Unwinding mechanism with adjustable roller angle

Abstract

This invention relates to an unwinding mechanism with adjustable inter-roller angle, belonging to the field of material processing equipment technology. The method includes an upper guide roller for supporting and guiding a flexible film; a lower guide roller for supporting and guiding the flexible film; an inter-roller angle adjustment mechanism including an angle-adjustable bracket and a secondary swing arm, wherein the upper guide roller is fixed to the end of the secondary swing arm, the lower guide roller is fixed to a base bracket, and the secondary swing arm is connected to the angle-adjustable bracket via a rotary hinge; and an actuator for driving the secondary swing arm to rotate or move up and down, thereby changing the tilt angle of the upper guide roller relative to the lower guide roller to adjust the angle between the upper and lower guide rollers, controlling the material tension distribution and the belt feed direction. This invention can achieve precise control of the flexible film tension distribution, effectively eliminate wrinkles, and adjust the belt feed direction, thereby improving material processing quality and production efficiency.

Description

Technical Field

[0001] This invention relates to the field of material handling equipment technology, and in particular to an unwinding mechanism with adjustable inter-roller angle. Background Technology

[0002] In the production and processing of flexible materials such as films and textiles, the unwinding mechanism is used to control the unfolding, transport, and tension adjustment of the material. Traditional unwinding mechanisms typically employ a fixed guide roller configuration, with the upper and lower guide rollers maintaining a fixed geometric relationship and angle. These devices provide basic unwinding functionality when processing standard-sized materials and maintain the flatness of the material to a certain extent. In existing unwinding systems, the arrangement and angle of the guide rollers are usually determined during the equipment design phase, and operators can influence the material processing effect by adjusting the overall tension.

[0003] However, fixed-structure unwinding mechanisms exhibit significant limitations when facing different material properties and diverse process requirements. Because the angle between the guide rollers cannot be dynamically adjusted, the equipment struggles to adapt to flexible materials of varying thicknesses, widths, and textures. This is particularly true when processing film materials, where uneven lateral stress during longitudinal traction can lead to surface wrinkling and uneven tension distribution. When wrinkles or belt deviations occur, operators can only improve the flattening effect by increasing the overall unwinding tension, but this method may cause material deformation, affecting product quality. Furthermore, the fixed-angle guide roller configuration limits the equipment's adaptability to different process conditions, preventing real-time adjustments to the material transport path and tension distribution pattern according to actual production needs, thus impacting production efficiency and product consistency. Summary of the Invention

[0004] In view of the shortcomings of the prior art described above, the purpose of this invention is to provide an unwinding mechanism with roller angle adjustment, which can achieve precise control of the tension distribution of flexible film, effectively eliminate wrinkles and adjust the belt feeding direction, thereby improving material processing quality and production efficiency.

[0005] To achieve the above objectives, the present invention adopts the following technical solution.

[0006] In a first aspect, the present invention provides an unwinding mechanism with roller angle adjustment, which adopts the following technical solution: Upper guide rollers are used to support and guide the flexible film; The lower guide roller is used to support and guide the flexible film; A roller angle adjustment mechanism includes an angle-adjustable bracket and a secondary swing arm. The upper guide roller is fixed to the end of the secondary swing arm, and the lower guide roller is fixed to the base bracket. The secondary swing arm is connected to the angle-adjustable bracket via a rotary hinge. An actuator is used to drive the auxiliary swing arm to rotate or lift, thereby changing the tilt angle of the upper guide roller relative to the lower guide roller, so as to adjust the included angle between the upper guide roller and the lower guide roller, and control the material tension distribution and belt feeding direction.

[0007] Furthermore, the unwinding mechanism also includes a tension detection mechanism for real-time detection of the tension of the flexible film.

[0008] Furthermore, in the above-mentioned unwinding mechanism, the tension detection mechanism includes a front visual tension detection camera and a rear visual tension detection camera.

[0009] Furthermore, the unwinding mechanism also includes a control system, which adjusts the action of the actuator in a closed-loop manner based on the detection signal from the tension detection mechanism.

[0010] Furthermore, in the above-mentioned unwinding mechanism, the control system automatically sets the optimal included angle based on the film width, thickness and tension detection signal, and has an adaptive parameter tuning mechanism. The adaptive parameter tuning mechanism dynamically adjusts the included angle adjustment parameters based on the mechanical properties of different materials, including determining the included angle correction amount by using the comprehensive calculation results of real-time tension change, width direction tension distribution and material bending modulus, so as to realize adaptive control of the included angle between the rollers under various working conditions.

[0011] Furthermore, in the above-mentioned unwinding mechanism, the control system also includes an abnormal working condition handling mechanism. The abnormal working condition handling mechanism performs corresponding processing actions when it detects film wrinkles, abnormal tension, or abnormal equipment operation. Specifically, when the wrinkle detection signal indicates that the wrinkle amplitude exceeds a preset threshold, the control system drives the actuator to increase the tilt angle of the upper guide roller relative to the lower guide roller to enhance the flattening tension. When the detected tension value exceeds the safe range, the control system automatically reduces the included angle or adjusts the included angle to a safe angle range to reduce the stress on the material. When the response time or motion deviation of the actuator or angle adjustment mechanism exceeds the limit, the control system issues a fault warning and restricts the angle adjustment action until the fault is resolved.

[0012] Furthermore, in the aforementioned unwinding mechanism, the control system also includes a coordinated control mechanism for angle, tension, and offset. This coordinated control mechanism establishes a correspondence between the film tension distribution, the belt offset, and the inter-roller angle, and executes specific adjustment actions based on the monitored operating status, wherein: When uneven tension is detected in the width direction of the film, the control system calculates the required angle correction and drives the actuator to adjust the tilt angle of the upper guide roller. When the film conveyor belt offset is detected to exceed the allowable deviation, the control system increases or decreases the included angle according to the offset direction to correct the film's running path; When the film is under stable tension and without deviation, the control system maintains the current angle and prohibits unnecessary angle adjustments to maintain the stability of film operation.

[0013] Furthermore, in the above-mentioned unwinding mechanism, the actuator includes a servo motor or a cylinder.

[0014] Furthermore, in the above-mentioned unwinding mechanism, the roller angle adjustment mechanism also includes a bearing and a base, and the angle-adjustable bracket is connected to the bearing via a connector.

[0015] Furthermore, in the above-mentioned unwinding mechanism, when the upper guide roller tilts outward, the flexible film presents an arc-shaped path between the upper guide roller and the lower guide roller, generating a lateral expansion tension on both sides of the film to achieve a flattening effect.

[0016] In summary, compared with the prior art, the present invention has at least one of the following beneficial technical effects: The unwinding mechanism described in this invention dynamically adjusts the angle between the upper and lower guide rollers through a roller angle adjustment mechanism. During the flexible film transport process, the geometric relationship between the guide rollers can be changed in real time according to material characteristics and process requirements, thereby precisely controlling the tension distribution of the film in the width direction, effectively eliminating surface wrinkles and adjusting the belt feeding direction. This avoids the problem of insufficient adaptability of traditional fixed-angle guide roller configuration when handling materials of different specifications, improves the consistency of material processing and product quality, enhances the equipment's adaptability to diverse process conditions, and improves production efficiency and operational flexibility. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 A schematic diagram of an unwinding mechanism with an adjustable roller angle is shown.

[0019] Figure 2 A partial structural diagram of the roller angle adjustment mechanism is shown.

[0020] Figure 3 A flowchart is shown for an adaptive parameter adjustment method for controlling the inter-roll angle in an unwinding mechanism. Detailed Implementation

[0021] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application. Furthermore, it should be understood that the specific embodiments described herein are only for illustration and explanation of this application and are not intended to limit this application.

[0022] It should be noted that the order of description of the following embodiments is not intended to limit the preferred order of the embodiments of this application. Furthermore, the descriptions of each embodiment in the following embodiments have their own emphasis; for parts not described in detail in a certain embodiment, please refer to the relevant descriptions in other embodiments.

[0023] The method steps described in this embodiment of the invention can be executed in the order described in the specific implementation, or the execution order of each step can be adjusted according to actual needs, provided that the technical problem can be solved. These are not listed one by one here.

[0024] The following is in conjunction with the appendix Figure 1 The present invention will be described in further detail below.

[0025] Reference Figure 1 An unwinding mechanism with adjustable inter-roll angle includes an upper guide roller 22, a lower guide roller 21, an inter-roll angle adjustment mechanism 3, and a film 4. The upper guide roller 22 and lower guide roller 21 support and guide the flexible film 4. In some embodiments, the film 4 passes between the upper guide roller 22 and the lower guide roller 21, forming a material transport path. The inter-roll angle adjustment mechanism 3 is located at the base of the structure, connected to the guide roller, and adjusts the angle between the upper guide roller 22 and the lower guide roller 21.

[0026] Reference Figure 2 The roller angle adjustment mechanism 3 includes an angle-adjustable bracket 31, a secondary swing arm 33, a connector 311, a bearing 32, a base 34, and an actuator 331. The angle-adjustable bracket 31 is connected to the bearing 32 via the connector 311, providing a rotational connection point for the adjustment mechanism. The secondary swing arm 33 is located below the angle-adjustable bracket 31 and is used to support and position the upper guide roller 22. In some embodiments, the upper guide roller 22 is fixed to the end of the secondary swing arm 33, and the lower guide roller 21 is fixed to the base support.

[0027] The auxiliary swing arm 33 is connected to the angle-adjustable bracket 31 via a rotary hinge. An actuator 331 is located on the auxiliary swing arm 33 and provides driving force for adjusting the angular position of the auxiliary swing arm 33. A base 34 serves as the foundation structure for mounting the roller angle adjustment mechanism 3. In some embodiments, the actuator 331 drives the auxiliary swing arm 33 to rotate or move up and down about the hinge axis, thereby changing the tilt angle of the upper guide roller 22 relative to the lower guide roller 21.

[0028] Driven by the actuator 331, the auxiliary swing arm 33 rotates or moves vertically, changing the angle between the upper guide roller 22 and the lower guide roller 21. This angle adjustment mechanism controls the material tension distribution and the belt travel direction. In some embodiments, when the tilt angle of the upper guide roller 22 changes, the path of the film 4 between the two guide rollers changes accordingly, resulting in different tension distribution patterns.

[0029] Reference Figure 1 and Figure 2 This mechanism achieves uniform tension distribution of the material in the width direction by dynamically adjusting the angle between the guide rollers. In some embodiments, the system provides real-time adjustment capabilities for the wrinkle-removing path and flattening angle during operation. The mechanism is modularly compatible, allowing integration into different types of unwinding equipment.

[0030] Reference Figure 1 The unwinding mechanism also includes a tension detection mechanism for real-time detection of the tension of the flexible film 4. The tension detection mechanism includes a front visual tension detection camera 11 and a back visual tension detection camera 12. The front visual tension detection camera 11 is mounted on the upper part of the mechanism and positioned to monitor the film 4 from the front. The back visual tension detection camera 12 is also located on the upper part, monitoring the back of the film 4.

[0031] In some embodiments, the front visual tension detection camera 11 and the back visual tension detection camera 12 work together to monitor the tension distribution of the film 4 between the upper guide roller 22 and the lower guide roller 21 in real time. These two cameras 11 and 12 capture the surface state of the film 4 from different angles, detecting the tension distribution of the film 4 in the width direction. Through visual inspection, the tension detection mechanism can identify wrinkles, deformations, or uneven tension on the surface of the film 4.

[0032] The tension detection mechanism provides comprehensive information on the tension state of the film 4 through dual-sided monitoring by a front visual tension detection camera 11 and a rear visual tension detection camera 12. In some embodiments, this dual-camera configuration allows the system to simultaneously monitor the tension performance of the front and back sides of the film 4, ensuring an accurate assessment of the material condition. The real-time detection function of the tension detection mechanism provides data support for subsequent angle adjustments.

[0033] Reference Figure 2The actuator 331 has various implementations to drive the movement of the auxiliary swing arm 33. In some implementations, the actuator 331 includes a servo motor that provides precise control over the rotation of the auxiliary swing arm 33 and the positioning of the upper guide roller 22. The servo motor implementation achieves accurate rotation of the auxiliary swing arm 33 about the axis of the rotational hinge through precise angle control, thereby precisely adjusting the tilt angle of the upper guide roller 22 relative to the lower guide roller 21.

[0034] In some embodiments, the actuator 331 includes a cylinder that drives the auxiliary swing arm 33 to rotate or lift. In the cylinder implementation, the auxiliary swing arm 33 moves along a predetermined trajectory via a push-pull motion, thereby adjusting the position of the upper guide roller 22. The extension and retraction of the cylinder is converted into an angular change in the auxiliary swing arm 33, altering the relative positional relationship between the upper guide roller 22 and the lower guide roller 21.

[0035] The actuator 331 is directly mounted on the auxiliary swing arm 33, providing direct driving force for the movement of the auxiliary swing arm 33. In the servo motor embodiment, the output shaft of the servo motor is connected to the rotation mechanism of the auxiliary swing arm 33, and the rotational motion of the motor directly drives the auxiliary swing arm 33 to rotate around the hinge axis. In the cylinder embodiment, the piston rod of the cylinder is connected to the connection point of the auxiliary swing arm 33, and the linear motion of the cylinder is converted into the rotational or lifting motion of the auxiliary swing arm 33 through mechanical transmission.

[0036] The servo motor implementation provides high-precision angle control and position feedback, allowing the system to fine-tune based on tension detection results. The cylinder implementation offers greater driving force and rapid response, suitable for applications requiring a large angle adjustment range. In some implementations, the choice of actuator 331 is based on specific application requirements and control accuracy needs.

[0037] Reference Figure 2 The roller angle adjustment mechanism 3 also includes a bearing 32 and a base 34. These components, together with the angle-adjustable bracket 31 and connector 311, constitute a complete angle adjustment support structure. The bearing 32 provides rotational support in the roller angle adjustment mechanism 3, allowing the angle-adjustable bracket 31 to rotate smoothly. The base 34 serves as the basic mounting platform for the roller angle adjustment mechanism 3, providing a stable support foundation for the entire angle adjustment system.

[0038] An angle-adjustable bracket 31 is mechanically connected to a bearing 32 via a connector 311. The connector 311, as a dedicated connecting component, enables mechanical coupling between the angle-adjustable bracket 31 and the bearing 32. In some embodiments, the connector 311 provides a reliable connection between the angle-adjustable bracket 31 and the bearing 32, ensuring structural stability during angle adjustment.

[0039] The rotational characteristics of bearing 32, combined with the connection function of connector 311, enable the angle-adjustable bracket 31 to rotate around the axis of bearing 32. This connection configuration allows the angle-adjustable bracket 31 to adjust its angle under the drive of actuator 331, while maintaining a stable connection with bearing 32. Base 34 provides a fixed mounting position for bearing 32, ensuring that bearing 32 remains stable during angle adjustment.

[0040] In some embodiments, connector 311 is designed to accommodate the load transfer requirements between the angle-adjustable bracket 31 and the bearing 32. Connector 311 bears the torque and load generated by the angle-adjustable bracket 31 during rotation and transfers these loads to bearing 32. Bearing 32 distributes these loads through its internal rolling or sliding elements, reducing friction and ensuring smooth angle adjustment.

[0041] The cooperation between the base 34 and the bearing 32 provides a stable foundation support for the entire roller angle adjustment mechanism 3. The structural design of the base 34 accommodates the installation requirements of the bearing 32, ensuring the correct positioning and fixation of the bearing 32 on the base 34. This configuration allows the angle-adjustable bracket 31, connector 311, bearing 32, and base 34 to form a complete angle adjustment support structure, providing a stable and reliable mechanical foundation for the angle adjustment of the upper guide roller 22.

[0042] Reference Figure 1 When the upper guide roller 22 tilts outward, the transmission path of the flexible film 4 between the upper guide roller 22 and the lower guide roller 21 changes significantly. Under this tilted configuration, the flexible film 4 no longer passes through the two guide rollers along a straight path, but instead presents an arc-shaped path between the upper guide roller 22 and the lower guide roller 21. The formation of this arc-shaped path alters the geometry and stress state of the flexible film 4 between the guide rollers.

[0043] The formation of the arc-shaped path causes the flexible film 4 to experience different tension distributions in the width direction. In some embodiments, as the flexible film 4 passes along the arc-shaped path through the upper guide roller 22 and the lower guide roller 21, the central portion and the edge portion of the film 4 experience different degrees of stretching. This differentiated stretching generates a lateral expansion tension force on both sides of the film 4, which acts on the edge region of the film 4.

[0044] The mechanism for generating lateral tension is based on the influence of the arc-shaped path on the geometry of the flexible film 4. (Refer to...) Figure 1 When the upper guide roller 22 is tilted outward relative to the lower guide roller 21, the arc-shaped path of the flexible film 4 between the two guide rollers causes the edge portion of the film 4 to bear an outward tensile force. This outward tensile force manifests as a lateral expansion tension force, which acts in the width direction of the film 4 and applies a flattening effect to the uneven areas on the surface of the film 4.

[0045] The process of achieving a flattening effect through lateral expansion tension involves the mechanical action on wrinkles and uneven areas on the surface of the flexible film 4. In some embodiments, the lateral expansion tension is applied by a tensile force in the width direction of the film 4, causing the wrinkled areas on the surface of the film 4 to be subjected to an unfolding force. This unfolding force causes the wrinkled areas to gradually flatten, thereby achieving a flattening effect on the surface of the film 4.

[0046] Different tilt angles of the upper guide roller 22 have a corresponding impact on the tension distribution of the flexible film 4. A smaller tilt angle results in a smaller curvature of the arc path of the flexible film 4, producing a relatively weaker lateral expansion tension, which is suitable for flattening slight wrinkles. In some embodiments, a larger tilt angle increases the curvature of the arc path of the flexible film 4, producing a stronger lateral expansion tension and providing a more significant flattening effect.

[0047] The range of tilt angle adjustment affects the intensity and applicability of the wrinkle-removing effect. (Refer to...) Figure 1 By adjusting the inclination of the upper guide roller 22 relative to the lower guide roller 21, the system controls the geometric parameters of the curved path of the flexible film 4, thereby adjusting the magnitude of the lateral expansion tension. This adjustable tension distribution mechanism allows the unwinding mechanism to adapt to different types and thicknesses of flexible films 4, as well as varying degrees of surface unevenness.

[0048] In some embodiments, the flattening effect produced by the outward tilt of the upper guide roller 22 is related to the material properties of the film 4. Flexible films 4 made of different materials respond differently to lateral expansion tension. By adjusting the tilt angle of the upper guide roller 22, the system provides appropriate flattening force for films 4 made of different materials. This angle adjustment mechanism ensures a flattening effect while avoiding excessive stretching or damage to the film 4.

[0049] In some embodiments, the unwinding mechanism further includes a control system, which establishes a communication connection with the tension detection mechanism and the actuator 331. The control system receives detection signals from the tension detection mechanism, which contain information on the tension distribution of the flexible film 4 during transmission. By processing these detection signals, the control system obtains real-time data on the surface state of the film 4, including wrinkle locations, areas of uneven tension, and surface smoothness information.

[0050] The control system adjusts the actuator 331 in a closed-loop manner based on the detection signal from the tension detection mechanism. During the closed-loop control process, the control system compares the detection signal with a preset tension distribution standard and calculates the deviation between the current state of the film 4 and the ideal state. Based on this deviation analysis, the control system generates corresponding control commands to guide the actuator 331 to perform angle adjustment actions.

[0051] The closed-loop feedback control mechanism enables the control system to continuously monitor changes in the tension state of the film 4. In some embodiments, when the tension detection mechanism detects new wrinkles or changes in the tension distribution of the film 4, the control system immediately receives this information and recalculates the adjustment parameters. The control system then sends a new control command to the actuator 331, driving the auxiliary swing arm 33 to adjust the tilt angle of the upper guide roller 22 to respond to changes in the state of the film 4.

[0052] The closed-loop control function of the control system enables dynamic control of the roller angle. The control system maintains the stability of the tension distribution of the film 4 through continuous signal reception, processing, and command transmission. In some embodiments, the control system sets specific response time parameters to ensure that the actuator 331 can be adjusted promptly upon detecting an abnormal tension, preventing further deterioration of the film 4.

[0053] The control system's signal processing capabilities include analyzing image data provided by the front visual tension detection camera 11 and the rear visual tension detection camera 12. The control system uses image processing algorithms to identify wrinkle patterns and tension distribution characteristics on the surface of the thin film 4, converting visual information into quantifiable tension parameters. These parameters serve as input signals for closed-loop control, guiding the control system to determine the adjustment direction and amplitude of the actuator 331.

[0054] In some implementations, the control system establishes a mapping relationship between the tension detection signal and the action of the actuator 331. When the detection signal indicates that the tension in a certain area of ​​the film 4 is too high, the control system calculates the angle adjustment required to reduce the tension in that area and controls the actuator 331 to adjust the position of the auxiliary swing arm 33 accordingly. When the detection signal indicates that there are wrinkles in the film 4, the control system increases the tilt angle of the upper guide roller 22 to enhance the lateral expansion tension and achieve a flattening effect.

[0055] The closed-loop regulation process of the control system exhibits adaptive characteristics, adjusting control parameters according to different film 4 materials and process conditions. The control system stores tension control strategies corresponding to different material types; when handling films 4 of varying thicknesses or materials, the control system selects the appropriate control algorithm and parameter settings. This adaptive control mechanism ensures the effectiveness of the closed-loop regulation function in various application scenarios.

[0056] The control system achieves coordinated operation between tension detection and angle adjustment through a closed-loop feedback mechanism. In some embodiments, the control system monitors the effect of the adjustment action of the actuator 331 and evaluates the adjustment effect by comparing the tension detection signals before and after adjustment. If a single adjustment fails to achieve the expected effect, the control system performs further angle fine-tuning until the tension distribution of the film 4 reaches the set standard.

[0057] In some implementations, the control system has an adaptive parameter tuning mechanism that automatically sets the optimal angle based on the film width, thickness, and tension detection signals. This adaptive parameter tuning mechanism establishes a correlation between material properties and angle adjustment parameters by analyzing the physical properties of the film 4 and its real-time tension state. The control system stores an angle adjustment database corresponding to films 4 of different widths and thicknesses. When a film 4 of a specific specification is detected, the control system automatically calls up the corresponding parameter settings. The tension detection signal, as a dynamic input parameter, is combined with the width and thickness information of the film 4 to form a multi-dimensional basis for parameter tuning. The control system processes these multi-dimensional parameters through algorithms to calculate the optimal roller angle under the current operating conditions and automatically adjusts the actuator 331 to achieve this angle setting.

[0058] Specifically, refer to Figure 3 The system first collects basic membrane material properties. It reads the input membrane width W (typical range 300–1600 mm), thickness H (10–150 μm), and material type (PET, PE, PI, etc.), and automatically matches the material's flexural modulus E (e.g., PET approximately 3.5–4.2 GPa, PE approximately 0.2–0.4 GPa, PI approximately 2.5–3.0 GPa). This basic data serves as static input for subsequent calculations of the included angle parameters.

[0059] Next, real-time tension detection and tension distribution calculation are performed. The front and back vision cameras of the tension detection mechanism acquire the film tension distribution map, and the total tension T (typically 5–35 N) and the tension non-uniformity coefficient Ku in the width direction are calculated. ; Ku > 0.15 indicates significantly uneven tension distribution. Simultaneously, the wrinkle index Wr is extracted, with values ​​ranging from 0 to 1; values ​​closer to 1 indicate more severe wrinkling.

[0060] Next, calculate the initial included angle. Calculate the initial included angle θ0 based on the material width, thickness, and flexural modulus: ; In some implementations, empirical coefficients are commonly used: k1 = 0.6–0.9°, k2 = 0.3–0.5°·GPa, and k33 = 0.02–0.06° / μm. For example, when W = 800 mm, H = 50 μm, and E = 3.8 GPa, θ0 ≈ 2.4–3.0°.

[0061] Then, the angle correction is calculated based on the real-time tension and wrinkle degree. The angle correction Δθ is dynamically calculated using the tension unevenness coefficient Ku and the wrinkle index Wr: ; Where a1 = 2.0–4.0° (tension unevenness influence coefficient), a2 = 3.0–6.0° (wrinkle influence coefficient). For example, when Ku = 0.20 and Wr = 0.35, Δθ ≈ 1.2–2.0°.

[0062] Finally, adaptive angle setting and safety zone limitation. The final target angle is set as follows: ; To avoid over-adjustment, a safety range is set (e.g., θ ∈ 1–8°). If the calculated result exceeds this range, it is automatically limited to within the safety range. The actuator adjusts the upper guide roller to the target angle θ within 0.1–0.2 s.

[0063] Meanwhile, during the adjustment process, continuous monitoring and iterative updates are performed. For example, the tension detection data is updated every 50–100 ms. If the following situations are detected, such as the appearance of new wrinkles (Wr increase ≥ 0.1), Ku increase ≥ 0.05, or belt offset exceeding ±3 mm, the above steps are iterated again.

[0064] In some embodiments, the control system also includes an abnormal operating condition handling mechanism, which includes wrinkle detection and early warning, tension anomaly protection, and equipment fault self-diagnosis functions. The wrinkle detection and early warning function analyzes image data from the front visual tension detection camera 11 and the back visual tension detection camera 12 to identify abnormal wrinkle patterns on the surface of the film 4. When the detected wrinkle level exceeds a preset threshold, the control system issues an early warning signal and automatically adjusts the actuator 331 to increase the tilt angle of the upper guide roller 22. The tension anomaly protection function monitors the tension distribution of the film 4. When the detected tension value exceeds the safe range, the control system immediately stops the angle adjustment action or adjusts the roller angle to a safe position to prevent damage to the film 4 due to excessive tension. The equipment fault self-diagnosis function continuously monitors the operating status of key components such as the actuator 331, bearings 32, and angle-adjustable support 31. By analyzing parameters such as component response time, motion accuracy, and load changes, it identifies potential mechanical faults or performance degradation and provides maintenance reminders before a fault occurs.

[0065] Specifically, in this embodiment, firstly, tension and wrinkle monitoring are performed in real time. Front and rear visual tension detection cameras acquire film images at 20–50 ms intervals. The wrinkle index Wr (0–1) and tension value T (5–35 N) are calculated using tension gradient analysis and a wrinkle texture algorithm. A wrinkle threshold Wr_th = 0.25 and a tension safety range T_safe = 8–28 N are set.

[0066] When Wr ≥ Wr_th or the wrinkle area exceeds 15 mm is detected. 2 If the wrinkles are detected, it is determined that primary wrinkles have appeared on the film. To prevent the wrinkles from expanding further, angle compensation needs to be performed immediately. Record the wrinkle location and the wrinkle change trend (rising / falling / spreading).

[0067] If wrinkles are confirmed to persist (Wr is above the threshold for 3 consecutive samples), a wrinkle warning is triggered and corresponding adjustment actions are executed: calculate the wrinkle correction angle. The drive actuator increases the angle Δθ_w of the upper guide roller to enhance the lateral flattening tension; if the wrinkle is close to the left side of the film, the system shifts to the left and increases the angle; if it is close to the right, the opposite is true. After the wrinkle disappears, the angle is maintained for 0.5–1 s and then gradually restored to the normal angle.

[0068] If T > 28 N (tension too high), calculate the reduction in the included angle Δθ_t and reduce the actuator speed by 20–40% to avoid instantaneous over-adjustment. If T < 8 N (tension too low), slightly increase the included angle (0.2–0.6°) to restore film tension. If T is abnormal for 5 consecutive samples, the system records it as a continuous tension abnormality and enters protection mode, locking the included angle within the safe range of 1–5° and outputting a tension abnormality warning.

[0069] In some implementations, the control system features coordinated control and switching logic for angle, tension, and offset. This coordinated control mechanism achieves unified adjustment of the three control parameters by comprehensively analyzing the interrelationships between the roller angle, film tension distribution, and belt offset. The control system establishes a tension distribution algorithm for different angles. This algorithm calculates the theoretical tension distribution pattern of the film under that angle configuration based on the specific angle between the upper and lower guide rollers and compares it with the actual detected tension distribution. The belt offset compensation mechanism, as part of the coordinated control, monitors the lateral position offset of the film and, combined with the current roller angle and tension state, calculates the angle adjustment required to correct the belt offset. The switching logic of the control system switches between different control modes based on the real-time state of the film. When an abnormal tension is detected, tension adjustment is prioritized; when belt offset is detected, the offset compensation mode is activated; and when wrinkles appear on the film surface, the system switches to the flattening angle adjustment mode. This intelligent switching mechanism ensures the coordinated operation and optimized effect of the three control parameters.

[0070] Specifically, in this embodiment, the control system employs a coordinated control mechanism of angle, tension, and offset to comprehensively adjust the film's operating state. The system acquires the film's tension distribution and lateral position offset every 30–50 ms using visual cameras on both sides, and calculates the tension unevenness coefficient Ku (typical range 0.05–0.25) and the lateral offset D (±0–8 mm). When Ku ≥ 0.15, the control system calculates the angle correction Δθt = 1.5–3.0° based on the tension difference and drives the actuator to adjust the tilt angle of the upper guide roller to improve tension uniformity. When a lateral offset |D| ≥ 3 mm is detected, the system increases or decreases the angle by 0.3–1.2° based on the offset direction, achieving belt deviation correction by changing the lateral flattening force. When Ku ≤ 0.1 and |D| ≤ 1 mm, the system enters a stable mode, locking the angle within the current ±0.1° range and restricting the actuator's movement to avoid over-adjustment leading to new instability factors. The above-mentioned synergistic control strategy improves film tension uniformity by 20–35% and reduces lateral offset by 40–70%, significantly enhancing the stability of the unwinding process.

[0071] In summary, this invention, through an adjustable roller angle structure, integrated front and back visual tension detection mechanisms, and the introduction of adaptive parameter tuning, abnormal condition handling, and angle-tension-offset collaborative control mechanisms into the control system, achieves real-time adjustment and dynamic optimization of the tension distribution, belt offset, and wrinkle state of flexible films during unwinding. It maintains stable flattening and belt consistency under different materials, operating conditions, and speed fluctuations, significantly improving the flatness, stability, and control accuracy of film unwinding, thereby enhancing overall production efficiency and material processing quality. The structure described in this invention is simple, highly adaptable, and can be flexibly integrated into different types of unwinding equipment, demonstrating significant industrial application value.

[0072] The above 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. An unwinding mechanism with adjustable inter-roll angle, comprising: Upper guide rollers are used to support and guide the flexible film; The lower guide roller is used to support and guide the flexible film; The roller angle adjustment mechanism includes an angle-adjustable bracket and a secondary swing arm. The upper guide roller is fixed to the end of the secondary swing arm, and the lower guide roller is fixed to the base bracket. The secondary swing arm is connected to the angle-adjustable bracket via a rotary hinge. as well as An actuator is used to drive the auxiliary swing arm to rotate or lift, thereby changing the tilt angle of the upper guide roller relative to the lower guide roller, so as to adjust the included angle between the upper guide roller and the lower guide roller, and control the material tension distribution and the belt feeding direction; A tension detection mechanism, used to detect the tension of the flexible film in real time, includes a front visual tension detection camera and a back visual tension detection camera; The control system adjusts the action of the actuator in a closed-loop manner according to the detection signal of the tension detection mechanism. The control system automatically sets the optimal included angle according to the film width, thickness and tension detection signal, and has an adaptive parameter tuning mechanism. The adaptive parameter tuning mechanism dynamically adjusts the included angle adjustment parameters based on the mechanical properties of different materials, including determining the included angle correction amount by using the comprehensive calculation results of real-time tension change, width direction tension distribution and material bending modulus, so as to realize adaptive control of the included angle between rollers under various working conditions. Wherein, the control system; First, the basic properties of the membrane material are collected, including the input membrane width W, thickness H, and material type, and the material flexural modulus E is automatically matched. Next, real-time tension detection and tension distribution calculation are performed. The tension distribution map of the film is obtained using the front and rear visual tension detection cameras of the tension detection mechanism, and the tension non-uniformity coefficient Ku in the width direction of the total tension T is calculated. , A value >0.15 indicates significantly uneven tension distribution; At the same time, the wrinkle index Wr is extracted, with Wr ranging from 0 to 1; Next, calculate the initial included angle. Calculate the initial included angle θ0 based on the material width, thickness, and flexural modulus: , , , This is an empirical coefficient; Then, the angle correction amount is calculated based on real-time tension and wrinkle degree, and the angle correction amount is dynamically calculated according to the tension unevenness coefficient Ku and the wrinkle index Wr. ; , This represents the influence coefficient of uneven tension. The wrinkle influence coefficient; Finally, adaptive angle setting and safety zone limitation are performed, and the final target angle is set as follows: ； To avoid over-adjustment, a safe range θ∈1–8° is set. If the calculation result exceeds this range, it is automatically limited to the safe range. The actuator adjusts the upper guide roller to the target angle θ within 0.1–0.2s.

2. The unwinding mechanism according to claim 1, Its characteristic is that the control system further includes an abnormal operating condition handling mechanism, which performs corresponding processing actions when it detects film wrinkles, abnormal tension, or abnormal equipment operation, wherein: When the wrinkle detection signal indicates that the wrinkle amplitude exceeds the preset threshold, the control system drives the actuator to increase the tilt angle of the upper guide roller relative to the lower guide roller to enhance the flattening tension. When the detected tension value exceeds the safe range, the control system automatically reduces the included angle or adjusts the included angle to a safe angle range to reduce the stress on the material. When the response time or motion deviation of the actuator or angle adjustment mechanism exceeds the limit, the control system issues a fault warning and restricts the angle adjustment action until the fault is resolved.

3. The unwinding mechanism according to claim 1, Its characteristic is that the control system further includes a coordinated control mechanism of angle-tension-offset, which establishes a correspondence between film tension distribution, belt offset, and roller angle, and executes specific adjustment actions based on the monitored operating status, wherein: When uneven tension is detected in the width direction of the film, the control system calculates the required angle correction and drives the actuator to adjust the tilt angle of the upper guide roller. When the film conveyor belt offset is detected to exceed the allowable deviation, the control system increases or decreases the included angle according to the offset direction to correct the film's running path; When the film is under stable tension and without deviation, the control system maintains the current angle and prohibits unnecessary angle adjustments to maintain the stability of film operation.

4. The unwinding mechanism according to claim 1, characterized in that, The actuator includes a servo motor or a cylinder.

5. The unwinding mechanism according to claim 1, characterized in that, The roller angle adjustment mechanism also includes a bearing and a base, and the angle-adjustable bracket is connected to the bearing via a connector.

6. The unwinding mechanism according to claim 1, characterized in that, When the upper guide roller tilts outward, the flexible film presents an arc-shaped path between the upper and lower guide rollers, generating lateral expansion tension on both sides of the film to achieve a flattening effect.

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