preset rolling diameter difference value range. By means of the method, the ultrasonic sensor and the U-shaped switch sensor are used for detecting the rolling diameter of the same to-be-detected coiled material at the same time, and the target rolling diameter value of the to-be-detected coiled material is obtained by combining the two modes.

Description

Technical Field

[0001] This invention relates to the field of roll-to-roll equipment technology, and more particularly to a roll diameter detection method, detection device, equipment, and medium. Background Technology

[0002] When a roll-to-roll machine operates automatically, the unwinding reel continuously feeds material, causing the diameter of the measured roll material corresponding to the unwinding reel to gradually decrease, while the rewinding reel continuously winds material, causing the diameter of the measured roll material corresponding to the rewinding reel to gradually increase. When the unwinding reel runs out of material, it needs to be replaced with a new roll material. The diameter of the new roll material will be much larger than the original roll diameter, meaning there will be a sudden change in roll diameter after replacement. Similarly, when the unwinding reel is full, it needs to be replaced with a new empty straight cylinder to store material. The diameter of the new empty straight cylinder will be much smaller than the original roll diameter, also resulting in a sudden change in roll diameter after replacement. With the increasing control precision of roll-to-roll equipment and the need to improve scrap control during production, the requirements for the accuracy of roll diameter detection during unwinding and rewinding are becoming increasingly stringent.

[0003] Currently, the methods for detecting roll diameter are relatively simple and prone to detection errors, which affect the stability of roll-to-roll equipment. Summary of the Invention

[0004] This invention provides a roll diameter detection method, detection device, equipment, and medium. The target roll diameter value of the tested roll material is obtained by combining ultrasonic sensor detection and U-shaped switch sensor detection, which accurately detects the roll diameter of the tested roll material and reduces manual intervention and device errors.

[0005] In a first aspect, embodiments of the present invention provide a roll diameter detection method, applied in a roll-to-roll device, the roll-to-roll device including an ultrasonic sensor, a U-shaped switch sensor and a baffle trigger assembly;

[0006] The ultrasonic sensor is set in the radial direction of the rotating shaft corresponding to the tested roll material, the U-shaped switch sensor is set at the preset sensing position corresponding to the same tested roll material, and the baffle trigger assembly is set on the rotating shaft corresponding to the same tested roll material.

[0007] The roll diameter detection method includes:

[0008] The test roll material is controlled to rotate to drive the rotation of the baffle trigger assembly, so that the baffle trigger assembly passes through the preset sensing position, and the sensing signal at the preset sensing position sensed by the U-shaped switch sensor is recorded in real time.

[0009] The ultrasonic sensor is controlled to emit ultrasonic signals toward the roll material under test, and to receive the reflected ultrasonic signals, and to record the analog signal corresponding to the ultrasonic signal received by the ultrasonic sensor in real time.

[0010] Based on the sensing signal at the preset sensing position sensed by the U-shaped switch sensor, the roll diameter of the tested roll material is detected and defined as the first roll diameter; and based on the analog signal corresponding to the ultrasonic signal received by the ultrasonic sensor, the roll diameter of the tested roll material is detected and defined as the second roll diameter.

[0011] When the difference between the first roll diameter and the second roll diameter meets the preset roll diameter difference range, the first roll diameter is determined as the target roll diameter value of the tested roll material.

[0012] Optionally, based on the sensing signal at the preset sensing position sensed by the U-shaped switch sensor, the roll diameter of the tested roll material is detected and defined as the first roll diameter, including:

[0013] The time difference between two consecutive sensing signals detected by the U-shaped switch sensor at the preset sensing position is obtained and defined as the first time difference;

[0014] The first roll diameter is determined based on the rotation speed of the tested roll material and the first time difference.

[0015] Optionally, determining the first roll diameter based on the rotational speed of the tested roll material and the first time difference includes:

[0016] The first roll diameter D1 is obtained according to the calculation formula D1=V×T / π; where V represents the rotation speed of the tested roll material, T represents the first time difference, and π represents pi.

[0017] Optionally, determining the first roll diameter based on the rotational speed of the tested roll material and the first time difference includes:

[0018] The first roll diameter is obtained by integrating the rotation speed of the tested roll material and the first time difference.

[0019] Optionally, based on the analog signal corresponding to the ultrasonic signal received by the ultrasonic sensor, the roll diameter of the tested roll material is detected and defined as a second roll diameter, including:

[0020] Based on the analog signal corresponding to the ultrasonic signal received by the ultrasonic sensor, the distance between the ultrasonic sensor and the tested roll material is determined and defined as the first distance.

[0021] The second roll diameter is determined based on the distance between the ultrasonic sensor and the rotation axis corresponding to the tested roll material and the first distance.

[0022] Optionally, based on the analog signal corresponding to the ultrasonic signal received by the ultrasonic sensor, the distance between the ultrasonic sensor and the tested roll material is determined and defined as a first distance, including:

[0023] The first distance L1 is obtained according to the calculation formula L1=K×J1; where J1 represents the analog signal corresponding to the ultrasonic signal received by the ultrasonic sensor, and K represents the distance scaling factor.

[0024] Optionally, determining the second roll diameter based on the distance between the ultrasonic sensor and the rotation axis corresponding to the tested roll material and the first distance includes:

[0025] The second roll diameter D2 is obtained according to the calculation formula D2=2×(L0- L1); where L0 represents the distance between the ultrasonic sensor and the rotation axis corresponding to the roll material being tested, and L1 represents the first distance.

[0026] Secondly, embodiments of the present invention also provide a roll diameter detection device, which is applied in a roll-to-roll device, the roll-to-roll device including an ultrasonic sensor, a U-shaped switch sensor and a baffle trigger assembly;

[0027] The ultrasonic sensor is set in the radial direction of the rotating shaft corresponding to the tested roll material, the U-shaped switch sensor is set at the preset sensing position corresponding to the same tested roll material, and the baffle trigger assembly is set on the rotating shaft corresponding to the same tested roll material.

[0028] The roll diameter detection device includes:

[0029] The trigger detection module is used to control the rotation of the tested roll material to drive the rotation of the baffle trigger assembly, so that the baffle trigger assembly passes through the preset sensing position, and records the sensing signal at the preset sensing position sensed by the U-shaped switch sensor in real time.

[0030] An ultrasonic testing module is used to control the ultrasonic sensor to emit ultrasonic signals toward the tested roll material, receive the reflected ultrasonic signals, and record the analog signal corresponding to the ultrasonic signal received by the ultrasonic sensor in real time.

[0031] The roll diameter detection module is used to detect the roll diameter of the tested roll material based on the sensing signal at the preset sensing position sensed by the U-shaped switch sensor, and define it as the first roll diameter; and to detect the roll diameter of the tested roll material based on the analog signal corresponding to the ultrasonic signal received by the ultrasonic sensor, and define it as the second roll diameter.

[0032] The roll diameter determination module is used to determine the first roll diameter as the target roll diameter value of the tested roll material when the difference between the first roll diameter and the second roll diameter meets a preset roll diameter difference range.

[0033] Thirdly, embodiments of the present invention also provide a terminal device, including:

[0034] One or more processors;

[0035] Storage device for storing one or more programs;

[0036] When the one or more programs are executed by the one or more processors, the one or more processors implement the roll diameter detection method as described in any of the first aspects.

[0037] Fourthly, embodiments of the present invention also provide a computer-readable storage medium having a computer program stored thereon, which, when executed by a processor, implements the roll diameter detection method as described in any of the first aspects.

[0038] This invention provides a roll diameter detection method, detection device, equipment, and medium. The roll diameter detection method first controls the rotation of the roll material to be tested, thereby driving the rotation of the baffle trigger assembly, so that the baffle trigger assembly passes through a preset sensing position, and records the sensing signal at the preset sensing position sensed by the U-shaped switch sensor in real time; controls an ultrasonic sensor to emit an ultrasonic signal toward the roll material to be tested, and receives the reflected ultrasonic signal, and records the analog signal corresponding to the ultrasonic signal received by the ultrasonic sensor in real time; then, based on the sensing signal at the preset sensing position sensed by the U-shaped switch sensor, the roll diameter of the roll material to be tested is detected and defined as the first roll diameter; and based on the analog signal corresponding to the ultrasonic signal received by the ultrasonic sensor, the roll diameter of the roll material to be tested is detected and defined as the second roll diameter; finally, when the difference between the first roll diameter and the second roll diameter meets a preset roll diameter difference range, the first roll diameter is determined as the target roll diameter value of the roll material to be tested. Using the above method, both ultrasonic sensors and U-shaped switch sensors are used to detect the diameter of the same roll material. This fully leverages the advantages of both ultrasonic sensors (for diameter detection) and U-shaped switch sensors (for diameter calculation). The target diameter value of the roll material is determined by a combination of these two methods, providing real-time and accurate diameter detection. This method is stable, reliable, simple to operate, and reduces manual intervention time and device operating errors. The principle is simple, requiring no manual operation. After roll-to-roll equipment changes rolls, the ultrasonic sensors can detect the sudden change in diameter in real time. During roll-to-roll operation, the U-shaped switch sensors eliminate the impact of sudden changes and errors detected by the ultrasonic sensors. This avoids sudden diameter changes, eliminates detection errors, and prevents human error. It addresses the problem of unstable winding and unwinding leading to speed mismatch and tension instability, thus causing overall equipment malfunction. This improves the operating efficiency and stability of roll-to-roll equipment, ensuring speed matching and tension stability.

[0039] It should be understood that the description in this section is not intended to identify key or essential features of the embodiments of the present invention, nor is it intended to limit the scope of the invention. Other features of the invention will become readily apparent from the following description. Attached Figure Description

[0040] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0041] Figure 1 This is a schematic diagram illustrating the positional relationship between an ultrasonic sensor and the roll material being tested, provided in an embodiment of the present invention.

[0042] Figure 2 This is a schematic diagram illustrating the positional relationship between a U-shaped switch sensor, a baffle trigger assembly, and the roll material being tested, provided in an embodiment of the present invention.

[0043] Figure 3 This is a schematic flowchart of a roll diameter detection method provided in an embodiment of the present invention;

[0044] Figure 4 This is a flowchart illustrating another roll diameter detection method provided in an embodiment of the present invention;

[0045] Figure 5 This is a flowchart illustrating another roll diameter detection method provided in an embodiment of the present invention;

[0046] Figure 6 This is a schematic diagram of the structure of a roll diameter detection device provided in an embodiment of the present invention;

[0047] Figure 7 This is a schematic diagram of the structure of a terminal device provided in an embodiment of the present invention. Detailed Implementation

[0048] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of the present invention.

[0049] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this invention are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of the invention described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover a non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0050] It should be noted that, based on verification, current methods for detecting the roll diameter of tested materials generally employ a single ultrasonic sensor for real-time monitoring. However, this real-time ultrasonic detection method is prone to abrupt changes and detection errors due to the continuous operation of the unwinding and rewinding shafts. Furthermore, the ultrasonic sensor itself is susceptible to data deviations caused by factors such as air pressure, temperature, installation-related detection angles, and noise. Alternatively, the roll diameter of the tested material can be detected using a U-switch sensor for real-time calculation. However, this method requires manual measurement and input of the new roll diameter after roll changes, which is prone to operational errors.

[0051] Based on this, embodiments of the present invention provide a roll diameter detection method, which is applied in roll-to-roll equipment. Figure 1 This is a schematic diagram illustrating the positional relationship between an ultrasonic sensor and the roll material being tested, provided in an embodiment of the present invention. Figure 2 This is a schematic diagram illustrating the positional relationship between a U-shaped switch sensor, a baffle trigger assembly, and the roll material being tested, as provided in an embodiment of the present invention. Figure 1 and Figure 2 As shown, the roll-to-roll device includes an ultrasonic sensor 10, a U-shaped switch sensor 20, and a baffle trigger assembly 30. The ultrasonic sensor 10 is set in the radial direction of the rotation axis corresponding to the roll being tested, the U-shaped switch sensor 20 is set at a preset sensing position corresponding to the same roll being tested, and the baffle trigger assembly 30 is set on the rotation axis corresponding to the same roll being tested. Figure 3 This is a flowchart illustrating a roll diameter detection method provided in an embodiment of the present invention. This roll diameter detection method is applicable to situations where roll-to-roll equipment combines detection and calculation of roll diameter. The roll diameter detection method can be executed by a roll diameter detection device, which can be implemented in hardware and / or software and can be configured in a control board. Figure 3 As shown, the roll diameter detection method includes:

[0052] S110. Control the rotation of the roll material to be tested to drive the rotation of the baffle trigger assembly, so that the baffle trigger assembly passes through the preset sensing position and records the sensing signal at the preset sensing position sensed by the U-shaped switch sensor in real time.

[0053] First, it should be noted that the roll-to-roll device in this embodiment of the invention includes multiple take-up reels, unwind reels, and corresponding main shafts. During the take-up and unwinding process of the roll-to-roll device, the roll material to be tested is placed on the main shaft. The normal operation of the roll-to-roll device is achieved through the cooperation of the corresponding take-up and unwind reels. For the roll-to-roll device to operate normally, speed matching and tension stability must be ensured. In other words, the take-up and unwinding speeds of the roll-to-roll device need to match the device's operating speed, which is directly proportional to the diameter of the roll material being tested. Therefore, it is crucial to be able to detect roll diameter changes in real time and adjust the take-up and unwinding speeds based on the determined target roll diameter. Furthermore, the specific structure of the roll-to-roll device can be found in existing technologies, and will not be described in detail here.

[0054] Based on this, this embodiment uses both an ultrasonic sensor 10 and a U-shaped switch sensor 20 to detect the diameter of the same roll material. When the roll diameter is measured by the ultrasonic sensor 10, the measured diameter is stable and the value is more accurate when the roll-to-roll device is in operation. However, the detection of the ultrasonic sensor 10 is affected by problems such as angle installation. Changes in the roll diameter cause changes in the detection angle, which leads to differences in the measured roll diameter. Moreover, the presence of factors such as noise will also affect the measured roll diameter value. Therefore, it is very necessary to use the U-shaped switch sensor 20 to calculate the roll diameter of the roll material in real time.

[0055] Specifically, please refer to Figure 1 and Figure 2 A U-shaped switch sensor 20 is positioned at a preset sensing position corresponding to the same tested roll material. A baffle trigger assembly 30 is positioned on a rotating shaft corresponding to the same tested roll material. The U-shaped switch sensor 20 is fixed, while the baffle trigger assembly 30 rotates synchronously with the tested roll material. During its rotation, the baffle trigger assembly 30 passes through the preset sensing position. When the baffle trigger assembly 30 passes through the preset sensing position, the U-shaped switch sensor 20 is triggered and detects the corresponding sensing signal. When the baffle trigger assembly 30 passes through the preset sensing position again, it indicates that the baffle trigger assembly 30 has rotated one revolution, meaning the corresponding tested roll material has also rotated one revolution. The roll diameter can then be determined based on the total rotation of the tested roll material. Thus, during the operation of the roll-to-roll equipment, the U-shaped switch sensor 20 is triggered by the baffle trigger component 30, which sends a corresponding sensing signal to the PLC control system and obtains the trigger time. When the trigger reaches two or more times, the roll diameter of the tested roll material can be calculated by obtaining the current state and the previous state.

[0056] S120: Control the ultrasonic sensor to emit ultrasonic signals toward the roll material being tested, receive the reflected ultrasonic signals, and record the analog signal corresponding to the ultrasonic signal received by the ultrasonic sensor in real time.

[0057] Specifically, please refer to Figure 1 and Figure 2 The ultrasonic sensor 10 is positioned radially along the rotation axis corresponding to the roll material being tested. For example, the ultrasonic sensor 10 can be located at the same height as the rotation axis. That is, the line connecting the ultrasonic sensor 10 and the rotation axis can be horizontal. The ultrasonic sensor 10 generates ultrasonic signals to the roll material and receives the reflected ultrasonic signals. The ultrasonic sensor 10 is connected to the analog signal channel of the PLC control system. The analog signal data is converted into numerical values ​​to obtain the distance between the ultrasonic sensor 10 and the roll material, thereby allowing subsequent calculations to determine the roll diameter.

[0058] S130. Based on the sensing signal at the preset sensing position sensed by the U-shaped switch sensor, the roll diameter of the tested roll material is detected and defined as the first roll diameter. Also, based on the analog signal corresponding to the ultrasonic signal received by the ultrasonic sensor, the roll diameter of the tested roll material is detected and defined as the second roll diameter.

[0059] Specifically, please refer to Figure 1 and Figure 2 The core of this embodiment is to simultaneously use ultrasonic sensor 10 and U-shaped switch sensor 20 to detect the roll diameter of the tested roll material, which further ensures the detection accuracy of the roll diameter of the tested roll material, which is conducive to improving the operational stability of the roll-to-roll equipment and ensuring speed matching and tension stability.

[0060] The working principle of the U-shaped switch sensor 20 is illustrated below. The U-shaped switch sensor 20 itself does not directly measure the roll diameter. Instead, it senses the change in the roll diameter of the tested material through the triggering of the baffle trigger component 30. Combined with the sensing signal at the preset sensing position sensed by the U-shaped switch sensor 20, the roll diameter of the tested material, i.e., the first roll diameter, is calculated in reverse. Furthermore, exemplarily, the U-shaped switch sensor 20 has a U-shaped groove. A light-emitting element and a photosensitive element are respectively built into both sides of the groove. The light-emitting element continuously emits infrared light to the other side of the groove, and the photosensitive element continuously receives the infrared light emitted by the light-emitting element, outputting a corresponding level signal based on the intensity of the received infrared light. When an unobstructed object (such as the baffle trigger component 30 corresponding to the tested roll material) enters the U-shaped groove, the infrared light emitted by the light-emitting element can be directly received by the photosensitive element, turning on the photosensitive element, and the U-shaped switch sensor 20 can output an effective level signal. Furthermore, when an obstruction (such as the baffle trigger assembly 30 corresponding to the tested roll material) enters the "U"-shaped groove, the obstruction is located between the light-emitting element and the photosensitive element. The infrared light emitted by the light-emitting element cannot be received by the photosensitive element, and the output level of the U-shaped switch sensor 20 changes to an invalid level, which can then be triggered to generate a corresponding sensing signal.

[0061] The working principle of the ultrasonic sensor 10 is illustrated below. The relevant controller can send a trigger signal to the ultrasonic sensor 10. Upon receiving the trigger signal, the ultrasonic sensor 10 immediately emits a beam of high-frequency ultrasonic signals directionally toward the surface of the roll material being tested. When the emitted ultrasonic signal encounters the surface of the roll material during propagation, it is reflected, forming a reflected wave (i.e., the reflected ultrasonic signal). This reflected wave propagates back to the ultrasonic sensor 10 and is captured by its receiving end. The ultrasonic sensor 10 can then transmit the received reflected ultrasonic signal to the PLC control system. The PLC control system can determine the roll diameter of the roll material being tested, i.e., the second roll diameter, based on the analog signal corresponding to the ultrasonic signal.

[0062] S140. When the difference between the first roll diameter and the second roll diameter meets the preset roll diameter difference range, the first roll diameter is determined as the target roll diameter value of the tested roll material.

[0063] The preset roll diameter difference range is a threshold for determining the validity of measurement data, determined by factors such as equipment accuracy, roll material characteristics (e.g., thickness uniformity), and process requirements. A smaller preset roll diameter difference range requires higher measurement accuracy and stability. For more details, please refer to [link / reference]. Figure 1 and Figure 2The first and second roll diameters are two independent measurements of the same roll material being tested. The first roll diameter is measured using a U-shaped switch sensor 20, while the second roll diameter is measured using an ultrasonic sensor 10. When the difference between the first and second roll diameters meets a preset range, it indicates good consistency between the two measurements and reliable data. The first roll diameter can then be determined as the target roll diameter value for the roll material, thus filtering out abnormal data caused by momentary interference, measurement errors, etc., ensuring the accuracy and reliability of the final target roll diameter value.

[0064] Furthermore, if the difference between the first roll diameter and the second roll diameter does not meet the preset roll diameter difference range, it indicates that there is a malfunction in the operation of the roll-to-roll equipment, which needs to be repaired. For example, relevant alarm signals can be used to remind the relevant maintenance personnel.

[0065] The technical solution in this invention utilizes both ultrasonic sensors and U-shaped switch sensors to detect the diameter of the same roll material. It fully leverages the advantages of both ultrasonic sensors (detecting the roll diameter) and U-shaped switch sensors (calculating the roll diameter). The target roll diameter value is determined by a combination of ultrasonic and U-shaped switch detection methods, enabling real-time and accurate detection of the roll diameter. This method is stable, reliable, simple, and easy to operate, reducing manual intervention time and device operating errors. The principle is simple, requiring no manual operation. After roll-to-roll equipment changes rolls, the ultrasonic sensors can detect the sudden change in roll diameter in real time. During roll-to-roll operation, the U-shaped switch sensors eliminate the impact of sudden changes and detection errors from the ultrasonic sensors, preventing roll diameter changes, eliminating detection errors, and avoiding human error. This solution addresses the problem of unstable winding and unwinding leading to speed mismatch and tension instability, resulting in abnormal overall equipment operation. It improves the operating efficiency and stability of roll-to-roll equipment, ensuring speed matching and tension stability.

[0066] Figure 4 This is a flowchart illustrating another roll diameter detection method provided by an embodiment of the present invention. This embodiment is an optimization based on the above embodiment. Optionally, the roll diameter of the tested roll material is detected based on the sensing signal at a preset sensing position sensed by the U-shaped switch sensor, and defined as the first roll diameter, including:

[0067] The time difference between the sensing signals at the preset sensing positions detected by the U-shaped switch sensor in two consecutive tests is obtained and defined as the first time difference.

[0068] The first roll diameter is determined based on the rotation speed of the tested roll material and the first time difference.

[0069] For details not covered in this embodiment, please refer to the above embodiments. Figure 4As shown, the roll diameter detection method includes:

[0070] S210. Control the rotation of the roll material to be tested to drive the rotation of the baffle trigger assembly, so that the baffle trigger assembly passes through the preset sensing position and records the sensing signal at the preset sensing position sensed by the U-shaped switch sensor in real time.

[0071] S220: Control the ultrasonic sensor to emit ultrasonic signals toward the roll material being tested, receive the reflected ultrasonic signals, and record the analog signal corresponding to the ultrasonic signal received by the ultrasonic sensor in real time.

[0072] S230. Obtain the time difference between the sensing signals at the preset sensing positions sensed by the U-shaped switch sensor in two adjacent tests, and define it as the first time difference.

[0073] Specifically, please refer to Figure 2 First, the positions of the U-shaped switch sensor 20 and the baffle trigger assembly 30 are confirmed to ensure that when the rotating shaft corresponding to the tested roll material rotates, the baffle trigger assembly 30 can trigger the U-shaped switch sensor 20 and obtain the corresponding sensing signal, which is then transmitted to the PLC control system. Furthermore, when the rotating shaft corresponding to the tested roll material rotates, the baffle trigger assembly 30 triggers the corresponding sensing signal each time it passes the U-shaped switch sensor 20. For every revolution of the tested roll material, the baffle trigger assembly 30 passes the U-shaped switch sensor 20 once. When the baffle trigger assembly 30 passes the U-shaped switch sensor 20 for the second time, the time difference between the sensing signals at the preset sensing positions sensed by the U-shaped switch sensor 20 in these two adjacent passes can be obtained.

[0074] S240. Determine the first roll diameter based on the rotation speed and the first time difference of the tested roll material, and detect the roll diameter of the tested roll material based on the analog signal corresponding to the ultrasonic signal received by the ultrasonic sensor, and define it as the second roll diameter.

[0075] In one specific embodiment, optionally, the first roll diameter is determined based on the rotational speed of the tested roll material and the first time difference, including: obtaining the first roll diameter D1 according to the calculation formula D1=V×T / π; where V represents the rotational speed of the tested roll material, T represents the first time difference, and π represents pi.

[0076] Specifically, please refer to Figure 2In determining the first roll diameter based on the rotational speed and the first time difference of the tested roll material, the rotational speed and the first time difference can be multiplied to obtain the circumference of the tested roll material. Then, the circumference of the tested roll material is divided by pi to obtain the first roll diameter. This enables real-time measurement of the roll diameter of the tested roll material, allowing for accurate and real-time measurement directly using the rotational speed and the first time difference, without the need for additional sensors.

[0077] In another specific embodiment, optionally, determining the first roll diameter based on the rotation speed of the tested roll material and the first time difference includes: integrating the rotation speed of the tested roll material and the first time difference to obtain the first roll diameter.

[0078] Specifically, please refer to Figure 2 In determining the first roll diameter based on the rotation speed and the first time difference of the tested roll material, the rotation speed and the first time difference can be integrated to obtain the first roll diameter. This reduces inaccurate roll diameter calculations caused by measurement and calculation errors, improving the accuracy of roll diameter calculation. Furthermore, with the calculated first roll diameter, the calculated roll diameter will be stable due to the stable operating speed of the roll-to-roll equipment and will not be easily affected by other external factors.

[0079] S250. When the difference between the first roll diameter and the second roll diameter meets the preset roll diameter difference range, the first roll diameter is determined as the target roll diameter value of the tested roll material.

[0080] Figure 5 This is a flowchart illustrating another roll diameter detection method provided by an embodiment of the present invention. This embodiment is an optimization based on the above embodiment. Optionally, the roll diameter of the tested roll material is detected based on the analog signal corresponding to the ultrasonic signal received by the ultrasonic sensor, and defined as a second roll diameter, including:

[0081] Based on the analog signal corresponding to the ultrasonic signal received by the ultrasonic sensor, the distance between the ultrasonic sensor and the tested roll material is determined and defined as the first distance.

[0082] The second roll diameter is determined based on the distance between the ultrasonic sensor and the rotation axis corresponding to the roll being tested, and the first distance.

[0083] For details not covered in this embodiment, please refer to the above embodiments. Figure 5 As shown, the roll diameter detection method includes:

[0084] S310. Control the rotation of the roll material to be tested to drive the rotation of the baffle trigger assembly, so that the baffle trigger assembly passes through the preset sensing position and records the sensing signal at the preset sensing position sensed by the U-shaped switch sensor in real time.

[0085] S320: Controls the ultrasonic sensor to emit ultrasonic signals toward the tested roll material, receives the reflected ultrasonic signals, and records the analog signal corresponding to the ultrasonic signal received by the ultrasonic sensor in real time.

[0086] S330. Based on the analog signal corresponding to the ultrasonic signal received by the ultrasonic sensor, determine the distance between the ultrasonic sensor and the tested roll material, and define it as the first distance.

[0087] Optionally, the distance between the ultrasonic sensor and the tested roll material is determined based on the analog signal corresponding to the ultrasonic signal received by the ultrasonic sensor, and defined as the first distance, including: obtaining the first distance L1 according to the calculation formula L1=K×J1; where J1 represents the analog signal corresponding to the ultrasonic signal received by the ultrasonic sensor, and K represents the distance scaling factor.

[0088] Specifically, please refer to Figure 1 First, the position and detection angle of the ultrasonic sensor 10 are confirmed, ensuring that the detection stroke of the ultrasonic sensor 10 is greater than the maximum distance between the ultrasonic sensor 10 and the tested roll material. Secondly, it is essential to ensure that the ultrasonic sensor 10 is aligned with the center of the tested roll material, which can also be understood as aligning the ultrasonic sensor 10 with the center of the corresponding rotation axis of the tested roll material; otherwise, the roll diameter detection will be inaccurate. Furthermore, the ultrasonic signal emitted by the ultrasonic sensor 10 is confirmed. First, the ultrasonic signal must match the working mode and output parameters of the analog channel. Second, the ultrasonic signal is emitted and the reflected ultrasonic signal is received, and the received ultrasonic signal is transmitted to the PLC control system.

[0089] Next, the detection distance of the ultrasonic sensor 10 is calibrated. Along the line connecting the ultrasonic sensor 10 and the rotation axis of the tested roll material, the point on the roll material closest to the ultrasonic sensor 10 can be considered the near point, and the distance between the near point and the ultrasonic sensor 10 can be defined as the near point distance A. The point on the roll material farthest from the ultrasonic sensor 10 can be considered the far point, and the distance between the far point and the ultrasonic sensor 10 can be defined as the far point distance B. Calibrating the near and far points separately to obtain the corresponding analog values ​​ensures the linearity of the detected distance within the distance interval [A, B]. For example, the ultrasonic sensor 10 emits an ultrasonic signal towards the near point and receives the reflected ultrasonic signal; the converted analog signal can be the near point analog value J1. Similarly, the ultrasonic sensor 10 emits an ultrasonic signal towards the far point and receives the reflected ultrasonic signal; the converted analog signal can be the far point analog value J2. That is, K = (BA) / (J2 - J1).

[0090] Next, the ultrasonic signal received by the ultrasonic sensor 10 is processed. First, the ultrasonic signal received by the ultrasonic sensor 10 is converted into a corresponding analog signal. This analog signal is then calculated and converted into the distance between the ultrasonic sensor 10 and the tested roll material by the PLC control system, which is the first distance L1. That is, the first distance L1 can be obtained according to the calculation formula L1=K×J1.

[0091] S340. Determine the second roll diameter based on the distance between the ultrasonic sensor and the rotation axis corresponding to the roll material being tested and the first distance. Also, detect the roll diameter of the roll material being tested based on the sensing signal at the preset sensing position sensed by the U-shaped switch sensor and define it as the first roll diameter.

[0092] Optionally, the second roll diameter is determined based on the distance between the ultrasonic sensor and the rotation axis corresponding to the roll material being tested, and the first distance, including: obtaining the second roll diameter D2 according to the calculation formula D2=2×(L0- L1); where L0 represents the distance between the ultrasonic sensor and the rotation axis corresponding to the roll material being tested, and L1 represents the first distance.

[0093] Specifically, please refer to Figure 1 After calculating the first distance L1, the real-time roll diameter of the tested roll material, i.e., the second roll diameter D2, can be calculated by combining the distance L0 between the ultrasonic sensor 10 and the rotation axis corresponding to the tested roll material. The distance between the ultrasonic sensor 10 and the rotation axis corresponding to the tested roll material can also be defined as the center distance, i.e., in... Figure 1 The center distance L0 is represented in the figure. The formula for calculating the second roll diameter D2 is D2 = 2 × (L0 - L1) = 2 × (L0 - K × J1) = 2 × (L0 - [(BA) / (J2 - J1)] × J1). In this way, the roll diameter of the tested roll material at any point can be obtained.

[0094] S350. When the difference between the first roll diameter and the second roll diameter meets the preset roll diameter difference range, the first roll diameter is determined as the target roll diameter value of the tested roll material.

[0095] This invention also provides a roll diameter detection device, which is applied in roll-to-roll equipment. (Continuing to refer to...) Figure 1 and Figure 2 The roll-to-roll device includes an ultrasonic sensor 10, a U-shaped switch sensor 20, and a baffle trigger assembly 30. The ultrasonic sensor 10 is set in the radial direction of the rotation axis corresponding to the roll being tested, the U-shaped switch sensor 20 is set at a preset sensing position corresponding to the same roll being tested, and the baffle trigger assembly 30 is set on the rotation axis corresponding to the same roll being tested. Figure 6This is a schematic diagram of a roll diameter detection device provided in an embodiment of the present invention. This roll diameter detection device is applicable to situations where roll-to-roll equipment is used to detect and calculate roll diameter. The roll diameter detection device can be implemented in hardware and / or software and is generally configured in a control board. Figure 6 As shown, the roll diameter detection device includes:

[0096] The trigger detection module 410 controls the rotation of the tested roll material to drive the rotation of the baffle trigger assembly, so that the baffle trigger assembly passes through a preset sensing position, and records the sensing signal at the preset sensing position sensed by the U-shaped switch sensor in real time; the ultrasonic detection module 420 controls the ultrasonic sensor to emit ultrasonic signals toward the tested roll material, and receives the reflected ultrasonic signals, and records the analog signal corresponding to the ultrasonic signal received by the ultrasonic sensor in real time; the roll diameter detection module 430 detects the roll diameter of the tested roll material according to the sensing signal at the preset sensing position sensed by the U-shaped switch sensor, and defines it as the first roll diameter, and detects the roll diameter of the tested roll material according to the analog signal corresponding to the ultrasonic signal received by the ultrasonic sensor, and defines it as the second roll diameter; the roll diameter determination module 440 determines the first roll diameter as the target roll diameter value of the tested roll material when the difference between the first roll diameter and the second roll diameter meets the preset roll diameter difference range.

[0097] The technical solution in this invention utilizes both ultrasonic sensors and U-shaped switch sensors to detect the diameter of the same roll material. It fully leverages the advantages of both ultrasonic sensors (detecting the roll diameter) and U-shaped switch sensors (calculating the roll diameter). The target roll diameter value is determined by a combination of ultrasonic and U-shaped switch detection methods, enabling real-time and accurate detection of the roll diameter. This method is stable, reliable, simple, and easy to operate, reducing manual intervention time and device operating errors. The principle is simple, requiring no manual operation. After roll-to-roll equipment changes rolls, the ultrasonic sensors can detect the sudden change in roll diameter in real time. During roll-to-roll operation, the U-shaped switch sensors eliminate the impact of sudden changes and detection errors from the ultrasonic sensors, preventing roll diameter changes, eliminating detection errors, and avoiding human error. This solution addresses the problem of unstable winding and unwinding leading to speed mismatch and tension instability, resulting in abnormal overall equipment operation. It improves the operating efficiency and stability of roll-to-roll equipment, ensuring speed matching and tension stability.

[0098] Based on the above technical solution, optionally, the roll diameter detection module 430 may specifically include a time difference acquisition unit and a first roll diameter determination unit. The time difference acquisition unit is used to acquire the time difference corresponding to the sensing signals at the preset sensing positions sensed by the U-shaped switch sensor in two adjacent tests, and define it as the first time difference. The first roll diameter determination unit is used to determine the first roll diameter based on the rotation speed of the roll material being tested and the first time difference.

[0099] Optionally, the first roll diameter determination unit may specifically include a first roll diameter determination subunit, which is used to obtain the first roll diameter D1 according to the calculation formula D1=V×T / π; where V represents the rotation speed of the roll being measured, T represents the first time difference, and π represents pi.

[0100] Optionally, the first roll diameter determination unit may specifically include a first roll diameter determination subunit, which is used to integrate the rotation speed of the roll material being tested and the first time difference to obtain the first roll diameter.

[0101] Optionally, the roll diameter detection module 430 may specifically include a first distance acquisition unit and a second roll diameter determination unit. The first distance acquisition unit is used to determine the distance between the ultrasonic sensor and the roll material under test based on the analog signal corresponding to the ultrasonic signal received by the ultrasonic sensor, and define it as a first distance. The second roll diameter determination unit is used to determine a second roll diameter based on the distance between the ultrasonic sensor and the rotation axis corresponding to the roll material under test and the first distance.

[0102] Optionally, the first distance acquisition unit may specifically include a first distance acquisition subunit, which is used to obtain the first distance L1 according to the calculation formula L1=K×J1; where J1 represents the analog signal corresponding to the ultrasonic signal received by the ultrasonic sensor, and K represents the distance scaling factor.

[0103] Optionally, the second roll diameter determination unit may specifically include a second roll diameter determination subunit, which is used to obtain the second roll diameter D2 according to the calculation formula D2=2×(L0- L1); where L0 represents the distance between the ultrasonic sensor and the rotation axis corresponding to the roll material being tested, and L1 represents the first distance.

[0104] The roll diameter detection device provided in this embodiment of the invention can execute the roll diameter detection method provided in any embodiment of the invention, and has the corresponding functional modules and beneficial effects of the method.

[0105] Figure 7 This is a schematic diagram of the structure of a terminal device provided in an embodiment of the present invention. The terminal device is intended to represent various forms of digital computers, such as laptop computers, desktop computers, workstations, personal digital assistants, servers, blade servers, mainframe computers, and other suitable computers. The terminal device can also represent various forms of mobile devices, such as personal digital processors, cellular phones, smartphones, wearable devices (such as helmets, glasses, watches, etc.), and other similar computing devices. The components shown herein, their connections and relationships, and their functions are merely illustrative and are not intended to limit the implementation of the invention described and / or claimed herein.

[0106] like Figure 7 As shown, the terminal device 100 includes one or more processors 110 and a storage device communicatively connected to the processors 110. The storage device may be a read-only memory (ROM) 120, a random access memory (RAM) 130, etc. The storage device stores computer programs executable by one or more processors. The processors 110 can perform various appropriate actions and processes based on the computer programs stored in the ROM 120 or loaded from storage unit 180 into the RAM 130. The RAM 130 may also store various programs and data required for the operation of the terminal device 100. The processors 110, ROM 120, and RAM 130 are interconnected via a bus 140. An input / output (I / O) interface 150 is also connected to the bus 140.

[0107] Multiple components in terminal device 100 are connected to I / O interface 150, including: input unit 160, such as keyboard, mouse, etc.; output unit 170, such as various types of displays, speakers, etc.; storage unit 180, such as disk, optical disk, etc.; and communication unit 190, such as network card, modem, wireless transceiver, etc. Communication unit 190 allows terminal device 100 to exchange information / data with other devices through computer networks such as the Internet and / or various telecommunications networks.

[0108] Processor 110 can be a variety of general-purpose and / or special-purpose processing components with processing and computing capabilities. Some examples of processor 110 include, but are not limited to, a central processing unit (CPU), a graphics processing unit (GPU), various special-purpose artificial intelligence (AI) computing chips, various processors running machine learning model algorithms, a digital signal processor (DSP), and any suitable processor, controller, microcontroller, etc. Processor 110 performs the various methods and processes described above, such as the roll diameter detection method.

[0109] In some embodiments, the volume diameter detection method may be implemented as a computer program tangibly contained in a computer-readable storage medium, such as storage unit 180. In some embodiments, part or all of the computer program may be loaded and / or installed on terminal device 100 via ROM 120 and / or communication unit 190. When the computer program is loaded into RAM 130 and executed by processor 110, one or more steps of the volume diameter detection method described above may be performed. Alternatively, in other embodiments, processor 110 may be configured to perform the volume diameter detection method by any other suitable means (e.g., by means of firmware).

[0110] Various embodiments of the systems and techniques described above herein can be implemented in digital electronic circuit systems, integrated circuit systems, field-programmable gate arrays (FPGAs), application-specific integrated circuits (ASICs), application-specific standard products (ASSPs), systems-on-a-chip (SoCs), payload-programmable logic devices (CPLDs), computer hardware, firmware, software, and / or combinations thereof. These various embodiments may include implementations in one or more computer programs that can be executed and / or interpreted on a programmable system including at least one programmable processor, which may be a dedicated or general-purpose programmable processor, capable of receiving data and instructions from a storage system, at least one input device, and at least one output device, and transmitting data and instructions to the storage system, the at least one input device, and the at least one output device.

[0111] Computer programs used to implement the methods of the present invention may be written in any combination of one or more programming languages. These computer programs may be provided to a processor of a general-purpose computer, a special-purpose computer, or other programmable data processing device, such that when executed by the processor, the computer programs cause the functions / operations specified in the flowcharts and / or block diagrams to be performed. The computer programs may be executed entirely on a machine, partially on a machine, or as a standalone software package, partially on a machine and partially on a remote machine, or entirely on a remote machine or server.

[0112] In the context of this invention, a computer-readable storage medium can be a tangible medium that may contain or store a computer program for use by or in conjunction with an instruction execution system, apparatus, or device. A computer-readable storage medium may include, but is not limited to, electronic, magnetic, optical, electromagnetic, infrared, or semiconductor systems, apparatus, or devices, or any suitable combination thereof. Alternatively, a computer-readable storage medium may be a machine-readable signal medium. More specific examples of machine-readable storage media include electrical connections based on one or more wires, portable computer disks, hard disks, random access memory (RAM), read-only memory (ROM), erasable programmable read-only memory (EPROM or flash memory), optical fibers, portable compact disk read-only memory (CD-ROM), optical storage devices, magnetic storage devices, or any suitable combination thereof.

[0113] To provide interaction with a user, the systems and techniques described herein can be implemented on a terminal device having: a display device for displaying information to the user (e.g., a CRT (cathode ray tube) or LCD (liquid crystal display) monitor); and a keyboard and pointing device (e.g., a mouse or trackball) through which the user provides input to the terminal device. Other types of devices can also be used to provide interaction with the user; for example, feedback provided to the user can be any form of sensory feedback (e.g., visual feedback, auditory feedback, or tactile feedback); and input from the user can be received in any form (including sound input, voice input, or tactile input).

[0114] The systems and technologies described herein can be implemented in computing systems that include backend components (e.g., as data servers), or middleware components (e.g., application servers), or frontend components (e.g., user computers with graphical user interfaces or web browsers through which users can interact with implementations of the systems and technologies described herein), or any combination of such backend, middleware, or frontend components. The components of the system can be interconnected via digital data communication of any form or medium (e.g., communication networks). Examples of communication networks include local area networks (LANs), wide area networks (WANs), blockchain networks, and the Internet.

[0115] A computing system can include clients and servers. Clients and servers are generally located far apart and typically interact through communication networks. The client-server relationship is created by computer programs running on the respective computers and having a client-server relationship with each other. The server can be a cloud server, also known as a cloud computing server or cloud host, which is a hosting product within the cloud computing service system to address the shortcomings of traditional physical hosts and VPS services, such as high management difficulty and weak business scalability.

[0116] It should be understood that the various forms of processes shown above can be used, with steps reordered, added, or deleted. For example, the steps described in this invention can be executed in parallel, sequentially, or in different orders, as long as the desired result of the technical solution of this invention can be achieved, and this is not limited herein.

[0117] The specific embodiments described above do not constitute a limitation on the scope of protection of this invention. Those skilled in the art should understand that various modifications, combinations, sub-combinations, and substitutions can be made according to design requirements and other factors. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this invention should be included within the scope of protection of this invention.

Claims

1. A method for detecting roll diameter, characterized in that, It is used in roll-to-roll equipment, which includes an ultrasonic sensor, a U-shaped switch sensor, and a baffle trigger assembly; The ultrasonic sensor is set in the radial direction of the rotating shaft corresponding to the tested roll material, the U-shaped switch sensor is set at the preset sensing position corresponding to the same tested roll material, and the baffle trigger assembly is set on the rotating shaft corresponding to the same tested roll material. The roll diameter detection method includes: The test roll material is controlled to rotate to drive the rotation of the baffle trigger assembly, so that the baffle trigger assembly passes through the preset sensing position, and the sensing signal at the preset sensing position sensed by the U-shaped switch sensor is recorded in real time. The ultrasonic sensor is controlled to emit ultrasonic signals toward the roll material under test, and to receive the reflected ultrasonic signals, and to record the analog signal corresponding to the ultrasonic signal received by the ultrasonic sensor in real time. Based on the sensing signal at the preset sensing position sensed by the U-shaped switch sensor, the roll diameter of the tested roll material is detected and defined as the first roll diameter; and based on the analog signal corresponding to the ultrasonic signal received by the ultrasonic sensor, the roll diameter of the tested roll material is detected and defined as the second roll diameter. When the difference between the first roll diameter and the second roll diameter meets the preset roll diameter difference range, the first roll diameter is determined as the target roll diameter value of the tested roll material.

2. The roll diameter detection method according to claim 1, characterized in that, Based on the sensing signal at the preset sensing position sensed by the U-shaped switch sensor, the roll diameter of the tested roll material is detected and defined as the first roll diameter, including: The time difference between two consecutive sensing signals detected by the U-shaped switch sensor at the preset sensing position is obtained and defined as the first time difference; The first roll diameter is determined based on the rotation speed of the tested roll material and the first time difference.

3. The roll diameter detection method according to claim 2, characterized in that, Determining the first roll diameter based on the rotation speed of the tested roll material and the first time difference includes: The first roll diameter D1 is obtained according to the calculation formula D1=V×T / π; where V represents the rotation speed of the tested roll material, T represents the first time difference, and π represents pi.

4. The roll diameter detection method according to claim 2, characterized in that, Determining the first roll diameter based on the rotation speed of the tested roll material and the first time difference includes: The first roll diameter is obtained by integrating the rotation speed of the tested roll material and the first time difference.

5. The roll diameter detection method according to claim 1, characterized in that, Based on the analog signal corresponding to the ultrasonic signal received by the ultrasonic sensor, the roll diameter of the tested roll material is detected and defined as the second roll diameter, including: Based on the analog signal corresponding to the ultrasonic signal received by the ultrasonic sensor, the distance between the ultrasonic sensor and the tested roll material is determined and defined as the first distance. The second roll diameter is determined based on the distance between the ultrasonic sensor and the rotation axis corresponding to the tested roll material and the first distance.

6. The roll diameter detection method according to claim 5, characterized in that, Based on the analog signal corresponding to the ultrasonic signal received by the ultrasonic sensor, the distance between the ultrasonic sensor and the tested roll material is determined and defined as a first distance, including: The first distance L1 is obtained according to the calculation formula L1=K×J1; where J1 represents the analog signal corresponding to the ultrasonic signal received by the ultrasonic sensor, and K represents the distance scaling factor.

7. The roll diameter detection method according to claim 5, characterized in that, Determining the second roll diameter based on the distance between the ultrasonic sensor and the rotation axis corresponding to the tested roll material and the first distance includes: The second roll diameter D2 is obtained according to the calculation formula D2=2×(L0- L1); where L0 represents the distance between the ultrasonic sensor and the rotation axis corresponding to the roll material being tested, and L1 represents the first distance.

8. A roll diameter detection device, characterized in that, It is used in roll-to-roll equipment, which includes an ultrasonic sensor, a U-shaped switch sensor, and a baffle trigger assembly; The ultrasonic sensor is set in the radial direction of the rotating shaft corresponding to the tested roll material, the U-shaped switch sensor is set at the preset sensing position corresponding to the same tested roll material, and the baffle trigger assembly is set on the rotating shaft corresponding to the same tested roll material. The roll diameter detection device includes: The trigger detection module is used to control the rotation of the tested roll material to drive the rotation of the baffle trigger assembly, so that the baffle trigger assembly passes through the preset sensing position, and records the sensing signal at the preset sensing position sensed by the U-shaped switch sensor in real time. An ultrasonic testing module is used to control the ultrasonic sensor to emit ultrasonic signals toward the tested roll material, receive the reflected ultrasonic signals, and record the analog signal corresponding to the ultrasonic signal received by the ultrasonic sensor in real time. The roll diameter detection module is used to detect the roll diameter of the tested roll material based on the sensing signal at the preset sensing position sensed by the U-shaped switch sensor, and define it as the first roll diameter; and to detect the roll diameter of the tested roll material based on the analog signal corresponding to the ultrasonic signal received by the ultrasonic sensor, and define it as the second roll diameter. The roll diameter determination module is used to determine the first roll diameter as the target roll diameter value of the tested roll material when the difference between the first roll diameter and the second roll diameter meets a preset roll diameter difference range.

9. A terminal device, characterized in that, include: One or more processors; Storage device for storing one or more programs; When the one or more programs are executed by the one or more processors, the one or more processors implement the roll diameter detection method as described in any one of claims 1-7.

10. A computer-readable storage medium having a computer program stored thereon, characterized in that, When executed by the processor, the program implements the roll diameter detection method as described in any one of claims 1-7.

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