Crude foil engine control method and device, crude foil engine, storage medium and program product

Abstract

The invention relates to the technical field of lithium battery copper foil manufacturing, and discloses a crude foil engine control method and device, a crude foil engine, a storage medium and a program product, and the crude foil engine comprises a cathode roller used for electrolyzing crude foil and a winding roller used for drawing and collecting copper foil; the measuring roller is used for measuring the linear speed and the winding tension of the crude foil; the method comprises the steps that the actual winding speed and the actual winding tension in the copper foil winding process of a winding roller and the measuring linear speed of a measuring roller are monitored; based on the actual winding speed and the measurement linear speed, the actual winding diameter is calculated; based on the actual winding tension and the actual winding diameter, the initial winding moment is calculated; determining a tension compensation torque based on the magnitude relationship between the actual winding tension and the preset winding tension; and the target winding torque is determined on the basis of the sum of the initial winding torque and the tension compensation torque, the winding roller is controlled to execute winding operation at the target winding torque, and speed and tension matching between cathode roller electrolytic foil generation and winding of the winding roller is achieved.

Description

Technical Field

[0001] This invention relates to the field of lithium battery copper foil manufacturing technology, specifically to foil production machine control methods, devices, foil production machines, storage media, and program products. Background Technology

[0002] In the foil production process, the speed and tension matching between the cathode roller electrolytic foil production and the winding roller is the key to ensuring continuous and stable production of high-quality copper foil. In related technologies, the system only relies on the motor encoder for speed feedback and lacks accurate tension detection. Furthermore, speed control is performed through simple pulse signals, resulting in a mismatch between the speed and tension of the winding roller. Summary of the Invention

[0003] This invention provides a control method, device, foil production machine, storage medium, and program product for a foil production machine, in order to solve the problem of copper foil breakage or wrinkling caused by mismatch between the speed and tension of the winding roller.

[0004] In a first aspect, the present invention provides a control method for a foil production machine, the foil production machine including a cathode roller, a winding roller and a measuring roller, the cathode roller being used for electrolytic foil production, the winding roller being used for traction and collection of copper foil; the measuring roller is installed between the cathode roller and the winding roller and is used to measure the foil production linear speed and winding tension. The method includes: Monitor the actual winding speed and actual winding tension of the winding roller during the copper foil winding process, as well as the measuring linear speed of the measuring roller; Calculate the actual winding diameter based on the actual winding speed and the measured linear speed. Calculate the initial winding length based on the actual winding tension and the actual winding diameter; The tension compensation torque is determined based on the relationship between the actual winding tension and the preset winding tension. The target winding torque is determined based on the sum of the initial winding torque and the tension compensation torque, and the winding roll is controlled to perform the winding operation with the target winding torque.

[0005] This invention measures the linear speed and the actual winding speed. When a deviation occurs, the control system drives the winding roller motor to adjust the speed of the winding roller, thereby synchronizing the actual winding speed with the measured linear speed. The actual winding tension is compared with the target tension set by the system. If the actual tension deviates from the set value, the control system adjusts the winding torque of the winding motor, thereby controlling the winding roller to perform the winding operation with the target winding torque to maintain constant tension, thus ensuring precise matching between the winding roller speed and tension.

[0006] In one alternative implementation, the actual winding diameter is calculated using the following formula: D = V' / (π×ω); Where D represents the actual winding diameter, V' represents the measured linear velocity, ω represents the actual winding speed, and π represents the compensation coefficient.

[0007] This invention calculates the actual winding diameter using this formula, enabling the online, continuous, and highly accurate acquisition of the dynamic winding diameter value without relying on mechanical measuring devices. This actual winding diameter provides an accurate feedback benchmark for winding speed synchronization and tension control, allowing the system to compensate in real time for the linear speed and torque adjustment requirements caused by changes in the winding diameter. This maintains a constant winding linear speed and stable winding tension during the winding process, effectively improving the flatness and compactness of the copper foil rolls and increasing production efficiency.

[0008] In one alternative implementation, the initial winding length is calculated using the following formula: T1 = F / D; Where T1 represents the initial winding torque, F represents the actual winding tension, and D represents the actual winding diameter.

[0009] This invention provides an instant torque reference for the take-up roller by synchronously mapping the real-time changes in tension and roll diameter to a feedforward reference for torque commands. This effectively offsets the impact of continuous changes in roll diameter on tension, enabling better maintenance of tension stability during the take-up of copper foil. It significantly reduces the adjustment burden on the subsequent closed-loop feedback controller, improves the overall system response speed and control stability, enhances the accuracy of the take-up roller in taking up copper foil, and achieves the matching of tension and speed during take-up.

[0010] In one optional implementation, the tension compensation torque is determined based on the relationship between the actual winding tension and the preset winding tension, including: Calculate the tension difference between the actual winding tension and the preset winding tension; Based on the tension difference, a PID control algorithm is used to determine the tension compensation torque.

[0011] This invention achieves closed-loop precise adjustment of tension fluctuations by real-time detection of the deviation between the winding tension and the preset tension, and by dynamically generating compensation torque using a PID control algorithm. This compensation mechanism can quickly respond to tension changes caused by material property fluctuations, minor mechanical transmission errors, or external interference. Through the PID control algorithm, feedforward compensation and adjustment are achieved, continuously and accurately stabilizing the actual tension at the process set value, improving the control accuracy and dynamic stability of the winding tension, and avoiding quality defects such as copper foil wrinkling and stretching deformation caused by tension fluctuations.

[0012] In one alternative implementation, the method further includes: Obtain the set rotational speed of the cathode roller; Monitor the actual rotation speed of the cathode roller during the electrolytic foil production process; The actual rotational speed is determined based on the actual rotational speed and the measuring linear speed of the measuring roller; The compensation speed is determined based on the difference between the actual measured speed and the set speed; The speed of the cathode roller is adjusted based on the compensation speed so that the actual measured speed is equal to the set speed.

[0013] This invention calculates the speed deviation between the actual rotational speed fed back by the cathode roller encoder and the measured linear speed detected by the measuring roller encoder. Then, it calibrates the actual measured speed in real time based on the speed deviation to determine the compensation speed. The compensation speed is not exactly equal to the final measured speed, but participates in the adjustment as a correction value. By dynamically increasing or decreasing the compensation value, the actual measured speed gradually converges to the target value consistent with the measured linear speed, thereby matching the cathode tube speed with the winding roller speed.

[0014] In one alternative implementation, the method further includes: Calculate the target winding speed based on the set rotation speed of the cathode roller and the actual winding diameter; Based on the relationship between the target winding speed and the actual winding speed, the winding roller is speed controlled so that the actual winding speed equals the target winding speed.

[0015] This invention ensures that the actual winding speed always precisely matches the target speed determined by the foil production process by using bidirectional closed-loop control of the winding roller based on the deviation between the target speed and the actual speed. This maintains constant winding tension and stable winding synchronization during continuous production, effectively avoiding defects such as copper foil stretching, loosening, wrinkling, or uneven stacking caused by speed asynchrony, and significantly improving the consistency of the coil material quality and the stability of the production process.

[0016] Secondly, the present invention provides a foil production machine control device, the foil production machine including a cathode roller, a winding roller and a measuring roller, the cathode roller being used for electrolytic foil production, the winding roller being used for traction and collection of copper foil; the measuring roller being installed between the cathode roller and the winding roller being used for measuring the foil production linear speed and winding tension. The device includes: The monitoring module is used to monitor the actual winding speed and actual winding tension of the winding roller during the copper foil winding process, as well as the measuring linear speed of the measuring roller; The first calculation module is used to calculate the actual winding diameter based on the actual winding speed and the measured linear speed. The second calculation module is used to calculate the initial winding roll length based on the actual winding tension and the actual winding roll diameter. The third calculation module is used to determine the tension compensation torque based on the relationship between the actual winding tension and the preset winding tension; The control module is used to determine the target winding torque based on the sum of the initial winding torque and the tension compensation torque, and to control the winding roller to perform the winding operation with the target winding torque.

[0017] Thirdly, the present invention provides a foil-making machine, comprising a cathode roller, a winding roller, and a measuring roller. The cathode roller is used for electrolytic foil production, and the winding roller is used for drawing and collecting copper foil. The measuring roller is installed between the cathode roller and the winding roller and is used to measure the foil production linear speed and winding tension. The foil-making machine also includes a controller, which includes: The memory and the processor are interconnected and communicate with each other. The memory stores computer instructions, and the processor executes the computer instructions to perform the foil-making machine control method described in the first aspect or any of its corresponding embodiments.

[0018] Fourthly, the present invention provides a computer-readable storage medium storing computer instructions for causing a computer to execute the foil-making machine control method of the first aspect or any corresponding embodiment described above.

[0019] Fifthly, the present invention provides a computer program product, including computer instructions for causing a computer to execute the foil-making machine control method described in the first aspect or any corresponding embodiment thereof. Attached Figure Description

[0020] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0021] Figure 1 This is a schematic diagram of an application scenario according to an embodiment of the present invention; Figure 2 This is a schematic flowchart of a first method for controlling a foil-making machine according to an embodiment of the present invention; Figure 3 This is a second flowchart illustrating the foil-making machine control method according to an embodiment of the present invention; Figure 4 This is a hardware system architecture diagram of the foil-making machine control method according to an embodiment of the present invention; Figure 5 This is a control logic block diagram of the foil-making machine control method according to an embodiment of the present invention; Figure 6 This is a structural block diagram of a foil-making machine control device according to an embodiment of the present invention; Figure 7This is a schematic diagram of the hardware structure of the controller of the foil-making machine according to an embodiment of the present invention. Detailed Implementation

[0022] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments 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.

[0023] It is understood that before using the technical solutions disclosed in the various embodiments of the present invention, users should be informed of the types, scope of use, and usage scenarios of the personal information involved in the present invention and their authorization should be obtained in accordance with relevant laws and regulations through appropriate means.

[0024] The terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0025] As an optional application scenario of this invention, such as Figure 1 As shown, the foil-forming machine includes a cathode roller 102, a take-up roller 104, and a measuring roller 103. The cathode roller 102 is used for electrolytically forming the foil, and the take-up roller 104 is used for drawing and collecting the copper foil. The measuring roller 103 is installed between the cathode roller 102 and the take-up roller 104 and is used to measure the linear speed and winding tension of the foil. The foil-forming machine is mainly used to electrolytically reduce copper ions into extremely thin metallic copper foil, especially for use in PCB printed circuit board and lithium battery manufacturing.

[0026] The foil-making machine also includes a controller 101, which is used to execute a foil-making machine control method to control the cathode roller 102 and the take-up roller 104. The overall process of the controller 101 executing the foil-making machine control method is detailed in the relevant description of the method embodiments below, and will not be repeated here.

[0027] The working principle of the foil making machine is mainly based on the principle of electrodeposition. The electrolysis system is an electrolytic cell containing copper sulfate electrolyte, and it is equipped with an anode and a rotating cathode roller 102.

[0028] The cathode roller 102 is a large titanium cylinder with an extremely smooth surface. It is connected to the negative terminal of the power supply and rotates at a set speed in the electrolyte. The anode, typically an insoluble anode made of lead-tin alloy, is placed parallel to the cathode roller and connected to the positive terminal of the power supply.

[0029] After being energized, the process raw materials in the electrolyte gain electrons on the surface of the cathode roller 102, are reduced to copper atoms, and are tightly deposited on the surface of the cathode roller 102. The cathode roller 102 continues to rotate, and the deposited copper layer continues to thicken. When the copper layer reaches the set thickness, it is peeled off by a peeling knife. The peeled copper foil undergoes processes such as washing and drying, and is finally wound into a roll. The thickness of the copper foil is mainly determined by the cathode current density, the rotation speed of the cathode roller 102, the electrolyte concentration, and the temperature. For example, the faster the rotation speed, the shorter the deposition time, and the thinner the copper foil after electrolysis.

[0030] Therefore, in the foil production process, the speed and tension matching between the cathode roller 102 (electrolytic foil production) and the winding roller 104 (winding) is crucial to ensuring continuous and stable production of high-quality copper foil. Matching speed and tension ensures that the copper foil is not torn or wrinkled.

[0031] In related technologies, during the foil production and winding processes of foil production machines, there are several issues. Firstly, the detection devices are inadequate. Many systems rely solely on motor encoders for speed feedback, lacking direct, high-response tension detection devices, thus failing to establish a precise tension closed loop. Secondly, the control system architecture is outdated: it employs decentralized, non-cooperative control units, such as independently controlling the cathode roller and winding roller with different drivers, communicating only through analog signals or simple pulse signals for speed, resulting in significant communication delays and poor anti-interference capabilities. Thirdly, there is a lack of dedicated computing modules: complex calculations such as roll diameter calculation and inertia dynamic compensation are typically handled by the main PLC, increasing the load on the main controller and making real-time performance difficult to guarantee. Finally, the actuators lack precision: if ordinary variable frequency motors are used for the winding motor, their torque control accuracy and dynamic response speed cannot meet the requirements of ultra-thin copper foil production.

[0032] Therefore, there is an urgent need for a dedicated control device with high integration, fast response, and comprehensive detection capabilities to solve the above problems.

[0033] Based on the above problems, this embodiment provides a foil production machine control method by focusing on analyzing the changes between the rotational speed of the cathode roller and the winding speed of the anode roller, and how to accurately control the actual speed of the winding roller so that the actual winding speed equals the target winding speed.

[0034] According to an embodiment of the present invention, a control method for a foil-making machine is provided. It should be noted that the steps shown in the flowchart in the accompanying drawings can be executed in a computer system such as a set of computer-executable instructions. Furthermore, although a logical order is shown in the flowchart, in some cases, the steps shown or described may be executed in a different order than that shown here.

[0035] This embodiment provides a control method for a foil-making machine, which can be used in foil-making machines, particularly for producing copper foil. Figure 2 This is a schematic flowchart of a first type of foil-making machine control method according to an embodiment of the present invention, as shown below. Figure 2 As shown, the process includes the following steps: Step S201: Monitor the actual winding speed and actual winding tension of the winding roller during the copper foil winding process, as well as the measuring linear speed of the measuring roller.

[0036] The actual winding speed during the copper foil winding process refers to the instantaneous linear velocity of the current roll diameter surface of the winding roller. The actual winding speed can be measured by the winding shaft encoder, providing key data for calculating the actual winding roll diameter.

[0037] The actual winding tension during the copper foil winding process refers to the pulling force exerted on the copper foil during winding. This actual winding tension is determined by a tension detection device.

[0038] Specifically, the tension detection device uses a roller or pin-type tension sensor, which is installed on the guide roller seat or floating roller structure before winding to detect the actual tension of the copper foil in real time and directly.

[0039] It should be noted that the measuring roller is an inert measuring roller installed on the copper foil conveying path between the cathode roller and the take-up roller. It does not provide power itself and is used to measure the linear speed of the take-up roller and the actual take-up tension.

[0040] Step S202: Calculate the actual winding diameter based on the actual winding speed and the measured linear speed.

[0041] It should be noted that the actual winding diameter refers to the diameter of the outermost layer of the copper foil roll on the winding tube at the current moment. When the winding roller performs the winding operation, as the copper foil is continuously wound up by the winding roller, the outer diameter of the copper foil surrounding the cylindrical shaft of the winding roller is the winding diameter.

[0042] The initial winding diameter is generally the outer diameter of the winding roller core. As time and winding speed increase, the actual winding diameter of each layer of copper foil will also increase.

[0043] It should be noted that the purpose of measuring the linear speed and the actual winding speed is to monitor these two speeds in real time. When a deviation occurs, the control system drives the winding roller motor to adjust the speed of the winding roller, so as to synchronize the actual winding speed with the measured linear speed.

[0044] Step S203: Calculate the initial winding length based on the actual winding tension and the actual winding diameter.

[0045] It should be noted that the initial winding torque provides a reference for the torque of tension control. It is calculated in real time based on the real-time changes in winding tension and winding diameter. That is, the winding diameter will also change with time and speed, in order to match the speed with the tension.

[0046] Step S204: Determine the tension compensation torque based on the relationship between the actual winding tension and the preset winding tension.

[0047] It should be noted that the tension compensation torque, as a fine adjustment quantity in closed-loop control, is based on deviation feedback compensation. The tension compensation torque eliminates the deviation between the actual tension and the target tension, thus ensuring the tension control accuracy.

[0048] Specifically, the tension compensation torque is a calculated amount of torque that needs to be added or reduced.

[0049] Step S205: Determine the target winding torque based on the sum of the initial winding torque and the tension compensation torque, and control the winding roller to perform the winding operation with the target winding torque.

[0050] It should be noted that the target winding torque is determined through the coordination of feedforward and feedback. When the total torque needs to be increased, the feedforward will automatically increase due to the increase in winding diameter. At the same time, if the actual tension is lower than the set value, the feedback controller will calculate and add positive compensation torque. When the winding diameter decreases or the actual tension is higher than the set value, the two will decrease together, so that the final torque is precisely matched to maintain the constant tension required.

[0051] The foil-making machine control method provided in this embodiment measures the linear speed and the actual winding speed. When a deviation occurs, the control system drives the winding roller motor to adjust the speed of the winding roller, thereby synchronizing the actual winding speed with the measured linear speed. The actual winding tension is compared with the target tension set by the system. If the actual tension deviates from the set value, the control system adjusts the winding torque of the winding motor, thereby controlling the winding roller to perform the winding operation with the target winding torque to maintain constant tension, thus making the winding roller speed and tension accurately matched.

[0052] This embodiment provides a control method for a foil-making machine, which can be used in foil-making machines, particularly for producing copper foil. Figure 3 This is a schematic diagram of a second process for controlling a foil-making machine according to an embodiment of the present invention, as shown below. Figure 3 As shown, the process includes the following steps: Step S301 involves monitoring the actual winding speed and tension of the winding roller during the copper foil winding process, as well as the measuring linear speed of the measuring roller. For details, please refer to [link to relevant documentation]. Figure 2 Step S201 of the illustrated embodiment will not be described again here.

[0053] Step S302: Calculate the actual winding diameter based on the actual winding speed and the measured linear speed.

[0054] Specifically, step S302 includes: The actual winding diameter is calculated using the following formula: D = V' / (π×ω); Where D represents the actual winding diameter, V' represents the measured linear velocity, ω represents the actual winding speed, and π represents the compensation coefficient.

[0055] Specifically, the actual winding speed is calculated using the following formula: ω=V' / (π×D); Where D represents the actual winding diameter, V' represents the measured linear velocity, ω represents the actual winding speed, and π represents the compensation coefficient.

[0056] This embodiment calculates the actual winding diameter using this formula, enabling the system to obtain a high-precision dynamic winding diameter value online and continuously without relying on mechanical measuring devices. This actual winding diameter provides an accurate feedback benchmark for winding speed synchronization and tension control, allowing the system to compensate for the linear speed and torque adjustment requirements caused by changes in the winding diameter in real time. This maintains a constant winding linear speed and stable winding tension during the winding process, effectively improving the flatness and compactness of the copper foil roll and increasing production efficiency.

[0057] Step S303: Calculate the initial winding length based on the actual winding tension and the actual winding diameter.

[0058] Specifically, step S303 includes: The initial winding length is calculated using the following formula: T1 = F / D; Where T1 represents the initial winding torque, F represents the actual winding tension, and D represents the actual winding diameter.

[0059] The initial winding torque provides a reference for the torque used in tension control. It is calculated in real time based on the real-time changes in winding tension and winding diameter. In other words, the winding diameter changes with time and speed to match the speed with the tension.

[0060] This embodiment synchronously maps the real-time changes in tension and roll diameter to a feedforward reference for torque commands, providing the take-up roller with an instantaneous torque reference that matches the current take-up operation. This effectively offsets the impact of continuous changes in roll diameter on tension, enabling better maintenance of tension stability during the take-up of copper foil. It significantly reduces the adjustment burden on the subsequent closed-loop feedback controller, improves the overall system response speed and control stability, enhances the accuracy of the take-up roller in taking up copper foil, and achieves the matching of tension and speed during take-up of copper foil.

[0061] Step S304: Determine the tension compensation torque based on the relationship between the actual winding tension and the preset winding tension.

[0062] Specifically, step S304 includes: Step S3041: Calculate the tension difference between the actual winding tension and the preset winding tension.

[0063] The preset winding tension is the winding tension set according to the user's actual needs for winding copper foil.

[0064] It should be noted that the actual winding tension detected by the tension detection sensor is fed back to the core controller. The core controller compares the actual winding tension with the preset winding tension to calculate the tension difference.

[0065] Step S3042: Based on the tension difference, a PID control algorithm is used to determine the tension compensation torque.

[0066] Specifically, PID control algorithm refers to proportional, integral, and derivative control algorithm, which calculates proportional, integral, and derivative terms based on the tension difference. For example, the proportional term is proportional to the current tension difference, the integral term is used to accumulate historical tension differences, and the derivative term is used to make advance adjustments based on the trend of tension difference changes. The three outputs are superimposed to obtain the tension compensation torque.

[0067] This embodiment achieves closed-loop precise adjustment of tension fluctuations by real-time detection of the deviation between the winding tension and the preset tension, and by using a PID control algorithm to dynamically generate compensation torque. This compensation mechanism can quickly respond to tension changes caused by material property fluctuations, minor mechanical transmission errors, or external interference. Through the PID control algorithm, feedforward compensation and adjustment are achieved, continuously and accurately stabilizing the actual tension at the process set value, improving the control accuracy and dynamic stability of the winding tension, and avoiding quality defects such as copper foil wrinkling and stretching deformation caused by tension fluctuations.

[0068] Step S305: Determine the target winding torque based on the sum of the initial winding torque and the tension compensation torque, and control the winding roll to perform the winding operation at the target winding torque. For details, please refer to [link to details]. Figure 2Step S205 of the illustrated embodiment will not be described again here.

[0069] Step S306: Obtain the set rotation speed of the cathode roller.

[0070] It should be noted that the set rotation speed of the cathode roller is calculated based on the user's requirements for production process specifications, copper foil thickness, and other factors. This set speed determines the copper foil thickness and production efficiency. For example, with a constant current density, the thinner the required copper foil thickness, the higher the cathode roller rotation speed, resulting in a shorter time for the cathode roller surface to pass through the electrolytic cell and a thinner deposited copper layer. Alternatively, with a constant copper foil thickness, a higher current density requires a higher cathode roller rotation speed. This is because more copper ions are deposited per unit time, necessitating a faster winding speed to collect the copper foil and maintain a constant thickness. The current density itself is determined by the power supply, the target foil production capacity, and the electrolyte process conditions.

[0071] Step S307: Monitor the actual rotation speed of the cathode roller during the electrolytic foil production process.

[0072] Specifically, the cathode roller drive system includes a cathode roller servo motor or a permanent magnet synchronous motor, and a matching servo driver. The cathode roller drive system feeds back the monitored actual rotation speed to the core controller.

[0073] Step S308: Determine the actual rotational speed based on the actual rotational speed and the measuring linear speed of the measuring roller.

[0074] The actual measured rotational speed is determined by back-calculating the required rotational speed value of the cathode roller drive shaft from the actual linear velocity detected by the measuring roller during the foil-making process.

[0075] For example, the system uses the measured linear velocity (e.g., 15.2 m / min) measured by the measuring roller encoder as a benchmark, and combines it with the known effective diameter of the cathode roller (e.g., 0.5 m), to calculate the theoretically accurate rotational speed that the cathode roller should reach under the current operating conditions (e.g., approximately 9.68 rpm) using the formula: actual measured rotational speed = measured linear velocity / (π × cathode roller diameter). This calculated value is the calibrated actual measured rotational speed, which serves as the feedback benchmark for the speed closed loop and is used to compare with the set rotational speed to generate adjustment commands.

[0076] It should be noted that this step essentially uses the actual process line speed provided by the measuring roller as a reference to perform feedback calibration on the actual rotational speed of the cathode roller drive system.

[0077] Step S309: Determine the compensation speed based on the difference between the actual measured speed and the set speed.

[0078] Specifically, the system calculates the speed deviation by comparing the actual rotational speed fed back by the cathode roller encoder with the measured linear speed detected by the measuring roller encoder. It then calibrates the actual measured rotational speed in real time based on this speed deviation to determine the compensation speed. For example, if the measured linear speed is displayed as 15 meters per minute, while the theoretical linear speed corresponding to the current rotational speed of the cathode roller is 14.5 meters per minute, the system will determine that there is a negative deviation of approximately 0.5 meters per minute. By adjusting the speed feedback parameters or outputting a calibration signal, the system will increase the actual measured rotational speed to a value matching 15 meters per minute, thereby ensuring that the foil thickness is consistent with the process-set rotational speed.

[0079] Step S310: Adjust the speed of the cathode roller based on the compensated rotation speed so that the actual measured rotation speed is equal to the set rotation speed.

[0080] It should be noted that the compensation speed is not exactly equal to the final measured speed, but rather participates in the adjustment as a correction value. For example, when the measured linear speed is 15 meters per minute, and the theoretical linear speed corresponding to the actual rotational speed is 14.5 meters per minute, the speed deviation is 0.5 meters per minute. In this case, the compensation speed is a positive adjustment value. The system increases the cathode roller speed according to the speed deviation of 0.5 meters per minute to match the measured linear speed of 15 meters per minute, so that the cathode tube speed matches the take-up roller speed. Conversely, if the actual rotational speed corresponds to the theoretical linear speed of 15.5 meters per minute, the speed deviation is -0.5 meters per minute. The compensation speed is a negative adjustment value. The system decreases the cathode roller speed according to the speed deviation of -0.5 meters per minute to match the measured linear speed of 15 meters per minute, so that the cathode tube speed matches the take-up roller speed. Regardless of the direction of the deviation, the system follows the control logic that "the larger the absolute value of the deviation, the stronger the adjustment force". By dynamically increasing or decreasing the compensation value, the actual measured speed gradually converges to the target value that is consistent with the measured linear speed, thereby matching the cathode tube speed with the winding roller speed.

[0081] This embodiment calculates the speed deviation between the actual rotational speed fed back by the cathode roller encoder and the measured linear speed detected by the measuring roller encoder. Then, the actual measured speed is calibrated in real time based on the speed deviation to determine the compensation speed. The compensation speed is not exactly equal to the final measured speed, but is used as a correction value for adjustment. By dynamically increasing or decreasing the compensation value, the actual measured speed is gradually converged to the target value that is consistent with the measured linear speed, so that the cathode tube speed matches the winding roller speed.

[0082] Step S311: Calculate the target winding speed based on the set rotation speed of the cathode roller and the actual winding diameter.

[0083] Specifically, the actual winding speed ω is calculated using the formula: ω=V' / (π×D), and the winding speed feedforward command ω' is further calculated. The winding speed feedforward command ω' and the actual winding speed ω of the winding shaft encoder are compared by the core controller to achieve control of the winding roller speed.

[0084] Step S312: Based on the relationship between the target winding speed and the actual winding speed, the winding roller is speed controlled so that the actual winding speed is equal to the target winding speed.

[0085] It should be noted that when controlling the speed of the take-up roll, the target take-up speed is not directly equal to the actual take-up speed, but is used as a reference value for the control system adjustment.

[0086] Specifically, when the actual winding speed is greater than the target winding speed, the drive frequency or winding torque of the winding motor is reduced proportionally to gradually converge the actual speed to the target winding speed. Conversely, when the actual winding speed is less than the target winding speed, the drive frequency or winding torque of the winding motor is increased proportionally. Ultimately, through this bidirectional dynamic adjustment, the actual winding speed is stably matched with the target value, thereby ensuring precise synchronization between the winding linear speed and the foil production speed.

[0087] For example, if the target winding speed is 15 meters per minute, but the actual winding speed is 15.5 meters per minute, the winding motor speed setting is reduced proportionally according to the control algorithm by a positive deviation of 0.5 meters per minute, gradually decreasing the actual speed to 15 meters per minute. When the target winding speed is 15 meters per minute, but the actual winding speed is 14.5 meters per minute, the winding motor speed setting is increased proportionally according to the control algorithm by a negative deviation of 0.5 meters per minute, until the actual winding speed reaches the target winding speed.

[0088] This embodiment uses bidirectional closed-loop control of the take-up roller based on the deviation between the target speed and the actual speed to ensure that the actual take-up line speed always precisely matches the target speed determined by the foil production process. This maintains constant take-up tension and stable take-up synchronization during continuous production, effectively avoiding defects such as copper foil stretching, loosening, wrinkling, or uneven stacking caused by speed asynchrony, and significantly improving the consistency of the roll material quality and the stability of the production process.

[0089] As one or more specific application embodiments of the present invention, such as Figures 4 to 5 As shown, the foil-making machine includes the following components: Core Controller: Enhances computation and control of the cathode roll and take-up roll, employing a high-performance programmable logic controller (PLC) or industrial PC (IPC). It is responsible for executing core control algorithms, including speed reference generation, roll diameter calculation, PID regulation, dynamic compensation logic, etc., and issuing control commands to the entire system.

[0090] The main speed reference detection and drive unit includes a cathode roller drive system and a main speed encoder.

[0091] Specifically, the cathode roller drive system includes a cathode roller servo motor or permanent magnet synchronous motor, and a matching servo driver. This driver connects to the core controller via a communication network, receives speed commands, and provides real-time feedback on the actual rotational speed and torque information of the cathode roller.

[0092] Main speed encoder: An absolute encoder installed on the end of the main shaft of the cathode roller. It is used to accurately measure the actual rotation angle and speed of the cathode roller, providing the system with the most direct and accurate main line speed feedback signal.

[0093] It should be noted that the main speed is the set speed of the cathode roller.

[0094] The winding execution and feedback unit includes a winding drive system and a winding shaft encoder.

[0095] Specifically, the winding drive system includes a servo motor, servo driver, or vector-controlled variable frequency motor and vector inverter. This winding drive system operates in torque mode and receives comprehensive torque commands from the core controller.

[0096] Take-up shaft encoder: An incremental encoder mounted on the take-up motor or take-up shaft to measure the real-time rotational speed of the take-up roller, providing key data for real-time roll diameter calculation.

[0097] The tension detection unit includes a tension sensor: a roller-type or pin-type tension sensor, directly mounted on the guide roller bearing seat or floating roller structure before winding. It is used to detect the actual tension of the copper foil in real time and feeds back standard analog (e.g., 4-20mA) or digital signals to the core controller, forming the basis of the tension closed loop.

[0098] The roll diameter calculation and linear speed detection unit includes a measuring roll encoder and a roll diameter calculation module.

[0099] Specifically, the measuring roller encoder is mounted on a driven measuring roller that does not slip with the foil. The linear velocity measured by this encoder is considered the true material linear velocity of the system and is used for real-time roll diameter calculation and calibration with the system's set speed V.

[0100] Roll diameter calculation module: This module can be a standalone hardware processor (such as a dedicated motion control card) or a functional block within the core controller. It receives the rotational speed signal ω from the take-up shaft encoder and the linear speed signal V' from the measuring roller encoder, and calculates and outputs the current take-up diameter in real time according to the formula D=V' / (π×ω).

[0101] The human-computer interaction and parameter storage unit includes a touch screen human-computer interface and a storage module.

[0102] Touchscreen human-machine interface: used to display real-time parameters (such as speed, tension, roll diameter, current, etc.), set target values ​​(such as foil production speed, target tension), set process parameter libraries for different products (such as PID parameter groups, compensation coefficients), and perform fault alarms and historical data queries.

[0103] Storage module: Integrated inside the controller or HMI, used to store multiple process recipe parameters to achieve "one-click specification change".

[0104] The foil production machine improved in this implementation has a high degree of system integration and fast response speed: it adopts high-speed real-time Ethernet to tightly connect all components, resulting in a short data exchange cycle and a significant reduction in system response delay, making it particularly suitable for high-speed production of ultra-thin copper foil.

[0105] High control precision: Direct tension closed-loop control is achieved through a tension sensor, avoiding errors caused by indirect measurement; accurate roll diameter calculation is performed through a measuring roller encoder, ensuring the accuracy of speed feedforward.

[0106] Excellent dynamic performance: Dedicated roll diameter calculation and dynamic compensation logic, combined with a high-performance servo drive system, can quickly offset disturbances caused by changes in acceleration / deceleration speed and roll diameter, effectively preventing foil breakage.

[0107] Automation and intelligence: The built-in process parameter library eliminates the need for repeated manual adjustments when switching product specifications, improving the intelligence level and production efficiency of the equipment.

[0108] High reliability: The modular design and selection of high-quality industrial components ensure long-term stable operation of the equipment in complex industrial environments.

[0109] This embodiment also provides a foil-making machine control device for implementing the above embodiments and preferred embodiments; details already described will not be repeated. As used below, the term "module" can refer to a combination of software and / or hardware that performs a predetermined function. Although the device described in the following embodiments is preferably implemented in software, hardware implementation, or a combination of software and hardware, is also possible and contemplated.

[0110] This embodiment provides a foil-making machine control device, such as... Figure 6 As shown, it includes: The monitoring module 601 is used to monitor the actual winding speed and actual winding tension of the winding roller during the copper foil winding process, as well as the measuring linear speed of the measuring roller. The first calculation module 602 is used to calculate the actual winding diameter based on the actual winding speed and the measured linear speed. The second calculation module 603 is used to calculate the initial winding length based on the actual winding tension and the actual winding diameter; The third calculation module 604 is used to determine the tension compensation torque based on the relationship between the actual winding tension and the preset winding tension. The control module 605 is used to determine the target winding torque based on the sum of the initial winding torque and the tension compensation torque, and to control the winding roller to perform the winding operation with the target winding torque.

[0111] In some alternative implementations, the first computing module 602 includes: The actual winding diameter is calculated using the following formula: D = V' / (π×ω); Where D represents the actual winding diameter, V' represents the measured linear velocity, ω represents the actual winding speed, and π represents the compensation coefficient.

[0112] In some alternative implementations, the second computing module 603 includes: The initial winding length is calculated using the following formula: T1 = F / D; Where T1 represents the initial winding torque, F represents the actual winding tension, and D represents the actual winding diameter.

[0113] In some alternative implementations, the third computing module 604 includes: The first calculation subunit is used to calculate the tension difference between the actual winding tension and the preset winding tension; The second calculation subunit is used to determine the tension compensation torque based on the tension difference using a PID control algorithm.

[0114] This embodiment provides a foil-making machine control device, which also includes: The acquisition module is used to acquire the set rotational speed of the cathode roller; The monitoring module is used to monitor the actual rotation speed of the cathode roller during the electrolytic foil production process. The first determining module is used to determine the actual measured rotational speed based on the actual rotational speed and the measuring linear speed of the measuring roller; The second determining module is used to determine the compensation speed based on the difference between the actual measured speed and the set speed; The adjustment module is used to adjust the speed of the cathode roller based on the compensation speed so that the actual measured speed is equal to the set speed.

[0115] The fourth calculation module is used to calculate the target winding speed based on the set rotation speed of the cathode roller and the actual winding diameter.

[0116] The speed control module is used to control the speed of the winding roller based on the relationship between the target winding speed and the actual winding speed, so that the actual winding speed is equal to the target winding speed.

[0117] The foil-making machine control device provided in this embodiment of the invention can execute the foil-making machine control method provided in any embodiment of the invention, and has the corresponding functional modules and beneficial effects for executing the method. Further functional descriptions of the various modules and units described above are the same as in the corresponding embodiments described above, and will not be repeated here.

[0118] Figure 7 This is a schematic diagram of the hardware structure of a controller for a foil-making machine provided in an embodiment of the present invention.

[0119] The following is a detailed reference. Figure 7 This diagram illustrates a hardware structure suitable for implementing a foil-making machine according to embodiments of the present invention. The controller may include a processor (e.g., a central processing unit, graphics processor, etc.) 701, which can perform various appropriate actions and processes based on a program stored in a read-only memory (ROM) 702 or a program loaded from memory 708 into random access memory (RAM) 703. RAM 703 also stores various programs and data required for the operation of the electronic device. The processor 701, ROM 702, and RAM 703 are interconnected via a bus 704. An input / output (I / O) interface 705 is also connected to the bus 704.

[0120] Typically, the following devices can be connected to I / O interface 705: input devices 706 including, for example, touchscreens, touchpads, keyboards, mice, cameras, microphones, accelerometers, gyroscopes, etc.; output devices 707 including, for example, liquid crystal displays (LCDs), speakers, vibrators, etc.; memory devices 708 including, for example, magnetic tapes, hard disks, etc.; and communication devices 709. Communication device 709 allows the controller to communicate wirelessly or wiredly with other devices to exchange data. Although Figure 7 A controller with various devices is shown, but it should be understood that it is not required to implement or have all of the devices shown, and may alternatively implement or have more or fewer devices.

[0121] In particular, according to embodiments of the present invention, the processes described above with reference to the flowcharts can be implemented as computer software programs. For example, embodiments of the present invention include a computer program product comprising a computer program carried on a non-transitory computer-readable medium, the computer program containing program code for performing the methods shown in the flowcharts. In such embodiments, the computer program can be downloaded and installed from a network via a communication device 709, or installed from a memory 708, or installed from a ROM 702. When the computer program is executed by the processor 701, it performs the functions defined in the foil-making machine control method of the embodiments of the present invention.

[0122] Figure 7 The controller shown is merely an example and should not be construed as limiting the functionality and scope of use of the embodiments of the present invention.

[0123] This invention also provides a computer-readable storage medium. The methods described above according to embodiments of the invention can be implemented in hardware or firmware, or implemented as computer code that can be recorded on a storage medium, or implemented as computer code downloaded via a network and originally stored on a remote storage medium or a non-transitory machine-readable storage medium and then stored on a local storage medium. Thus, the methods described herein can be processed by software stored on a storage medium using a general-purpose computer, a dedicated processor, or programmable or dedicated hardware. The storage medium can be a magnetic disk, optical disk, read-only memory, random access memory, flash memory, hard disk, or solid-state drive, etc.; further, the storage medium can also include combinations of the above types of memory. It is understood that computers, processors, microprocessor controllers, or programmable hardware include storage components capable of storing or receiving software or computer code. When the software or computer code is accessed and executed by the computer, processor, or hardware, the foil-making machine control method shown in the above embodiments is implemented.

[0124] A portion of this invention can be applied as a computer program product, such as computer program instructions, which, when executed by a computer, can invoke or provide the methods and / or technical solutions according to the invention through the operation of the computer. Those skilled in the art will understand that the forms in which computer program instructions exist in a computer-readable medium include, but are not limited to, source files, executable files, installation package files, etc. Correspondingly, the ways in which computer program instructions are executed by a computer include, but are not limited to: the computer directly executing the instructions, or the computer compiling the instructions and then executing the corresponding compiled program, or the computer reading and executing the instructions, or the computer reading and installing the instructions and then executing the corresponding installed program. Here, the computer-readable medium can be any available computer-readable storage medium or communication medium accessible to a computer.

[0125] Although embodiments of the invention have been described in conjunction with the accompanying drawings, those skilled in the art can make various modifications and variations without departing from the spirit and scope of the invention, and such modifications and variations all fall within the scope defined by the appended claims.

Claims

1. A control method for a foil-making machine, characterized in that, The foil-making machine includes a cathode roller, a take-up roller, and a measuring roller. The cathode roller is used for electrolytic foil production, and the take-up roller is used for traction and take-up of copper foil. The measuring roller is installed between the cathode roller and the take-up roller and is used to measure the foil production linear speed and take-up tension. The method includes: The actual winding speed and actual winding tension of the winding roller during the copper foil winding process, as well as the measuring linear speed of the measuring roller, are monitored. Calculate the actual winding diameter based on the actual winding speed and the measured linear speed; Calculate the initial winding length based on the actual winding tension and the actual winding diameter; Based on the relationship between the actual winding tension and the preset winding tension, the tension compensation torque is determined; The target winding torque is determined based on the sum of the initial winding torque and the tension compensation torque, and the winding roller is controlled to perform the winding operation with the target winding torque.

2. The method according to claim 1, characterized in that, The actual winding diameter is calculated using the following formula: D = V' / (π×ω); Where D represents the actual winding diameter, V' represents the measured linear velocity, ω represents the actual winding speed, and π represents the compensation coefficient.

3. The method according to claim 1, characterized in that, The initial winding length is calculated using the following formula: T1 = F / D; Where T1 represents the initial winding torque, F represents the actual winding tension, and D represents the actual winding diameter.

4. The method according to claim 3, characterized in that, The step of determining the tension compensation torque based on the relationship between the actual winding tension and the preset winding tension includes: Calculate the tension difference between the actual winding tension and the preset winding tension; Based on the tension difference, a PID control algorithm is used to determine the tension compensation torque.

5. The method according to claim 1, characterized in that, The method further includes: Obtain the set rotational speed of the cathode roller; Monitor the actual rotation speed of the cathode roller during the electrolytic foil production process; The actual rotational speed is determined based on the actual rotational speed and the measuring linear speed of the measuring roller; The compensation speed is determined based on the difference between the actual measured speed and the set speed; The speed of the cathode roller is adjusted based on the compensated rotational speed so that the actual measured rotational speed is equal to the set rotational speed.

6. The method according to claim 5, characterized in that, The method further includes: The target winding speed is calculated based on the set rotation speed of the cathode roller and the actual winding diameter. Based on the relationship between the target winding speed and the actual winding speed, the winding roller is speed controlled so that the actual winding speed is equal to the target winding speed.

7. A control device for a foil-making machine, characterized in that, The foil-making machine includes a cathode roller, a take-up roller, and a measuring roller. The cathode roller is used for electrolytic foil production, and the take-up roller is used for traction and take-up of copper foil. The measuring roller is installed between the cathode roller and the take-up roller and is used to measure the foil production linear speed and take-up tension. The device includes: The monitoring module is used to monitor the actual winding speed and actual winding tension of the winding roller during the copper foil winding process, as well as the measuring linear speed of the measuring roller; The first calculation module is used to calculate the actual winding diameter based on the actual winding speed and the measured linear speed. The second calculation module is used to calculate the initial winding roll length based on the actual winding tension and the actual winding roll diameter; The third calculation module is used to determine the tension compensation torque based on the relationship between the actual winding tension and the preset winding tension; The control module is used to determine the target winding torque based on the sum of the initial winding torque and the tension compensation torque, and to control the winding roller to perform the winding operation with the target winding torque.

8. A foil-making machine, characterized in that, The foil-forming machine includes a cathode roller, a take-up roller, and a measuring roller. The cathode roller is used for electrolytic foil formation, and the take-up roller is used for drawing and collecting copper foil. The measuring roller is installed between the cathode roller and the take-up roller and is used to measure the foil-forming linear speed and winding tension. The foil-forming machine also includes a controller, which includes: A memory and a processor are communicatively connected, the memory stores computer instructions, and the processor executes the foil-making machine control method according to any one of claims 1 to 6 by executing the computer instructions.

9. A computer-readable storage medium, characterized in that, The computer-readable storage medium stores computer instructions for causing the computer to perform the foil-making machine control method according to any one of claims 1 to 6.

10. A computer program product, characterized in that, Includes computer instructions for causing a computer to perform the foil-making machine control method according to any one of claims 1 to 6.

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