Method and device for controlling tape casting thickness of ceramic body

Abstract

The invention relates to the technical field of thickness control, and discloses a ceramic green body tape casting thickness control method and device.The method comprises the steps that thickness measurement is conducted on a tape casting green body through a plurality of laser sensors arranged at the downstream preset position of a scraper, and the maximum deviation difference value is calculated; when the maximum deviation difference value is larger than a preset threshold value, a partition compensation mode is adopted, and when the maximum deviation difference value is smaller than or equal to the preset threshold value, a global compensation mode is adopted; when the partition compensation mode is adopted, the scraper left axis compensation amount, the scraper middle axis compensation amount and the scraper right axis compensation amount are calculated through the first compensation coefficient; when the global compensation mode is adopted, the unified compensation amount is calculated and assigned to the scraper left axis compensation amount, the scraper middle axis compensation amount and the scraper right axis compensation amount at the same time, and the control precision and uniformity of the casting thickness of the ceramic atomization core blank are improved.

Description

Technical Field

[0001] This invention relates to the field of thickness control technology, and in particular to a method and apparatus for controlling the thickness of ceramic blanks during tape casting. Background Technology

[0002] The uniformity of thickness during the tape casting process of ceramic atomizing cores directly determines the porosity distribution and atomization performance stability of the final product. The tape casting process controls the spreading thickness of the ceramic slurry on the carrier film using a scraper. However, due to factors such as fluctuations in slurry rheological properties, uneven scraper wear, and mechanical assembly errors, spatial gradient defects such as left-right asymmetry, thinner edges, or a bulging center often occur in the transverse thickness distribution of the blank. Existing tape casting thickness control technologies use single-point laser thickness measurement or manual sampling, which can only obtain thickness information at local locations and cannot identify the spatial distribution characteristics of the thickness across the entire blank surface. When transverse thickness gradients occur, traditional methods can only perform overall scraper lifting and lowering adjustments, lacking the ability to specifically compensate for thickness deviations in different areas, resulting in significant thickness inhomogeneity even after adjustment. Summary of the Invention

[0003] This invention provides a method and apparatus for controlling the thickness of ceramic blanks during casting, which improves the control accuracy and uniformity of the thickness of ceramic atomized core blanks during casting.

[0004] In a first aspect, the present invention provides a method for controlling the thickness of a ceramic green body during tape casting, the method comprising: The thickness of the cast blank is measured by multiple laser sensors arranged at a preset position downstream of the scraper, and the first deviation value of the left region, the second deviation value of the central region, and the third deviation value of the right region are calculated. Calculate the maximum deviation difference between the first deviation value, the second deviation value, and the third deviation value. When the maximum deviation difference value is greater than a preset threshold, a partition compensation mode is adopted. When the maximum deviation difference value is less than or equal to the preset threshold, a global compensation mode is adopted. When using the partitioned compensation mode, the first deviation value is multiplied by the first compensation coefficient to obtain the scraper left axis compensation amount, the second deviation value is multiplied by the first compensation coefficient to obtain the scraper center axis compensation amount, and the third deviation value is multiplied by the first compensation coefficient to obtain the scraper right axis compensation amount. When using the global compensation mode, a unified compensation amount is calculated and the unified compensation amount is simultaneously assigned to the scraper left axis compensation amount, the scraper center axis compensation amount, and the scraper right axis compensation amount.

[0005] In conjunction with the first aspect, in a first implementation of the first aspect of the present invention, the step of measuring the thickness of the cast blank by means of multiple laser sensors arranged at a preset position downstream of the scraper, and calculating a first deviation value for the left region, a second deviation value for the central region, and a third deviation value for the right region, includes: Multiple laser sensors are arranged at a predetermined position downstream of the scraper; The laser beams of preset wavelength are emitted to multiple positions laterally of the cast blank by the multiple laser sensors, the reflected light at each position is received and the spot displacement is captured by the CCD linear array detector, and the spot displacement of each laser sensor is obtained. Based on the trigonometric function relationship between the spot displacement of each laser sensor and the preset incident angle, the thickness is converted to obtain the instantaneous thickness measurement value at each lateral position. The measurement points in the left, center, and right regions of the instantaneous thickness measurement are averaged to obtain the first deviation value in the left region, the second deviation value in the center region, and the third deviation value in the right region.

[0006] In conjunction with the first aspect, in a second implementation of the first aspect of the present invention, the step of calculating the regional average of the measuring points in the left region, the central region, and the right region of the instantaneous thickness measurement value to obtain a first deviation value in the left region, a second deviation value in the central region, and a third deviation value in the right region includes: The difference between the instantaneous thickness measurement value and the target thickness is calculated to obtain the thickness deviation value at each measuring point; The thickness deviation values ​​of each measuring point are divided into three groups: left area deviation value group, central area deviation value group, and right area deviation value group, based on the left area measuring point, central area measuring point, and right area measuring point. The arithmetic mean of the deviation values ​​in the left region is calculated to obtain the first deviation value of the left region; the arithmetic mean of the deviation values ​​in the center region is calculated to obtain the second deviation value of the center region; and the arithmetic mean of the deviation values ​​in the right region is calculated to obtain the third deviation value of the right region.

[0007] In conjunction with the first aspect, in a third implementation of the first aspect of the present invention, the step of calculating the maximum deviation difference value among the first deviation value, the second deviation value, and the third deviation value, employing a partition compensation mode when the maximum deviation difference value is greater than a preset threshold, and employing a global compensation mode when the maximum deviation difference value is less than or equal to the preset threshold, includes: The absolute value of the difference between the first deviation value and the second deviation value is calculated to obtain the first deviation difference value; the absolute value of the difference between the second deviation value and the third deviation value is calculated to obtain the second deviation difference value; and the absolute value of the difference between the first deviation value and the third deviation value is calculated to obtain the third deviation difference value. Select the largest deviation difference value from the first deviation difference value, the second deviation difference value, and the third deviation difference value; The maximum deviation difference value is compared with a preset threshold. When the maximum deviation difference value is greater than a preset threshold, a partition compensation mode is adopted; when the maximum deviation difference value is less than or equal to the preset threshold, a global compensation mode is adopted.

[0008] In conjunction with the first aspect, in the fourth implementation of the first aspect of the present invention, when the partition compensation mode is adopted, the first deviation value is multiplied by the first compensation coefficient to obtain the scraper left axis compensation amount, the second deviation value is multiplied by the first compensation coefficient to obtain the scraper center axis compensation amount, and the third deviation value is multiplied by the first compensation coefficient to obtain the scraper right axis compensation amount; when the global compensation mode is adopted, a unified compensation amount is calculated and the unified compensation amount is simultaneously assigned to the scraper left axis compensation amount, the scraper center axis compensation amount, and the scraper right axis compensation amount, including: When the partition compensation mode is adopted, the first deviation value is multiplied by the first compensation coefficient to obtain the scraper left axis compensation amount, the second deviation value is multiplied by the first compensation coefficient to obtain the scraper middle axis compensation amount, and the third deviation value is multiplied by the first compensation coefficient to obtain the scraper right axis compensation amount. When the global compensation mode is adopted, the instantaneous thickness measurement values ​​at each lateral position are arithmetically averaged and the difference is calculated with the target thickness to obtain the full-width average deviation value; the full-width average deviation value is multiplied by the first compensation coefficient to obtain the unified compensation amount, and the unified compensation amount is simultaneously assigned to the scraper left axis compensation amount, scraper center axis compensation amount, and scraper right axis compensation amount.

[0009] In conjunction with the first aspect, in a fifth implementation of the first aspect of the present invention, the method for controlling the thickness of the ceramic blank during casting further includes: The scraper left axis compensation amount is sent to the scraper left axis servo motor, the scraper middle axis compensation amount is sent to the middle axis servo motor, and the scraper right axis compensation amount is sent to the right axis servo motor to drive the corresponding axis scraper to move downward or upward. The vertical displacement adjustment is performed by driving the corresponding ball screws of each axis servo motor at a preset speed until the displacement stroke corresponding to their respective compensation amount is completed, thus obtaining the adjusted scraper gap state.

[0010] In conjunction with the first aspect, in the sixth implementation of the first aspect of the present invention, the step of sending the scraper left-axis compensation amount to the scraper left-axis servo motor, sending the scraper middle-axis compensation amount to the middle-axis servo motor, and sending the scraper right-axis compensation amount to the right-axis servo motor to drive the corresponding axis scraper to move downward or upward includes: The scraper left axis compensation amount is sent to the scraper left axis servo motor, the scraper middle axis compensation amount is sent to the middle axis servo motor, and the scraper right axis compensation amount is sent to the right axis servo motor; The left axis servo motor of the scraper receives the compensation amount of the left axis of the scraper and performs a sign judgment on the value; the middle axis servo motor receives the compensation amount of the middle axis of the scraper and performs a sign judgment on the value; the right axis servo motor receives the compensation amount of the right axis of the scraper and performs a sign judgment on the value. When the compensation amount is negative, a reverse command signal is generated; when the compensation amount is positive, a forward command signal is generated. The left axis servo motor of the scraper controls the rotation direction of the left axis according to the reverse rotation command signal or the forward rotation command signal; the middle axis servo motor controls the rotation direction of the middle axis according to the reverse rotation command signal or the forward rotation command signal; and the right axis servo motor controls the rotation direction of the right axis according to the reverse rotation command signal or the forward rotation command signal. When the reverse rotation command signal is received, the scraper of the corresponding axis is driven to move vertically downward; when the forward rotation command signal is received, the scraper of the corresponding axis is driven to move vertically upward.

[0011] In conjunction with the first aspect, in the seventh implementation of the first aspect of the present invention, the method for controlling the thickness of the ceramic blank during casting further includes: Under the adjusted scraper gap, the cast blank is kept running at the carrier film running speed for a preset time until the cast blank under the new gap condition reaches the detection position of the laser sensor. The thickness of the cast blank is measured at multiple transverse positions by the multiple laser sensors and the arithmetic average of the thickness values ​​of all measuring points is calculated to obtain the adjusted full-width average thickness. The residual deviation is obtained by calculating the difference between the adjusted full-width average thickness and the target thickness. The absolute value of the residual deviation is obtained by performing an absolute value operation on the residual deviation. The absolute value of the residual deviation is then compared with the accuracy threshold. When the absolute value of the residual deviation is greater than the accuracy threshold, the residual deviation is multiplied by the second compensation coefficient to obtain the secondary compensation amount. Based on the secondary compensation amount, the three-axis servo adjustment process of the scraper is re-executed. When the absolute value of the residual deviation is less than or equal to the accuracy threshold, the adjusted scraper gap state remains unchanged and the casting production continues.

[0012] In conjunction with the first aspect, in the eighth implementation of the first aspect of the present invention, the step of multiplying the residual deviation by a second compensation coefficient to obtain a secondary compensation amount when the absolute value of the residual deviation is greater than the accuracy threshold, re-executing the three-axis servo adjustment process of the scraper based on the secondary compensation amount, and maintaining the adjusted scraper gap state unchanged and continuing the casting production when the absolute value of the residual deviation is less than or equal to the accuracy threshold, includes: A secondary compensation trigger signal is generated when the absolute value of the residual deviation is greater than the accuracy threshold, and a steady-state maintenance signal is generated when the absolute value of the residual deviation is less than or equal to the accuracy threshold. When the secondary compensation trigger signal is received, the residual deviation is multiplied by the second compensation coefficient to obtain the secondary compensation amount, and the scraper three-axis servo adjustment process is re-executed based on the secondary compensation amount; When the steady-state maintenance signal is received, the adjusted scraper gap remains unchanged, the controller enters the steady-state monitoring mode to continuously collect the thickness distribution vector and continue the casting production.

[0013] In a second aspect, the present invention provides a ceramic green body casting thickness control device, the ceramic green body casting thickness control device comprising: The thickness measurement module is used to measure the thickness of the cast blank by means of multiple laser sensors arranged at a preset position downstream of the scraper, and to calculate the first deviation value of the left region, the second deviation value of the center region and the third deviation value of the right region. The compensation mode analysis module is used to calculate the maximum deviation difference value among the first deviation value, the second deviation value, and the third deviation value. When the maximum deviation difference value is greater than a preset threshold, a partition compensation mode is adopted, and when the maximum deviation difference value is less than or equal to the preset threshold, a global compensation mode is adopted. The compensation amount calculation module is used to calculate the scraper left axis compensation amount by multiplying the first deviation value by the first compensation coefficient when the partition compensation mode is adopted, to calculate the scraper center axis compensation amount by multiplying the second deviation value by the first compensation coefficient, and to calculate the scraper right axis compensation amount by multiplying the third deviation value by the first compensation coefficient when the partition compensation mode is adopted; when the global compensation mode is adopted, the module calculates the unified compensation amount and assigns the unified compensation amount to the scraper left axis compensation amount, the scraper center axis compensation amount, and the scraper right axis compensation amount simultaneously.

[0014] The technical solution provided by this invention achieves synchronous multi-point thickness measurement of the cast ceramic blank through a laser sensor array, extending traditional single-point detection to spatially distributed acquisition, which can completely capture the thickness distribution characteristics of the left, central, and right regions of the blank. By calculating the maximum deviation difference between the three regions and comparing it with a preset threshold, it can accurately determine whether the thickness problem originates from the overall offset of the scraper or the tilt of the scraper posture, thereby automatically selecting a global compensation mode or a zone compensation mode. Through independent vertical displacement control of the left, central, and right axes, three-dimensional spatial adjustment of the scraper posture is achieved in the zone compensation mode, so that the compensation amount of each region is precisely matched with the deviation of the corresponding region, solving the technical problem that the transverse thickness gradient cannot be adjusted in a targeted manner. By measuring the residual deviation after adjustment and comparing it with the accuracy threshold, a secondary compensation is automatically triggered when the first adjustment fails to meet the standard. The secondary compensation uses a higher compensation coefficient to accelerate the convergence speed, ensuring the achievement of the final control accuracy. This invention solves the problems of traditional single-point feedback being unable to identify spatial gradients and the lack of spatial targeting in scraper adjustment, improving the control accuracy and uniformity of the thickness of the cast ceramic atomized core blank.

[0015] Other features and advantages of the invention will be set forth in the description which follows, and will be apparent in part from the description, or may be learned by practicing the invention. The objects and other advantages of the invention are realized and obtained in accordance with the structures particularly pointed out in the description, claims and drawings.

[0016] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, preferred embodiments are described below in detail with reference to the accompanying drawings. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of an embodiment of the ceramic green body casting thickness control method in the present invention; Figure 2 This is a schematic diagram of one embodiment of the ceramic blank casting thickness control device in the present invention. Detailed Implementation

[0018] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0019] The terms "comprising" and "having," and any variations thereof, used in the embodiments of this invention are intended to cover non-exclusive inclusion. For example, a process, method, system, product, or device that includes a series of steps or units is not limited to the steps or units listed, but may optionally include other steps or units not listed, or may optionally include other steps or units inherent to these processes, methods, products, or devices.

[0020] To facilitate understanding of this embodiment, a method for controlling the thickness of a ceramic green body during tape casting, as disclosed in this embodiment of the invention, will first be described in detail. For example... Figure 1 As shown, this method includes the following steps: 101. The thickness of the cast blank is measured by multiple laser sensors arranged at a preset position downstream of the scraper, and the first deviation value of the left area, the second deviation value of the central area and the third deviation value of the right area are calculated. Specifically, multiple laser sensors are positioned at a predetermined location downstream of the scraper in the casting machine, serving as the core sensing unit for thickness measurement. The sensors are positioned 120mm downstream of the scraper, effectively avoiding the initial disturbance zone of the slurry and reflecting the direct control of the scraper gap on the forming thickness. In the transverse direction, the laser sensors are arranged along the effective width of the blank at equal intervals, with edge sensors recessed by 5mm to avoid edge effects. The entire sensor array consists of seven laser triangulation sensors, providing thickness measurement coverage for the left, center, and right regions respectively. Each sensor emits a 650nm laser beam with a fixed incident angle of 45° to meet the optimal sensitivity requirements of the triangulation method. A built-in CCD linear array detector captures the displacement of the reflected laser spot on the imaging surface in real time. Through optical calibration, a stable geometric trigonometric function mapping relationship is established between the spot displacement and the thickness. Based on a preset zero-point thickness reference value combined with the spot offset, thickness conversion is performed to obtain the instantaneous thickness measurement value of each laser sensor at the current sampling moment. The controller categorizes instantaneous thickness measurements according to spatial location, assigning the three measuring points S1 to S3 to the left region, S4 to the center region, and S5 to S7 to the right region. It then performs a region-wide average calculation on the thickness measurements within each of the three regions to obtain the first average thickness value for the left region, the second average thickness value for the center region, and the third average thickness value for the right region. Using a set target thickness value as a benchmark, the controller calculates the difference between the thickness values ​​of the three regions and the target value to obtain the first deviation value for the left region, the second deviation value for the center region, and the third deviation value for the right region.

[0021] 102. Calculate the maximum deviation difference between the first deviation value, the second deviation value, and the third deviation value. When the maximum deviation difference value is greater than the preset threshold, the partition compensation mode is adopted. When the maximum deviation difference value is less than or equal to the preset threshold, the global compensation mode is adopted. Specifically, the controller calculates the absolute value of the difference between the first and second deviation values ​​to obtain the first deviation difference value, reflecting the thickness fluctuation range between the left and central regions; it calculates the absolute value of the difference between the second and third deviation values ​​to obtain the second deviation difference value, reflecting the deviation gradient between the central and right regions; and it calculates the absolute value of the difference between the first and third deviation values ​​to obtain the third deviation difference value, reflecting the degree of thickness change between the two ends of the billet. The largest deviation difference value among the three sets of regional deviation difference values ​​is selected and recorded as the maximum deviation difference value. The maximum deviation difference value is compared with a preset deviation difference threshold, which is set according to the target thickness range; a typical value is 0.02 mm, equivalent to 10% of the target thickness of 0.200 mm. When the maximum deviation exceeds the preset threshold, it is determined that there is a significant spatial gradient in the transverse thickness of the current billet, indicating that there is a significant thickness inconsistency between different regions. At this time, the zone compensation mode is activated, so that the three axes of the scraper perform differentiated gap adjustment to correct the deviation in each region. If the maximum deviation is less than or equal to the preset threshold, it is considered that the thickness deviation is mainly manifested as an overall deviation rather than a local imbalance. At this time, the control system activates the global compensation mode, so that the three axes of the scraper keep in a synchronous linkage state and perform a consistent overall lifting operation, thereby applying a uniform thickness correction to the entire billet.

[0022] 103. When using the partition compensation mode, the first deviation value is multiplied by the first compensation coefficient to obtain the scraper left axis compensation amount, the second deviation value is multiplied by the first compensation coefficient to obtain the scraper center axis compensation amount, and the third deviation value is multiplied by the first compensation coefficient to obtain the scraper right axis compensation amount. When using the global compensation mode, the unified compensation amount is calculated and simultaneously assigned to the scraper left axis compensation amount, scraper center axis compensation amount, and scraper right axis compensation amount.

[0023] Specifically, when using the zoned compensation mode, it indicates that there is significant unevenness in the transverse thickness of the billet, meaning that the thickness deviation between different regions exhibits spatial gradient characteristics. In this case, the controller multiplies the first deviation value (corresponding to the thickness deviation in the left region) with a preset first compensation coefficient to obtain the corresponding scraper left-axis compensation amount, which is used to adjust the vertical displacement of the left servo motor. Simultaneously, the controller multiplies the second deviation value (i.e., the thickness deviation in the central region) by the first compensation coefficient to obtain the scraper central-axis compensation amount, driving the central servo motor to perform corresponding adjustments. The controller then multiplies the third deviation value (the deviation in the right region) by the first compensation coefficient to obtain the scraper right-axis compensation amount, driving the right motor to complete independent adjustments, thus achieving differentiated control compensation for the scraper's three-point posture. In this mode, the compensation amounts received by the three servo motors are different, determined independently based on the thickness error of their respective regions, correcting the transverse thickness inconsistency caused by factors such as posture deviation, uneven slurry flow, or edge retraction. If the global compensation mode is adopted, it indicates that the current lateral thickness error is a uniform deviation, meaning that the thickness error in each area tends to be uniform within the width of the paper. At this time, the controller will arithmetically average all the instantaneous lateral thickness measurements collected to obtain the current average thickness across the entire width. The difference between the average thickness across the entire width and the target thickness is then used as the average deviation value, representing the degree of deviation of the current overall thickness. The average deviation value across the entire width is multiplied by the first compensation coefficient to calculate the uniform compensation amount, which is then simultaneously assigned to the left, middle, and right axes of the scraper. This drives the three servo motors to synchronously adjust upward or downward with the same displacement step, achieving uniform correction of the overall height of the scraper.

[0024] In one specific embodiment, the process of performing step 101 may specifically include the following steps: Multiple laser sensors are arranged at a predetermined position downstream of the scraper; Multiple laser sensors emit laser beams of preset wavelengths to multiple positions laterally on the cast blank, receive the reflected light at each position, and capture the spot displacement by a CCD linear array detector to obtain the spot displacement of each laser sensor. The thickness is converted based on the trigonometric function relationship between the spot displacement of each laser sensor and the preset incident angle to obtain the instantaneous thickness measurement value at each lateral position. The average values ​​of the instantaneous thickness measurements from the left, center, and right regions were calculated to obtain the first deviation value for the left region, the second deviation value for the center region, and the third deviation value for the right region.

[0025] Specifically, the installation position of the laser sensor array in the ceramic green body casting device is selected, set at 120mm downstream of the scraper, to ensure that the slurry has completed its initial leveling without significant leveling deformation, thus accurately reflecting the actual control effect of the scraper gap on the forming thickness. Seven laser triangulation sensors, numbered S1 to S7, are evenly spaced along the transverse direction of the casting machine at the installation position. S1 and S7 are located 5mm inward from both ends of the green body to avoid abnormal fluctuations caused by edge effects, while the central sensor S4 is aligned with the center line of the casting machine. The remaining sensors are evenly distributed with adjacent spacing equal to 1 / 6 of the effective width of the green body, forming a thickness sampling array covering the entire width. During system operation, each laser sensor continuously emits a 650nm red laser beam towards its corresponding lateral measurement point. The laser beam illuminates the surface of the cast billet at a fixed incident angle of 45°. After diffuse reflection from the surface, the light returns to the sensor. The reflected light is received by a CCD linear array detector integrated within the sensor, which records the displacement of the reflected light spot on the imaging surface. A stable univariate geometric trigonometric function mapping relationship is established between the displacement and the actual height of the billet surface. By calibrating the zero-position thickness reference value of each sensor and substituting the light spot displacement Δd into the thickness transformation formula, the optical displacement is converted into the instantaneous thickness value of the current measurement point, resulting in a set of thickness data for the seven lateral positions corresponding to the sampling time. The controller divides the thickness measurement value into regions based on the spatial location of the measurement points. The thicknesses at points S1, S2, and S3 are used as the input for the left region, S4 as the input for the center region, and S5, S6, and S7 as the input for the right region. The controller performs an arithmetic mean on the instantaneous thickness values ​​in each of the three regions to obtain the average thickness values ​​for the left, center, and right regions. The controller then performs a difference calculation with the set target thickness to obtain the first deviation value for the left region, the second deviation value for the center region, and the third deviation value for the right region.

[0026] In one specific embodiment, the process of performing regional averaging calculations on the measuring points in the left, central, and right regions of the instantaneous thickness measurement values ​​to obtain the first deviation value in the left region, the second deviation value in the central region, and the third deviation value in the right region can specifically include the following steps: The difference between the instantaneous thickness measurement value and the target thickness is calculated to obtain the thickness deviation value at each measuring point; The thickness deviation values ​​of each measuring point are divided into three groups: left area deviation value group, central area deviation value group, and right area deviation value group, based on the left area measuring point, central area measuring point, and right area measuring point. The arithmetic mean of the deviation values ​​in the left region is calculated to obtain the first deviation value in the left region; the arithmetic mean of the deviation values ​​in the central region is calculated to obtain the second deviation value in the central region; and the arithmetic mean of the deviation values ​​in the right region is calculated to obtain the third deviation value in the right region.

[0027] Specifically, based on the multi-point thickness measurement data provided by multiple laser sensors positioned downstream of the scraper, the instantaneous thickness measurement value corresponding to each sensor is collected at fixed sampling intervals during the casting process, and a thickness data vector H(t)=[h1(t), h2(t), h3(t), h4(t), h5(t), h6(t), h7(t)] is constructed, where h1 to h7 correspond to the actual thickness values ​​of the seven laser measurement points from left to right. After acquiring the thickness vector, the controller calls the set target thickness value as the benchmark, calculates the difference between each thickness value in H(t) and the target thickness value, and obtains the thickness deviation value of each measurement point, forming a deviation value vector ΔH(t)=[Δh1, Δh2, Δh3, Δh4, Δh5, Δh6, Δh7], reflecting the degree of deviation between the current actual thickness and the target thickness at each point in the lateral direction. Based on the spatial arrangement of the measuring points, the deviation value vector is divided into three groups according to regional logic, constructing the deviation value group for the left region [Δh1, Δh2, Δh3], the deviation value group for the central region [Δh4], and the deviation value group for the right region [Δh5, Δh6, Δh7], respectively, to achieve spatial segmentation mapping of the lateral thickness deviation. An arithmetic mean operation is performed on the deviation values ​​of the three groups, calculating the first deviation value for the left region, the second deviation value for the central region, and the third deviation value for the right region, to obtain the average deviation of the three independent regions.

[0028] In one specific embodiment, the process of performing step 102 may specifically include the following steps: The absolute value of the difference between the first deviation value and the second deviation value is calculated to obtain the first deviation difference value. The absolute value of the difference between the second deviation value and the third deviation value is calculated to obtain the second deviation difference value. The absolute value of the difference between the first deviation value and the third deviation value is calculated to obtain the third deviation difference value. Select the largest deviation difference value from the first deviation difference value, the second deviation difference value, and the third deviation difference value; Compare the maximum deviation value with a preset threshold; When the maximum deviation difference value is greater than the preset threshold, the partition compensation mode is adopted; when the maximum deviation difference value is less than or equal to the preset threshold, the global compensation mode is adopted.

[0029] Specifically, the absolute values ​​of the differences between each pair of the first deviation value Δh1, the second deviation value Δh2, and the third deviation value Δh3 are extracted, and the first deviation difference value is calculated as |Δh1|. Δh2| is used to measure the thickness inconsistency between the left and center regions; the second deviation difference value is calculated as |Δh2|. Δh3| represents the degree of change in thickness error between the central region and the right-side region; the third deviation difference is calculated as |Δh1|. Δh3| is used to assess the degree of symmetry in thickness control at both ends. The above three deviation difference values ​​reflect the thickness balance or spatial tilt trend of the billet in different transverse regions. The one with the largest value is selected as the "maximum deviation difference value" for this round of judgment, which is the most significant spatial gradient amplitude in the thickness error between the current transverse regions. The maximum deviation difference value is compared with a preset judgment threshold, which is set to 0.02mm and empirically determined based on the allowable fluctuation range of the target thickness set in the process. When the maximum deviation difference value is greater than the judgment threshold, it indicates that the thickness deviation between at least one set of regions has exceeded the acceptable range of the process, indicating that there is a significant spatial gradient or posture imbalance problem in the current lateral thickness distribution. At this time, the system determines that it is a non-uniform deviation characteristic and starts the partition compensation mode. Differentiated local compensation operations are performed by adjusting the positions of the left, middle and right axes of the scraper. When the maximum deviation difference value is less than or equal to the preset threshold, it indicates that the current thickness deviation is consistent in the lateral space. The error mainly shows an overall increasing or decreasing trend, which belongs to a uniform deviation that can be uniformly corrected. At this time, the system starts the global compensation mode. The three-axis servo mechanism synchronously adjusts the overall height of the scraper with the same displacement to achieve overall correction of the average thickness.

[0030] In one specific embodiment, the process of performing step 103 may specifically include the following steps: When using the zone compensation mode, the first deviation value is multiplied by the first compensation coefficient to obtain the scraper left axis compensation amount, the second deviation value is multiplied by the first compensation coefficient to obtain the scraper middle axis compensation amount, and the third deviation value is multiplied by the first compensation coefficient to obtain the scraper right axis compensation amount. When the global compensation mode is adopted, the instantaneous thickness measurement values ​​at each lateral position are arithmetically averaged and the difference is calculated with the target thickness to obtain the average deviation value of the whole width. The average deviation value of the whole width is multiplied by the first compensation coefficient to obtain the unified compensation amount, and the unified compensation amount is simultaneously assigned to the left axis compensation amount, the middle axis compensation amount, and the right axis compensation amount of the scraper.

[0031] Specifically, when using the zoned compensation mode, it indicates that there are significant differences in the thickness deviation of different regions in the transverse direction of the cast blank. The three axes of the scraper need to be adjusted separately to achieve targeted correction of the thickness in each region. In this case, the controller multiplies the first deviation value by the first compensation coefficient, and the product is used as the compensation amount for the left axis of the scraper, driving the left-side servo motor to perform independent vertical position adjustment. Then, the second deviation value is multiplied by the first compensation coefficient, and the product is the compensation amount for the central axis of the scraper, driving the central axis servo motor to perform independent adjustment. The third deviation value is multiplied by the first compensation coefficient, and the result is the compensation amount for the right axis of the scraper, used for correction operations on the right side. The first compensation coefficient is empirically set to 0.65 based on the drying shrinkage rate of the ceramic slurry, ensuring a physical linear correspondence between the compensation amount and the change in the thickness of the dried blank. Through the above three independent calculation formulas, differentiated compensation of the three-point posture of the scraper is achieved, thereby eliminating the problem of uneven transverse thickness caused by slurry distribution, scraper wear, or changes in carrier film tension. When the system determines that the current thickness deviation is an overall offset in lateral consistency, i.e., it enters global compensation mode, the controller will temporarily stop using the three sets of regional deviation values ​​individually. Instead, it will perform an arithmetic average of all instantaneous thickness measurements from multiple lateral laser sensors to obtain a full-width average thickness value representing the current overall forming state. Then, it will calculate the difference between the full-width average thickness value and the process target thickness value to obtain the full-width average deviation value at the current moment. The controller will multiply the full-width average deviation value by the first compensation coefficient to calculate a uniform compensation amount. This compensation amount is simultaneously assigned to the three servo motors on the left, middle, and right axes of the scraper, causing the three axes to rise and fall synchronously with the same displacement amplitude, thereby adjusting the overall gap height between the scraper and the carrier film.

[0032] In one specific embodiment, the method for controlling the thickness of ceramic preform casting further includes the following steps: The scraper left axis compensation amount is sent to the scraper left axis servo motor, the scraper middle axis compensation amount is sent to the middle axis servo motor, and the scraper right axis compensation amount is sent to the right axis servo motor, driving the corresponding axis scraper to move downward or upward. The vertical displacement adjustment is performed by driving the corresponding ball screws of each axis servo motor at a preset speed until the displacement stroke corresponding to their respective compensation amount is completed, thus obtaining the adjusted scraper gap state.

[0033] Specifically, the controller sends the scraper's left-axis compensation, middle-axis compensation, and right-axis compensation as three independent commands to the control interfaces of the left-axis servo motor, middle-axis servo motor, and right-axis servo motor, respectively. The controller determines the direction of motion based on the positive or negative value of the compensation. When the compensation is positive, it indicates that the thickness of the corresponding area is too high, and the scraper needs to be driven downward to fine-tune the gap between the scraper and the carrier film, thereby suppressing the thickness of subsequent slurry deposition. When the compensation is negative, it indicates that the area is too thin, and the controller needs to instruct the corresponding servo motor to drive the scraper upward to appropriately widen the gap, thereby increasing the amount of slurry deposited in that area. The servo motor drives the ball screw to rotate based on the received displacement commands. The mechanical transmission structure between the ball screw and the scraper bracket achieves high-precision linear adjustment of 1μm vertical displacement per step, based on the precise coupling relationship between the screw lead and the motor step angle. After receiving their respective compensation commands, all three motors execute the displacement operation at a uniformly set adjustment speed of 5μm / s to ensure the smoothness of the scraper adjustment process and prevent surface fluctuations or uneven molding caused by disturbances in the slurry laminar flow. During the movement, the servo drive system continuously feeds back the current displacement status of the motor in a closed-loop manner and compares it with the compensation command value. When the real-time displacement reaches the absolute value corresponding to the set compensation amount and is in the same direction, the controller immediately terminates the movement command for that axis, locks the scraper position, and completes the adjustment process for that axis. When all three servo axes have reached their compensation target displacement and remain stationary, it indicates that the scraper posture has been adjusted, and a new scraper gap state is entered. The subsequent slurry casting process will continue according to the newly set scraper posture.

[0034] In one specific embodiment, the process of sending the scraper left axis compensation amount to the scraper left axis servo motor, the scraper middle axis compensation amount to the middle axis servo motor, and the scraper right axis compensation amount to the right axis servo motor, and driving the corresponding axis scraper to move downward or upward, can specifically include the following steps: Send the scraper left axis compensation amount to the scraper left axis servo motor, send the scraper middle axis compensation amount to the middle axis servo motor, and send the scraper right axis compensation amount to the right axis servo motor; The left axis servo motor of the scraper receives the compensation amount of the left axis of the scraper and performs a sign judgment on the value; the middle axis servo motor receives the compensation amount of the middle axis of the scraper and performs a sign judgment on the value; the right axis servo motor receives the compensation amount of the right axis of the scraper and performs a sign judgment on the value. When the compensation amount is negative, a reverse command signal is generated; when the compensation amount is positive, a forward command signal is generated. The left axis servo motor controls the rotation direction of the left axis according to the reverse rotation command signal or the forward rotation command signal; the middle axis servo motor controls the rotation direction of the middle axis according to the reverse rotation command signal or the forward rotation command signal; and the right axis servo motor controls the rotation direction of the right axis according to the reverse rotation command signal or the forward rotation command signal. When the reverse rotation command signal is received, the corresponding axis scraper is driven to move vertically downward; when the forward rotation command signal is received, the corresponding axis scraper is driven to move vertically upward.

[0035] Specifically, the compensation values ​​for the left, center, and right axes of the scraper are sent as control commands via a communication bus to the servo motor control units of the left, center, and right axes, respectively. Each servo motor, upon receiving its corresponding compensation value, performs a sign resolution operation, determining the positive or negative attribute of the compensation value: when the received compensation value is positive, the controller's internal logic module generates a forward rotation command signal, indicating that the motor needs to perform a rotational operation in the upward direction; when the compensation value is negative, a reverse rotation command signal is generated, instructing the motor to perform a rotational action in the downward direction. This sign determination is quickly completed in the microcontroller using a sign bit, triggering the setting or resetting of the corresponding direction control bit. In the actual execution process, the left-axis servo motor of the scraper determines the rotation direction of the drive shaft according to the command signal. If the signal is forward, it drives the left ball screw to rotate counterclockwise, thereby raising the scraper; if the signal is reverse, it rotates clockwise, causing the scraper to descend. The middle-axis servo motor and the right-axis servo motor execute the same direction control logic, determining the rotation direction of their connected ball screws according to the sign of the compensation amount. The screw pitch and nut structure convert the rotational motion into linear displacement, realizing the vertical displacement adjustment of the scraper in the middle and right sides. Since the compensation amount is within the micrometer range, and the corresponding motor step angle and screw lead are configured with high precision, each rotation control command can control the scraper to rise or fall in 1μm steps, thus meeting the precision control requirements in ceramic blank thickness adjustment.

[0036] In one specific embodiment, the method for controlling the thickness of ceramic preform casting further includes the following steps: Under the adjusted scraper gap, the cast blank is kept running at the carrier film running speed for a preset time until the cast blank under the new gap condition reaches the laser sensor detection position. The thickness of the cast blank is measured at multiple transverse positions by multiple laser sensors and the arithmetic mean of the thickness values ​​of all measuring points is calculated to obtain the adjusted full-width average thickness. The residual deviation is obtained by calculating the difference between the adjusted full-width average thickness and the target thickness. The absolute value of the residual deviation is obtained by performing an absolute value operation on the residual deviation. The absolute value of the residual deviation is then compared with the accuracy threshold. When the absolute value of the residual deviation is greater than the accuracy threshold, the residual deviation is multiplied by the second compensation coefficient to obtain the secondary compensation amount. Based on the secondary compensation amount, the three-axis servo adjustment process of the scraper is re-executed. When the absolute value of the residual deviation is less than or equal to the accuracy threshold, the adjusted scraper gap state remains unchanged and the casting production continues.

[0037] Specifically, after the three axes of the scraper complete their attitude adjustment and form a new gap state according to the current compensation amount, the system enters a preset waiting phase. During this period, the controller maintains the current gap configuration and allows the cast billet to move forward at a constant speed under the traction of the carrier film, so that the billet generated under the new gap conditions gradually moves to the location of the laser sensor array. Considering the distance between the sensor and the scraper installation position and the time required for slurry leveling, the preset running time is set to 15 seconds to ensure that the thickness data collected by the laser sensor completely corresponds to the area of ​​the new billet formed under the adjusted gap conditions. After this waiting period, the laser sensor array restarts the synchronous sampling process, measures the thickness at multiple positions in the transverse direction of the cast billet, and performs an arithmetic average calculation using the real-time thickness data from the seven laser measuring points to obtain the adjusted full-width average thickness of the current billet. The controller calculates the difference between the average thickness value and the target thickness set by the process to obtain the residual deviation value after this compensation, and performs an absolute value calculation on the residual deviation value to eliminate directional interference, retaining only the deviation magnitude as a reference for error intensity. The absolute value of the residual deviation is compared with a set precision control threshold of ±0.012 mm to determine whether the thickness is within the acceptable fluctuation range. When the residual deviation exceeds the precision control threshold, it is determined that the first compensation is insufficient to pull the billet thickness back to the control target range. Therefore, a second compensation process is executed. The controller multiplies the residual deviation value by an enhanced second compensation coefficient (e.g., 0.85) to obtain a new second compensation amount. Based on the second compensation amount, the scraper three-axis servo adjustment process is restarted, repeating the previous compensation mode determination, rotation direction determination, and servo motor displacement execution steps to complete the iterative adjustment action. When the absolute value of the residual deviation is less than or equal to the precision threshold, it indicates that the current adjustment has met the process precision requirements. The controller then maintains the current scraper gap state unchanged and directly enters the continuous casting production state, waiting for the next error trigger event.

[0038] In one specific embodiment, the process of multiplying the residual deviation by a second compensation coefficient to obtain a secondary compensation amount when the absolute value of the residual deviation is greater than the accuracy threshold, and re-executing the three-axis servo adjustment process of the scraper based on the secondary compensation amount, and maintaining the adjusted scraper gap state and continuing the tape casting production when the absolute value of the residual deviation is less than or equal to the accuracy threshold, can specifically include the following steps: A secondary compensation trigger signal is generated when the absolute value of the residual deviation is greater than the accuracy threshold, and a steady-state maintenance signal is generated when the absolute value of the residual deviation is less than or equal to the accuracy threshold. When a secondary compensation trigger signal is received, the residual deviation is multiplied by the second compensation coefficient to obtain the secondary compensation amount, and the scraper three-axis servo adjustment process is re-executed based on the secondary compensation amount; When a steady-state maintenance signal is received, the adjusted scraper gap remains unchanged, the controller enters steady-state monitoring mode to continuously collect the thickness distribution vector and continue casting production.

[0039] Specifically, the absolute value of the residual deviation is compared with a set accuracy threshold, which is set to 0.012 mm, as the basis for determining whether to continue compensation. When the absolute value of the residual deviation is greater than the accuracy threshold, it indicates that the first compensation has not yet controlled the thickness deviation within the target tolerance range, and a "secondary compensation trigger signal" is automatically generated as a control flag to reactivate the servo adjustment process. Conversely, when the absolute value of the residual deviation is less than or equal to the accuracy threshold, it indicates that the target accuracy has been achieved in this round of adjustment, and a "steady-state maintenance signal" is generated to notify the control module to maintain the current scraper gap state and keep the system running stably. If the controller receives a secondary compensation trigger signal, it multiplies the residual deviation value with the second compensation coefficient to calculate the enhanced secondary compensation amount. The second compensation coefficient is set to 0.85 to enhance the convergence rate. Then, it re-enters the scraper three-axis servo adjustment process, controls the rotation direction of the three servo motors by judging the positive or negative sign of the compensation amount, and drives the ball screw at a specified speed to achieve precise displacement, forming a new gap state before continuing the next round of closed-loop feedback detection. When the controller receives a steady-state maintenance signal, it locks the current three-axis position of the scraper, prohibits further displacement operations, and enters the steady-state monitoring mode. In the steady-state monitoring mode, the controller continuously collects the thickness distribution vector of the sensor array at a set frequency, and records and evaluates the average value and standard deviation of each cycle. Only when a new thickness deviation trigger condition occurs in the future (such as continuously exceeding ±0.015mm) will it re-enter the adjustment process.

[0040] The ceramic blank casting thickness control method, after obtaining the first deviation value of the left region, the second deviation value of the central region, and the third deviation value of the right region, further includes a servo adjustment trigger judgment step: A sliding window data buffer is established for the first, second, and third deviation values ​​within multiple consecutive sampling periods. The capacity of the sliding window data buffer is set to a preset number of sampling periods. The region deviation values ​​obtained in each new sampling period are sequentially stored at the tail position of the corresponding sliding window data buffer. When the buffer data volume reaches the capacity limit, the earliest deviation value at the head position is automatically deleted. The arithmetic mean of multiple consecutive first deviation values ​​in the left region of the sliding window data buffer is calculated to obtain the continuous average deviation value of the left region. The arithmetic mean of multiple consecutive second deviation values ​​in the central region of the sliding window data buffer is calculated to obtain the continuous average deviation value of the central region. The arithmetic mean of multiple consecutive third deviation values ​​in the right region of the sliding window data buffer is calculated to obtain the continuous average deviation value of the central region. The arithmetic mean of the values ​​is used to obtain the continuous average deviation value of the right region. The absolute values ​​of the continuous average deviation values ​​of the left region, the center region, and the right region are calculated separately. When any one of the absolute values ​​of the continuous average deviation values ​​of the three regions is greater than the trigger threshold, a servo adjustment trigger command is generated. When none of the absolute values ​​of the continuous average deviation values ​​of the three regions are greater than the trigger threshold, a thickness monitoring continue command is generated. When a servo adjustment trigger command is received, the continuous average deviation value of the left region is used as the final first deviation value, the continuous average deviation value of the center region is used as the final second deviation value, and the continuous average deviation value of the right region is used as the final third deviation value. Based on the final first deviation value, the final second deviation value, and the final third deviation value, the subsequent zoning identification judgment and scraper three-axis servo adjustment process are executed. When a thickness monitoring continue command is received, the current scraper gap state remains unchanged and the region deviation value of the next sampling period is collected.

[0041] The method for controlling the thickness of ceramic blank casting after completing the three-axis servo adjustment of the scraper and obtaining the adjusted scraper gap state also includes an adaptive correction step for the compensation coefficient: Before each three-axis servo adjustment of the scraper, the deviation value of the region before adjustment is recorded; after the three-axis servo adjustment of the scraper is completed and a preset stabilization time has elapsed, the deviation value of the region after adjustment is measured; the deviation value of the region before adjustment, the actual compensation amount, and the deviation value of the region after adjustment are encapsulated and stored to form single-time adjustment effect record data; the single-time adjustment effect record data is parsed and extracted, and the difference between the deviation value of the region before adjustment and the deviation value of the region after adjustment is calculated to obtain the actual thickness change; the ratio of the actual thickness change to the actual compensation amount is calculated to obtain the single-time compensation efficiency value; a historical data queue of compensation efficiency is established, and... Each calculated single-time compensation efficiency value is sequentially stored in the historical compensation efficiency data queue. When the number of single-time compensation efficiency values ​​stored in the historical compensation efficiency data queue reaches a preset statistical quantity, the arithmetic mean of all single-time compensation efficiency values ​​in the queue is calculated to obtain the average compensation efficiency value. The ratio of the average compensation efficiency value to the theoretical corresponding value of the first compensation coefficient is calculated to obtain the compensation efficiency deviation ratio. When the absolute value of the difference between the compensation efficiency deviation ratio and the value 1 is greater than the preset deviation ratio threshold, the current first compensation coefficient is multiplied by the reciprocal of the compensation efficiency deviation ratio to obtain the corrected first compensation coefficient, and the corrected first compensation coefficient replaces the original first compensation coefficient. When the absolute value of the difference between the compensation efficiency deviation ratio and the value 1 is not greater than the preset deviation ratio threshold, the current first compensation coefficient remains unchanged.

[0042] The ceramic green body casting thickness control method also includes control effect evaluation and parameter optimization steps when the controller enters steady-state monitoring mode to continuously collect thickness distribution vectors and continue casting production. In steady-state monitoring mode, all instantaneous thickness measurements at all lateral positions collected within a preset number of evaluation cycles are statistically summarized. All thickness values ​​from all sampling cycles are expanded to form a thickness data set. The arithmetic mean of all thickness values ​​in the thickness data set is calculated to obtain the statistical average thickness. The sum of squares of the deviations between all thickness values ​​in the thickness data set and the statistical average thickness is calculated, and the square root is divided by the total number of data points to obtain the thickness standard deviation. The ratio of the thickness standard deviation to the statistical average thickness is calculated and multiplied by 100 to obtain the thickness coefficient of variation percentage. The thickness coefficient of variation percentage is compared sequentially with a first control effect threshold and a second control effect threshold, where the second control effect threshold is greater than the first control effect threshold. When the thickness coefficient of variation percentage is not greater than the first control effect threshold, the control effect is optimized. When the control effect threshold is reached, the control effect is deemed excellent, and the current control parameters remain unchanged. When the percentage value of the thickness coefficient of variation is greater than the first control effect threshold but not greater than the second control effect threshold, the control effect is deemed acceptable but needs optimization. The current trigger threshold is multiplied by a preset tightening coefficient to obtain the optimized trigger threshold, which replaces the original trigger threshold, thereby improving the sensitivity of subsequent deviation judgment. When the percentage value of the thickness coefficient of variation is greater than the second control effect threshold, abnormal interference is determined, a process abnormality alarm signal is generated, and the operator is notified to check the equipment. Within the preset observation period after the trigger threshold optimization, the percentage value of the thickness coefficient of variation is recalculated and compared with the first control effect threshold. When the optimized percentage value of the thickness coefficient of variation decreases to no greater than the first control effect threshold, the optimization is confirmed to be effective, and the optimized trigger threshold is maintained. When the optimized percentage value of the thickness coefficient of variation is still greater than the first control effect threshold, the trigger threshold is restored to the value before optimization, and parameter adjustment suggestion information is generated.

[0043] In the case of a partitioned compensation mode, the process of multiplying the first deviation value by the first compensation coefficient to obtain the scraper's left-axis compensation amount, multiplying the second deviation value by the first compensation coefficient to obtain the scraper's central-axis compensation amount, and multiplying the third deviation value by the first compensation coefficient to obtain the scraper's right-axis compensation amount is implemented using an adaptive iterative step-size optimization algorithm. This includes: constructing a thickness deviation cost function, and weighting the squares of the first, second, and third deviation values ​​to obtain the current thickness deviation cost value. The weight coefficients for the left, central, and right regions are set according to the degree of influence of each region on the final product performance. The thickness deviation cost function uses the scraper's left-axis compensation amount, the scraper's central-axis compensation amount, and the scraper's right-axis compensation amount as the basis for calculation. The compensation amounts of the blade center axis and the scraper right axis are the independent variables, and the thickness deviation cost is the dependent variable. The optimization objective is to find the three-axis compensation combination that minimizes the thickness deviation cost. The iterative optimization parameters are initialized: when using the partitioned compensation mode, the initial iteration step size is set to the first preset step size value; when using the global compensation mode, the initial iteration step size is set to the second preset step size value, where the first preset step size value is greater than the second preset step size value. The initial values ​​of the scraper left axis compensation, scraper center axis compensation, and scraper right axis compensation are set to the products of the first deviation value and the first compensation coefficient, the second deviation value and the first compensation coefficient, and the third deviation value and the first compensation coefficient, respectively. A historical gradient squared value is established. A cumulative variable is established and initialized with a preset small positive number. A cumulative variable for updating the squared historical compensation amount is also established and initialized with a preset small positive number. An adaptive iterative step-size optimization process is executed. Partial derivatives of the thickness deviation cost function with respect to the left-axis, middle-axis, and right-axis compensation amounts of the scraper are calculated to obtain the three-axis compensation gradient vector. The components of the three-axis compensation gradient vector are squared and then weighted and accumulated with the historical gradient squared cumulative variable to obtain the current gradient squared cumulative value. The updated historical gradient squared cumulative variable is multiplied by a preset decay factor and then added to the product of the current gradient squared cumulative value and a preset smoothing factor to obtain the updated historical gradient squared cumulative variable. The historical compensation amount update squared cumulative variable is then calculated. The adaptive step size of the current iteration is obtained by taking the square root of the ratio of the squared cumulative variable to the updated historical gradient squared cumulative variable. The three-axis compensation gradient vector is multiplied by the adaptive step size of the current iteration to obtain the three-axis compensation update. The new value of the scraper left-axis compensation is obtained by subtracting the update of the scraper left-axis compensation from the current value of the scraper middle-axis compensation. The new value of the scraper middle-axis compensation is obtained by subtracting the update of the scraper middle-axis compensation from the current value of the scraper right-axis compensation. The new value of the scraper right-axis compensation is obtained by subtracting the update of the scraper right-axis compensation from the current value of the scraper right-axis compensation. The updated historical compensation update squared cumulative variable is obtained by squaring each component of the three-axis compensation update and then performing a weighted cumulative update with the historical compensation update squared cumulative variable.To determine the convergence condition of the iteration, the absolute values ​​of each component in the three-axis compensation update are summed to obtain the total update. When the total update is less than a preset convergence threshold or the number of iterations reaches a preset maximum number of iterations, the iteration terminates, and the current new values ​​of the scraper's left-axis, middle-axis, and right-axis compensation are output as the optimal compensation values. When the total update is not less than the preset convergence threshold and the number of iterations has not reached the preset maximum number of iterations, the new values ​​of the scraper's left-axis, middle-axis, and right-axis compensation are used as the current values ​​of the scraper's left-axis, middle-axis, and right-axis compensation for the next iteration, and the process returns to execute the adaptive iterative step size optimization step.

[0044] The above describes the method for controlling the thickness of ceramic green body during casting in the embodiments of the present invention. The following describes the device for controlling the thickness of ceramic green body during casting in the embodiments of the present invention. Please refer to [link / reference]. Figure 2 One embodiment of the ceramic blank casting thickness control device of the present invention includes: The thickness measurement module 201 is used to measure the thickness of the cast blank by means of multiple laser sensors arranged at a preset position downstream of the scraper, and to calculate the first deviation value of the left region, the second deviation value of the center region and the third deviation value of the right region. The compensation mode analysis module 202 is used to calculate the maximum deviation difference between the first deviation value, the second deviation value and the third deviation value. When the maximum deviation difference value is greater than the preset threshold, the partition compensation mode is adopted, and when the maximum deviation difference value is less than or equal to the preset threshold, the global compensation mode is adopted. The compensation calculation module 203 is used to calculate the scraper left axis compensation amount by multiplying the first deviation value by the first compensation coefficient when the partition compensation mode is adopted, to calculate the scraper middle axis compensation amount by multiplying the second deviation value by the first compensation coefficient, and to calculate the scraper right axis compensation amount by multiplying the third deviation value by the first compensation coefficient when the partition compensation mode is adopted; when the global compensation mode is adopted, it calculates the unified compensation amount and assigns the unified compensation amount to the scraper left axis compensation amount, scraper middle axis compensation amount and scraper right axis compensation amount at the same time.

[0045] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the specific working processes of the systems and units described above can be referred to the corresponding processes in the foregoing method embodiments, and will not be repeated here.

[0046] If the integrated unit is implemented as a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the present invention, in essence, or the part that contributes to the prior art, or all or part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of the present invention. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0047] The above-described embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for controlling the thickness of a ceramic green body during tape casting, characterized in that, include: The thickness of the cast blank is measured by multiple laser sensors arranged at a preset position downstream of the scraper, and the first deviation value of the left region, the second deviation value of the central region, and the third deviation value of the right region are calculated. Calculate the maximum deviation difference between the first deviation value, the second deviation value, and the third deviation value. When the maximum deviation difference value is greater than a preset threshold, a partition compensation mode is adopted. When the maximum deviation difference value is less than or equal to the preset threshold, a global compensation mode is adopted. When using the partitioned compensation mode, the first deviation value is multiplied by the first compensation coefficient to obtain the scraper left axis compensation amount, the second deviation value is multiplied by the first compensation coefficient to obtain the scraper center axis compensation amount, and the third deviation value is multiplied by the first compensation coefficient to obtain the scraper right axis compensation amount. When using the global compensation mode, a unified compensation amount is calculated and the unified compensation amount is simultaneously assigned to the scraper left axis compensation amount, the scraper center axis compensation amount, and the scraper right axis compensation amount.

2. The method for controlling the thickness of ceramic green body during tape casting according to claim 1, characterized in that, The process of measuring the thickness of the cast blank using multiple laser sensors positioned at a predetermined location downstream of the scraper, and calculating the first deviation value for the left region, the second deviation value for the central region, and the third deviation value for the right region, includes: Multiple laser sensors are arranged at a predetermined position downstream of the scraper; The laser beams of preset wavelength are emitted to multiple positions laterally of the cast blank by the multiple laser sensors, the reflected light at each position is received and the spot displacement is captured by the CCD linear array detector, and the spot displacement of each laser sensor is obtained. Based on the trigonometric function relationship between the spot displacement of each laser sensor and the preset incident angle, the thickness is converted to obtain the instantaneous thickness measurement value at each lateral position. The measurement points in the left, center, and right regions of the instantaneous thickness measurement are averaged to obtain the first deviation value in the left region, the second deviation value in the center region, and the third deviation value in the right region.

3. The method for controlling the thickness of ceramic green body during tape casting according to claim 2, characterized in that, The step of calculating the regional average of the measuring points in the left, center, and right regions of the instantaneous thickness measurement value to obtain the first deviation value of the left region, the second deviation value of the center region, and the third deviation value of the right region includes: The difference between the instantaneous thickness measurement value and the target thickness is calculated to obtain the thickness deviation value at each measuring point; The thickness deviation values ​​of each measuring point are divided into three groups: left area deviation value group, central area deviation value group, and right area deviation value group, based on the left area measuring point, central area measuring point, and right area measuring point. The arithmetic mean of the deviation values ​​in the left region is calculated to obtain the first deviation value of the left region; the arithmetic mean of the deviation values ​​in the center region is calculated to obtain the second deviation value of the center region; and the arithmetic mean of the deviation values ​​in the right region is calculated to obtain the third deviation value of the right region.

4. The method for controlling the thickness of ceramic green body during casting according to claim 1, characterized in that, The calculation of the maximum deviation difference between the first deviation value, the second deviation value, and the third deviation value, wherein a partition compensation mode is adopted when the maximum deviation difference value is greater than a preset threshold, and a global compensation mode is adopted when the maximum deviation difference value is less than or equal to the preset threshold, includes: The absolute value of the difference between the first deviation value and the second deviation value is calculated to obtain the first deviation difference value; the absolute value of the difference between the second deviation value and the third deviation value is calculated to obtain the second deviation difference value; and the absolute value of the difference between the first deviation value and the third deviation value is calculated to obtain the third deviation difference value. Select the largest deviation difference value from the first deviation difference value, the second deviation difference value, and the third deviation difference value; The maximum deviation difference value is compared with a preset threshold. When the maximum deviation difference value is greater than a preset threshold, a partition compensation mode is adopted; when the maximum deviation difference value is less than or equal to the preset threshold, a global compensation mode is adopted.

5. The method for controlling the thickness of ceramic green body during tape casting according to claim 1, characterized in that, When using the partitioned compensation mode, the first deviation value is multiplied by the first compensation coefficient to obtain the scraper left-axis compensation amount, the second deviation value is multiplied by the first compensation coefficient to obtain the scraper center-axis compensation amount, and the third deviation value is multiplied by the first compensation coefficient to obtain the scraper right-axis compensation amount; when using the global compensation mode, a unified compensation amount is calculated and simultaneously assigned to the scraper left-axis compensation amount, scraper center-axis compensation amount, and scraper right-axis compensation amount, including: When the partition compensation mode is adopted, the first deviation value is multiplied by the first compensation coefficient to obtain the scraper left axis compensation amount, the second deviation value is multiplied by the first compensation coefficient to obtain the scraper middle axis compensation amount, and the third deviation value is multiplied by the first compensation coefficient to obtain the scraper right axis compensation amount. When the global compensation mode is adopted, the instantaneous thickness measurement values ​​at each lateral position are arithmetically averaged and the difference is calculated with the target thickness to obtain the full-width average deviation value; the full-width average deviation value is multiplied by the first compensation coefficient to obtain the unified compensation amount, and the unified compensation amount is simultaneously assigned to the scraper left axis compensation amount, scraper center axis compensation amount, and scraper right axis compensation amount.

6. The method for controlling the thickness of ceramic green body during tape casting according to claim 1, characterized in that, The method for controlling the thickness of ceramic preform casting also includes: The scraper left axis compensation amount is sent to the scraper left axis servo motor, the scraper middle axis compensation amount is sent to the middle axis servo motor, and the scraper right axis compensation amount is sent to the right axis servo motor to drive the corresponding axis scraper to move downward or upward. The vertical displacement adjustment is performed by driving the corresponding ball screws of each axis servo motor at a preset speed until the displacement stroke corresponding to their respective compensation amount is completed, thus obtaining the adjusted scraper gap state.

7. The method for controlling the thickness of ceramic green body during tape casting according to claim 6, characterized in that, The step of sending the scraper left-axis compensation amount to the scraper left-axis servo motor, the scraper middle-axis compensation amount to the middle-axis servo motor, and the scraper right-axis compensation amount to the right-axis servo motor to drive the corresponding axis scraper to move downward or upward includes: The scraper left axis compensation amount is sent to the scraper left axis servo motor, the scraper middle axis compensation amount is sent to the middle axis servo motor, and the scraper right axis compensation amount is sent to the right axis servo motor; The left axis servo motor of the scraper receives the compensation amount of the left axis of the scraper and performs a sign judgment on the value; the middle axis servo motor receives the compensation amount of the middle axis of the scraper and performs a sign judgment on the value; the right axis servo motor receives the compensation amount of the right axis of the scraper and performs a sign judgment on the value. When the compensation amount is negative, a reverse command signal is generated; when the compensation amount is positive, a forward command signal is generated. The left axis servo motor controls the rotation direction of the left axis according to the reverse rotation command signal or the forward rotation command signal; the middle axis servo motor controls the rotation direction of the middle axis according to the reverse rotation command signal or the forward rotation command signal; and the right axis servo motor controls the rotation direction of the right axis according to the reverse rotation command signal or the forward rotation command signal. When the reverse rotation command signal is received, the corresponding axis scraper is driven to move vertically downward; when the forward rotation command signal is received, the corresponding axis scraper is driven to move vertically upward.

8. The method for controlling the thickness of ceramic green body during tape casting according to claim 7, characterized in that, The method for controlling the thickness of ceramic preform casting also includes: Under the adjusted scraper gap, the cast blank is kept running at the carrier film running speed for a preset time until the cast blank under the new gap condition reaches the detection position of the laser sensor. The thickness of the cast blank is measured at multiple transverse positions by the multiple laser sensors and the arithmetic average of the thickness values ​​of all measuring points is calculated to obtain the adjusted full-width average thickness. The residual deviation is obtained by calculating the difference between the adjusted full-width average thickness and the target thickness. The absolute value of the residual deviation is obtained by performing an absolute value operation on the residual deviation. The absolute value of the residual deviation is then compared with the accuracy threshold. When the absolute value of the residual deviation is greater than the accuracy threshold, the residual deviation is multiplied by the second compensation coefficient to obtain the secondary compensation amount. Based on the secondary compensation amount, the three-axis servo adjustment process of the scraper is re-executed. When the absolute value of the residual deviation is less than or equal to the accuracy threshold, the adjusted scraper gap state remains unchanged and the casting production continues.

9. The method for controlling the thickness of ceramic green body during tape casting according to claim 8, characterized in that, When the absolute value of the residual deviation is greater than the accuracy threshold, the residual deviation is multiplied by the second compensation coefficient to obtain a secondary compensation amount. Based on the secondary compensation amount, the three-axis servo adjustment process of the scraper is re-executed. When the absolute value of the residual deviation is less than or equal to the accuracy threshold, the adjusted scraper gap state is kept unchanged and casting production continues, including: A secondary compensation trigger signal is generated when the absolute value of the residual deviation is greater than the accuracy threshold, and a steady-state maintenance signal is generated when the absolute value of the residual deviation is less than or equal to the accuracy threshold. When the secondary compensation trigger signal is received, the residual deviation is multiplied by the second compensation coefficient to obtain the secondary compensation amount, and the scraper three-axis servo adjustment process is re-executed based on the secondary compensation amount; When the steady-state maintenance signal is received, the adjusted scraper gap remains unchanged, the controller enters the steady-state monitoring mode to continuously collect the thickness distribution vector and continue the casting production.

10. A device for controlling the thickness of ceramic green body during casting, characterized in that, A method for controlling the thickness of a ceramic preform during casting as described in any one of claims 1-9, comprising: The thickness measurement module is used to measure the thickness of the cast blank by means of multiple laser sensors arranged at a preset position downstream of the scraper, and to calculate the first deviation value of the left region, the second deviation value of the center region and the third deviation value of the right region. The compensation mode analysis module is used to calculate the maximum deviation difference value among the first deviation value, the second deviation value, and the third deviation value. When the maximum deviation difference value is greater than a preset threshold, a partition compensation mode is adopted, and when the maximum deviation difference value is less than or equal to the preset threshold, a global compensation mode is adopted. The compensation amount calculation module is used to calculate the scraper left axis compensation amount by multiplying the first deviation value by the first compensation coefficient when the partition compensation mode is adopted, to calculate the scraper middle axis compensation amount by multiplying the second deviation value by the first compensation coefficient, and to calculate the scraper right axis compensation amount by multiplying the third deviation value by the first compensation coefficient when the partition compensation mode is adopted. When the global compensation mode is adopted, the module calculates the unified compensation amount and assigns the unified compensation amount to the scraper left axis compensation amount, the scraper middle axis compensation amount, and the scraper right axis compensation amount simultaneously.

Images