Coating machine operation method and device, computer equipment, storage medium and coating machine

Abstract

The invention relates to a coating machine operation method and device, computer equipment, a storage medium and a coating machine, in the operation process of the coating machine, in combination with a tension set value and a real-time rolling diameter, the needed rotation mode when a winding and unwinding servo motor meets the tension requirement is determined, so that the winding and unwinding servo motor is controlled to rotate, and the tension requirement of the coating machine is met. And then the output torque is adjusted according to the tension set value and the tension sampling value. In this way, the output torque can be adjusted under the condition that the winding and unwinding servo motor rotates to meet the tension requirement, and high tension control precision is achieved.

Description

Technical Field

[0001] This application relates to the field of coating technology, and in particular to a coating machine operation method, apparatus, computer equipment, storage medium, computer program product, and coating machine. Background Technology

[0002] A coating machine is a device that applies a layer of adhesive, coating, or ink with specific functions to the surface of a substrate. Tension control is typically achieved through magnetic powder tension control technology. Coating machines are used in battery manufacturing processes to uniformly coat electrode slurry onto the surface of metal foil to form positive and negative electrode sheets.

[0003] However, among related technologies, the tension control accuracy of coating machines is relatively poor. Summary of the Invention

[0004] Therefore, it is necessary to provide a coating machine operation method, apparatus, computer equipment, storage medium, computer program product, and coating machine to improve the tension control accuracy of the coating machine.

[0005] In a first aspect, this application provides a method for operating a coating machine, comprising: acquiring a tension setpoint, a real-time roll diameter, and a tension sampling value of the coating machine; determining, based on the tension setpoint and the real-time roll diameter, the required rotation mode of the take-up and unwinding servo motor to meet the tension requirements; and adjusting the output torque based on the tension setpoint and the tension sampling value when the take-up and unwinding servo motor operates in the required rotation mode.

[0006] The above-described coating machine operation method, during the coating machine's operation, combines the tension setpoint and real-time roll diameter to determine the required rotation mode of the take-up and unwinding servo motors to meet the tension demand. This control of the take-up and unwinding servo motors' rotation is then used to adjust the output torque based on the tension setpoint and sampled tension value. In this way, output torque adjustment can be performed while maintaining the rotation mode of the take-up and unwinding servo motors to meet the tension demand, resulting in high tension control accuracy.

[0007] In some embodiments, determining the required rotation mode of the take-up and unwinding servo motor to meet the tension requirement based on the tension setting value and the real-time roll diameter includes: determining the friction start torque based on the real-time roll diameter; and determining the required rotation mode of the take-up and unwinding servo motor to meet the tension requirement based on the friction start torque and the tension setting value.

[0008] The above scheme determines the required rotation mode of the take-up and unwinding servo motor to meet tension requirements by using the corresponding frictional starting torque and tension setpoint under different real-time roll diameters. In this way, combined with the mechanical friction force during the coating machine's operation, the operation control of the coating machine is achieved, improving the operational reliability of the take-up and unwinding servo motor.

[0009] In some embodiments, determining the required rotation mode of the take-up and unwinding servo motor to meet the tension requirement based on the friction start torque and the tension set value includes: determining the mechanical friction force of the coating machine based on the friction start torque; if the tension set value is greater than the mechanical friction force, determining that the required rotation mode of the take-up and unwinding servo motor to meet the tension requirement is reverse rotation or stationary rotation; if the tension set value is equal to the mechanical friction force, determining that the required rotation mode of the take-up and unwinding servo motor to meet the tension requirement is stationary rotation; and if the tension set value is less than the mechanical friction force, determining that the required rotation mode of the take-up and unwinding servo motor to meet the tension requirement is forward rotation.

[0010] The above scheme controls the forward, reverse, and stationary rotation of the winding and unwinding servo motors according to the relationship between the mechanical friction force corresponding to the friction start torque and the winding tension setting value, effectively improving the operating accuracy of the winding and unwinding servo motors.

[0011] In some embodiments, the real-time winding diameter includes a real-time take-up winding diameter and a real-time unwinding winding diameter, the tension setting value includes a take-up tension setting value and an unwinding tension setting value, the take-up and unwinding servo motors include a take-up servo motor and an unwinding servo motor, and the friction start torque includes a first friction start torque corresponding to the real-time take-up winding diameter and a second friction start torque corresponding to the real-time unwinding winding diameter; determining the required rotation mode of the take-up and unwinding servo motors to meet the tension requirements based on the friction start torque and the tension setting value includes: determining the required rotation mode of the take-up servo motors to meet the tension requirements based on the first friction start torque and the take-up tension setting value; and determining the required rotation mode of the unwinding servo motors to meet the tension requirements based on the second friction start torque and the unwinding tension setting value.

[0012] In the above scheme, the winding and unwinding are driven by winding servo motors and unwinding servo motors, respectively. Correspondingly, the rotation mode of the winding servo motor and the unwinding servo motor is determined, which effectively improves the operational reliability of the winding servo motor and the unwinding servo motor.

[0013] In some embodiments, the tension sampling value includes a winding tension sampling value and an unwinding tension sampling value; adjusting the output torque according to the tension setting value and the tension sampling value when the winding / unwinding servo motor is operating in the desired rotation mode includes: adjusting the winding output torque according to the winding tension setting value and the winding tension sampling value when the winding servo motor is operating in the desired rotation mode; and adjusting the unwinding output torque according to the unwinding tension setting value and the unwinding tension sampling value when the unwinding servo motor is operating in the desired rotation mode.

[0014] In the above scheme, the winding and unwinding of the coating machine are controlled by winding servo motors and unwinding servo motors, respectively. Correspondingly, the output torque of winding and unwinding is adjusted separately, which effectively improves the accuracy of the output torque of the coating machine.

[0015] In some embodiments, determining the frictional starting torque based on the real-time roll diameter includes: determining the frictional starting torque based on the real-time roll diameter and the correspondence between roll diameter and starting torque.

[0016] The above scheme, by combining the real-time roll diameter and the correspondence between roll diameter and starting torque, determines the friction starting torque corresponding to different real-time roll diameters, and has a high efficiency in determining the friction starting torque.

[0017] In some embodiments, the method for determining the correspondence between roll diameter and starting torque includes: when the coating machine is running in forward rotation for debugging, determining the first magnetic powder starting torque, the first motor starting torque, and the first friction starting torque corresponding to each roll diameter under different rotation states of the take-up and unwind servo motor; when the coating machine is running in reverse rotation for debugging, determining the second magnetic powder starting torque, the second motor starting torque, and the second friction starting torque corresponding to each roll diameter under different rotation states of the take-up and unwind servo motor; and determining the correspondence between roll diameter and starting torque based on the first magnetic powder starting torque, the first motor starting torque, the first friction starting torque, the second magnetic powder starting torque, the second motor starting torque, and the second friction starting torque.

[0018] In the above scheme, during the debugging phase, the coating machine is controlled to rotate forward and in reverse respectively. In order to obtain the magnetic powder starting torque, motor starting torque and friction starting torque corresponding to different rotation modes and different roll diameters of the winding and unwinding servo motor in the forward or reverse state, the precise correspondence between roll diameter and starting torque can be obtained.

[0019] In some embodiments, determining the first magnetic powder starting torque, the first motor starting torque, and the first friction starting torque corresponding to each roll diameter under different rotation states of the take-up and unwinding servo motor includes: acquiring the first adjustment tension sampling value, the first magnetic powder starting torque, and the first motor starting torque under different rotation states and different roll diameters of the take-up and unwinding servo motor when the adjustment tension setting value is zero; and determining the corresponding first friction starting torque based on the first adjustment tension sampling value, the first magnetic powder starting torque, and the first motor starting torque.

[0020] The above scheme controls the adjustment tension setting to zero when the coating machine is rotating forward, and collects the first adjustment tension sampling value of the take-up and unwinding servo motor under different rotation states and different roll diameters. Based on this, the first friction start torque corresponding to different rotation states and different roll diameters can be calculated. In this way, a high-precision first friction start torque can be obtained.

[0021] In some embodiments, determining the second magnetic powder starting torque, the second motor starting torque, and the second friction starting torque corresponding to each roll diameter under different rotation states of the take-up and unwinding servo motor includes: acquiring the second adjustment tension sampling value of the take-up and unwinding servo motor under different rotation states and different roll diameters, as well as the second magnetic powder starting torque and the second motor starting torque, when the adjustment tension setting value is zero; and determining the corresponding second friction starting torque based on the second adjustment tension sampling value, the second magnetic powder starting torque, and the second motor starting torque.

[0022] The above scheme controls the adjustment tension setting to zero when the coating machine is in reverse, and collects the second adjustment tension sampling value of the take-up and unwinding servo motor under different rotation states and different roll diameters. Based on this, the second friction starting torque corresponding to different rotation states and different roll diameters can be calculated. In this way, a high-precision second friction starting torque can be obtained.

[0023] In some embodiments, the coating machine operation method further includes: calculating the current starting torque based on the tension sampling value and the real-time roll diameter; determining the starting torque error based on the current starting torque, the real-time roll diameter, and the correspondence between the roll diameter and the starting torque; and outputting an alarm prompt message when the starting torque error meets the alarm conditions.

[0024] The above-mentioned solution can also monitor the coating machine during operation by back-calculating the current starting torque in real time. If there is a large error in the current starting torque, an alarm message will be output in a timely manner, which can effectively improve the operational reliability of the coating machine.

[0025] In some embodiments, determining the starting torque error based on the current starting torque, the real-time roll diameter, and the correspondence between roll diameter and starting torque includes: determining the theoretical starting torque based on the real-time roll diameter and the correspondence between roll diameter and starting torque; and determining the starting torque error based on the current starting torque and the theoretical starting torque.

[0026] The above scheme determines the theoretical starting torque by using the real-time roll diameter and the correspondence between roll diameter and starting torque, and combines the theoretical starting torque with the current starting torque to determine the starting torque error, thereby improving the accuracy of the starting torque error.

[0027] In some embodiments, determining the starting torque error based on the current starting torque and the theoretical starting torque includes: obtaining the current starting torque and the theoretical starting torque corresponding to at least two different roll diameters; determining a first variation parameter based on the current starting torque and at least two roll diameters; determining a second variation parameter based on the theoretical starting torque and at least two roll diameters; and determining the starting torque error based on the first variation parameter and the second variation parameter.

[0028] The above scheme combines analysis of at least two roll diameters and their corresponding current starting torques to obtain a first variation parameter of the starting torque relative to the roll diameter, and combines analysis of at least two roll diameters and their corresponding theoretical starting torques to obtain a second variation parameter of the theoretical starting torque relative to the roll diameter. The starting torque error is then determined by the second variation parameter and the first variation parameter, reducing the influence of data measurement errors and further improving the accuracy of the starting torque error.

[0029] In some embodiments, the starting torque error includes at least one of friction starting torque error, motor starting torque error, and magnetic powder starting torque error.

[0030] The above scheme allows the starting torque error to be at least one of friction starting torque error, motor starting torque error, and magnetic powder starting torque error. By using one or more of these errors, the operation monitoring of the coating machine can be achieved, thereby meeting different monitoring needs.

[0031] In some embodiments, outputting an alarm message when the starting torque error meets the alarm conditions includes: outputting an alarm message when at least one of the friction starting torque error, the motor starting torque error, and the magnetic powder starting torque error is greater than a preset error threshold.

[0032] The above scheme only requires that at least one of the friction starting torque error, motor starting torque error, and magnetic powder starting torque error is greater than a preset error threshold to be considered to meet the alarm conditions, thus having high alarm reliability.

[0033] In some embodiments, the coating machine operation method further includes: recording the operating parameters of the take-up servo motor and the unwind servo motor respectively during the operation of the coating machine; and changing the operating parameters of the take-up servo motor and the unwind servo motor upon receiving a switching command.

[0034] The above solution allows the operating parameters of the winding servo motor and the unwinding servo motor to be recorded separately during the operation of the coating machine. When there is a switching requirement, the operating parameters of the two motors can be directly changed to achieve one-click switching between forward and reverse rotation, which has high operational convenience.

[0035] A coating machine operating device includes: a parameter acquisition module for acquiring the coating machine's tension setpoint, real-time roll diameter, and tension sampling value; a rotation analysis module for determining the required rotation mode of the take-up and unwinding servo motor to meet the tension requirements based on the tension setpoint and the real-time roll diameter; and a torque adjustment module for adjusting the output torque based on the tension setpoint and the tension sampling value when the take-up and unwinding servo motor operates in the required rotation mode.

[0036] A computer device includes a memory and a processor, the memory storing a computer program, and the processor executing the computer program to implement the steps of the above-described coating machine operation method.

[0037] A computer-readable storage medium having a computer program stored thereon, which, when executed by a processor, implements the steps of the above-described coating machine operation method.

[0038] A computer program product includes a computer program that, when executed by a processor, implements the steps of the above-described coating machine operation method.

[0039] A coating machine includes: a magnetic powder tension control device, a take-up servo motor, a take-up roller, an unwind servo motor, and an unwind roller. The take-up servo motor is connected to the take-up roller, and the unwind servo motor is connected to the unwind roller. The take-up servo motor and the unwind servo motor are respectively connected to the magnetic powder tension control device. The magnetic powder tension control device is used to execute the steps of the above-described coating machine operation method. Attached Figure Description

[0040] Various other advantages and benefits will become apparent to those skilled in the art upon reading the detailed description of the preferred embodiments below. The accompanying drawings are for illustrative purposes only and are not intended to limit the scope of this application. Furthermore, the same reference numerals denote the same parts throughout the drawings. In the drawings:

[0041] Figure 1 This is a schematic diagram of the coating machine operation method in some embodiments of this application;

[0042] Figure 2 This is a schematic diagram of the coating machine operation method in some other embodiments of this application;

[0043] Figure 3 This is a schematic diagram illustrating the process for determining the rotation mode of the take-up and unwind servo motor in some embodiments of this application;

[0044] Figure 4 This is a schematic diagram of the coating machine operation method in some embodiments of this application;

[0045] Figure 5 This is a schematic diagram of the coating machine operation method in some embodiments of this application;

[0046] Figure 6 This is a schematic diagram of the coating machine operation method in some other embodiments of this application;

[0047] Figure 7 This is a schematic diagram of the coating machine operation method in some embodiments of this application;

[0048] Figure 8 This is a schematic diagram of the starting torque error determination process in some embodiments of this application;

[0049] Figure 9 This is a schematic diagram of the starting torque error determination process in some other embodiments of this application;

[0050] Figure 10 This is a schematic diagram of the coating machine operation method in some embodiments of this application;

[0051] Figure 11 This is a schematic diagram of the coating machine operating device structure in some embodiments of this application;

[0052] Figure 12 This is a schematic diagram of the coating machine operating device structure in some other embodiments of this application;

[0053] Figure 13 This is a schematic diagram of the coating machine operating device structure in some embodiments of this application;

[0054] Figure 14 This is a schematic diagram of the coating machine operating device structure in some embodiments of this application;

[0055] Figure 15 This is a schematic diagram of the internal structure of a computer device in some embodiments of this application;

[0056] Figure 16 This is a schematic diagram of the coating machine structure in some embodiments of this application. Detailed Implementation

[0057] The embodiments of the technical solution of this application will now be described in detail with reference to the accompanying drawings. These embodiments are only used to more clearly illustrate the technical solution of this application and are therefore merely examples, and should not be used to limit the scope of protection of this application.

[0058] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains; the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the application; the terms “comprising” and “having”, and any variations thereof, in the specification, claims, and foregoing description of the drawings are intended to cover non-exclusive inclusion.

[0059] In the description of the embodiments of this application, technical terms such as "first" and "second" are used only to distinguish different objects and should not be construed as indicating or implying relative importance or implicitly specifying the number, specific order, or primary and secondary relationship of the indicated technical features. In the description of the embodiments of this application, "multiple" means two or more, unless otherwise explicitly defined.

[0060] In this document, the term "embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.

[0061] In the description of the embodiments in this application, the term "and / or" is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, and B existing alone. Additionally, the character " / " in this document generally indicates that the preceding and following related objects have an "or" relationship.

[0062] In the description of the embodiments of this application, the term "multiple" refers to two or more (including two), similarly, "multiple sets" refers to two or more (including two sets), and "multiple pieces" refers to two or more (including two pieces).

[0063] In the description of the embodiments of this application, unless otherwise expressly specified and limited, technical terms such as "installation," "connection," "joining," and "fixing" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. For those skilled in the art, the specific meaning of the above terms in the embodiments of this application can be understood according to the specific circumstances.

[0064] Currently, judging from market trends, the application of power batteries is becoming increasingly widespread. Power batteries are not only used in energy storage systems such as hydropower, thermal power, wind power, and solar power plants, but also extensively used in electric vehicles such as electric bicycles, electric motorcycles, and electric cars, as well as in military equipment and aerospace. With the continuous expansion of power battery applications, market demand is also constantly increasing.

[0065] Electrodes are essential components in power batteries. Power battery electrodes are generally made by coating a metal foil surface with electrode slurry using a coating machine. The coating machine uses magnetic powder tension control technology to control the tension.

[0066] However, in magnetic particle control technology, due to the unavoidable mechanical friction and starting tension during the operation of the coating machine, the coating machine cannot achieve zero tension or very low tension operation, which seriously affects the tension control accuracy of the coating machine.

[0067] To alleviate the problem of poor tension control accuracy in coating machines, research has shown that during machine operation, the rotation mode of the take-up and unwinding servo motors can be adjusted in real time based on the set tension value and the real-time roll diameter to meet tension requirements. Furthermore, by combining the tension setpoint and the sampled tension value, the output torque of the coating machine can be adjusted, resulting in a wider tension control range and thus achieving more precise tension control.

[0068] Based on the above considerations, this application provides a coating machine operation method, which can acquire the coating machine's tension setpoint, real-time roll diameter, and tension sampling value during the coating machine's operation. Then, by combining the tension setpoint and real-time roll diameter, the required rotation mode of the take-up and unwinding servo motor to meet the tension requirements is determined, thereby controlling the rotation of the take-up and unwinding servo motor. Finally, the output torque is adjusted based on the tension setpoint and tension sampling value.

[0069] The above solution allows for output torque adjustment by combining the tension setpoint and tension sampling value, while the winding and unwinding servo motors rotate to meet tension requirements. This results in a wider tension control range for the coating machine and significantly improves tension control accuracy.

[0070] The coating machine operation method provided in this application is applied to a coating machine. Specifically, it can be used in the electrode processing of power batteries, but it can also be used in the coating processes of other products, such as packaging material processing and electronic component manufacturing processes. No specific limitations are imposed. To facilitate understanding of the technical solution of this application, the following embodiments are all explained using the coating machine for the electrode processing of power batteries.

[0071] The coating machine includes a take-up roller, an unwind roller, a take-up servo motor, an unwind servo motor, and a magnetic powder tension control device. The take-up servo motor drives the take-up roller to rotate, and the unwind servo motor drives the unwind roller to rotate. The roll of material unwound by the unwind roller is coated and then wound up and collected at the take-up roller. After the coating machine switches its rotation direction, the take-up roller will perform the unwinding action, and the unwind roller will perform the take-up action.

[0072] Please see Figure 1 This application provides a method for operating a coating machine, including steps 102, 104 and 106.

[0073] Step 102: Obtain the tension setting value, real-time roll diameter, and tension sampling value of the coating machine.

[0074] Specifically, the tension setpoint is the tension value that the user sets and expects the coating machine to achieve during operation. The real-time roll diameter is the diameter (or outer diameter) of the roll material on the coating machine's take-up and untake-up components (e.g., take-up and untake-up rollers), which changes in real time as the coating machine operates. The tension sample value is the tension value obtained by sampling the actual tension of the roll material during the actual operation of the coating machine.

[0075] It should be noted that the method for setting the tension setting value is not unique. In one embodiment, the coating machine is equipped with a touch screen, and the user can input the tension setting value through the touch screen according to actual needs when using the coating machine. The method for obtaining the real-time roll diameter is not unique. In one embodiment, it can be obtained by a roll diameter acquisition device (e.g., a roll diameter sensor) and sent to the magnetic powder tension control device of the coating machine.

[0076] In another embodiment, the real-time roll diameter can also be calculated by a magnetic powder tension control device. In this embodiment, the magnetic powder tension control device includes a magnetic powder controller, an encoder, and a logic processor (which can be a programmable logic controller (PLC)). The encoder is connected to the shaft of the take-up / untake-up servo motor, and the logic processor is connected to both the magnetic powder controller and the encoder. During the operation of the coating machine, the traveling length of the coating machine is obtained through the encoder. Then, combined with the rotation angle of the take-up / untake-up servo motor, the corresponding roll diameter, i.e., the take-up / untake-up roll diameter, can be calculated using the arc length formula.

[0077] It is understood that the take-up and unwinding servo motors include a take-up servo motor and an unwinding servo motor. The real-time take-up diameter and the real-time unwinding diameter are calculated separately. The take-up servo motor and the unwinding servo motor are each equipped with an encoder. By collecting the travel length of the take-up component through the encoder, and combining it with the rotation angle of the take-up servo motor and the arc length formula, the real-time take-up diameter can be calculated. Similarly, by collecting the travel length of the unwinding component through the encoder, and combining it with the rotation angle of the unwinding servo motor and the arc length formula, the real-time unwinding diameter can be calculated.

[0078] The method for obtaining tension sampling values ​​is not unique. In one embodiment, a tension detector, such as a tension sensor, can be configured on the coating machine to obtain real-time tension sampling values. It should be noted that, in order to ensure that the real-time roll diameter corresponds to the tension sampling values, in one embodiment, the relevant parameters obtained with the roll diameter (which may be the roll diameter, travel length, or rotation angle) and the tension sampling values ​​will be configured to be sampled synchronously, thereby improving the accuracy of subsequent coating machine operation control.

[0079] It is understood that, in one embodiment, corresponding to the winding and unwinding of the coating machine, tension detectors can be set at locations near the winding component (winding roller) and near the unwinding component (unwinding roller) respectively, so as to obtain the winding tension sampling value and the unwinding tension sampling value, so as to realize the analysis and control of winding and unwinding respectively in the future.

[0080] Step 104: Based on the tension setting value and the real-time roll diameter, determine the required rotation mode of the take-up and unwinding servo motors to meet the tension requirements.

[0081] Specifically, the take-up and unwind servo motors meet the tension requirements, meaning that the coating machine operates with zero or very low tension through their rotation. The rotation modes of the take-up and unwind servo motors include forward rotation, reverse rotation, or stationary rotation. Forward rotation refers to rotation in the direction specified by the command signal (e.g., clockwise), while reverse rotation refers to rotation in the opposite direction (e.g., counterclockwise).

[0082] During the operation of the coating machine, the rotation direction of the take-up and unwind servo motor is adjustable in real time. Each time the magnetic powder tension control device obtains the real-time roll diameter, it will analyze it in conjunction with the tension set value. Based on the analysis results, it will adjust the rotation mode of the take-up and unwind servo motor, or control the take-up and unwind servo motor to maintain the current state of operation.

[0083] Step 106: With the take-up and untake-up servo motors operating in the desired rotation mode, adjust the output torque according to the tension set value and the tension sample value.

[0084] Specifically, after the unwinding and winding servo motors operate in the required rotation mode, in order to further improve the operational reliability of the coating machine and ensure that the actual tension value of the coating machine reaches the tension set value, feedback adjustment is required by combining the tension set value and the tension sampling value.

[0085] It should be noted that the method by which the magnetic powder tension control device adjusts the output torque based on the tension setpoint and the tension sample value is not unique. In one embodiment, closed-loop PID (Proportional Integral Derivative) regulation can be used. Further, in one embodiment, the magnetic powder tension control device includes a magnetic powder controller and a PLC. In this case, the PLC can acquire and analyze the combined tension setpoint and tension sample value, output an analog signal to the magnetic powder controller, and then output torque through the magnetic powder controller, thereby achieving the adjustment of the output torque. This allows for a wider tension control range and achieves precise tension control.

[0086] It is understood that, in one embodiment, the winding component and the unwinding component of the coating machine are respectively equipped with magnetic powder tension control devices. The magnetic powder tension control devices, in combination with the real-time roll diameter, tension sampling value and tension setting value corresponding to the winding component, can output the corresponding torque to the winding component; the magnetic powder tension control devices, in combination with the real-time roll diameter, tension sampling value and tension setting value corresponding to the unwinding component, can output the corresponding torque to the unwinding component.

[0087] The above-described coating machine operation method, during the coating machine's operation, combines the tension setpoint and real-time roll diameter to determine the required rotation mode of the take-up and unwinding servo motors to meet the tension demand. This control of the take-up and unwinding servo motors' rotation is then used to adjust the output torque based on the tension setpoint and sampled tension value. In this way, output torque adjustment can be performed while maintaining the rotation mode of the take-up and unwinding servo motors to meet the tension demand, resulting in high tension control accuracy.

[0088] Please see Figure 2 In some embodiments, step 104 includes steps 202 and 204.

[0089] Step 202: Determine the friction start torque based on the real-time roll diameter.

[0090] Step 204: Based on the friction start torque and tension setting value, determine the required rotation mode of the winding and unwinding servo motor to meet the tension requirements.

[0091] Specifically, the frictional starting torque is the starting torque generated by mechanical friction during the operation of the coating machine. In actual scenarios, the mechanical friction force changes with the roll diameter of the coating machine, and consequently, the frictional starting torque will also vary. Therefore, in this embodiment, when determining the rotation mode of the take-up and unwind servo motors, it is first necessary to determine the frictional starting torque based on the real-time roll diameter, and then determine the required rotation mode based on the frictional starting torque and the tension setpoint.

[0092] It should be noted that, in one embodiment, the friction starting torque differs for winding and unwinding. That is, even if the real-time winding diameter and the real-time unwinding diameter are the same, the friction starting torque for winding and the starting torque for unwinding may be different. Therefore, in practical scenarios, it is necessary to analyze and confirm the friction starting torque and the required rotation method for winding and unwinding separately.

[0093] Furthermore, in one embodiment, the coating machine operates in both forward and reverse directions. The frictional starting torques corresponding to the winding and unwinding of the coating machine differ between these two states. That is, for the same real-time winding diameter or the same real-time unwinding diameter, the corresponding frictional starting torques will be different in both forward and reverse directions. Therefore, in practical scenarios, it is first necessary to determine the rotation state of the coating machine, and then determine the rotation mode of the winding and unwinding servo motors based on the frictional starting torque corresponding to the real-time roll diameter under the current rotation state.

[0094] The above scheme determines the required rotation mode of the take-up and unwinding servo motor to meet tension requirements by using the corresponding frictional starting torque and tension setpoint under different real-time roll diameters. In this way, combined with the mechanical friction force during the coating machine's operation, the operation control of the coating machine is achieved, improving the operational reliability of the take-up and unwinding servo motor.

[0095] Please see Figure 3 In some embodiments, step 204 includes steps 302, 304, 306 and 308.

[0096] Step 302: Determine the mechanical friction force of the coating machine based on the friction start torque.

[0097] Step 304: When the tension setting value is greater than the mechanical friction force, determine whether the required rotation mode of the take-up and unwind servo motor to meet the tension requirement is reverse or stationary.

[0098] Step 306: When the tension setting value is equal to the mechanical friction force, determine that the required rotation mode of the take-up and unwind servo motor to meet the tension requirement is stationary.

[0099] Step 308: When the tension setting value is less than the mechanical friction force, determine that the required rotation mode of the take-up and unwind servo motor to meet the tension requirement is forward rotation.

[0100] Specifically, mechanical friction refers to the mechanical friction experienced by the coating machine during operation at the real-time roll diameter corresponding to the frictional starting torque. The frictional starting torque can be understood as the torque that resists rotation caused by friction when two objects rotate relative to each other through a contact surface. Its magnitude is related to the frictional force and the distance from the line of action of the force to the center of rotation (i.e., the lever arm). In the coating machine, the specific size of the lever arm can be measured and stored in the magnetic powder tension control device using a certain method, without being limited to a specific value. Therefore, after determining the frictional starting torque corresponding to the real-time roll diameter, the mechanical friction force can be further calculated.

[0101] Following this, the magnetic powder tension control device determines the required rotation mode of the take-up and unwinding servo motors to meet the tension requirements based on the relationship between the tension setpoint and the mechanical friction force. Specifically, when the tension setpoint is greater than the mechanical friction force, the take-up and unwinding servo motors rotate in reverse or remain stationary (generally in reverse, but this can be adjusted according to requirements); when the tension setpoint is equal to the mechanical friction force, the take-up and unwinding servo motors remain stationary; and when the tension setpoint is less than the mechanical friction force, the take-up and unwinding servo motors rotate in forward.

[0102] The above scheme controls the forward, reverse, and stationary rotation of the winding and unwinding servo motors according to the relationship between the mechanical friction force corresponding to the friction start torque and the winding tension setting value, effectively improving the operating accuracy of the winding and unwinding servo motors.

[0103] Please see Figure 4 In some embodiments, the real-time roll diameter includes the real-time take-up roll diameter and the real-time unwind roll diameter, the tension setting value includes the take-up tension setting value and the unwind tension setting value, the take-up and unwind servo motors include the take-up servo motor and the unwind servo motor, and the friction start torque includes the first friction start torque corresponding to the real-time take-up roll diameter and the second friction start torque corresponding to the real-time unwind roll diameter; step 204 includes steps 402 and 404.

[0104] Step 402: Based on the first friction start torque and the winding tension setting value, determine the required rotation mode of the winding servo motor to meet the tension requirements.

[0105] Step 404: Based on the second friction start torque and the unwinding tension setting value, determine the rotation mode required for the unwinding servo motor to meet the tension requirements.

[0106] Specifically, as shown in the above embodiment, during the operation of the coating machine, the winding and unwinding are controlled separately. Correspondingly, when confirming the required rotation mode of the winding and unwinding servo motors to meet the tension requirements, the required rotation modes of the winding servo motor and the unwinding servo motor need to be confirmed separately.

[0107] Specifically, in a real-world scenario, if the coating machine rotates forward, the take-up roller takes up the roll material, and the unwind roller unwinds it. Using the friction start torque confirmation method corresponding to forward rotation, the first friction start torque corresponding to the real-time take-up diameter of the take-up roller and the second friction start torque corresponding to the real-time unwind diameter of the unwind roller (obtained simultaneously with the real-time take-up diameter) are obtained. Then, combining the take-up tension setting and the first friction start torque, the required rotation mode of the take-up servo motor is confirmed; similarly, combining the unwind tension setting and the second friction start torque, the required rotation mode of the unwind servo motor is confirmed. In other words, when the coating machine is rotating forward, the required rotation modes of the take-up servo motor and the unwind servo motor are analyzed and determined separately.

[0108] When the coating machine reverses, the take-up roller unwinds the roll material, while the unwind roller winds it up. Using the friction start torque confirmation method corresponding to the reverse operation, the first friction start torque corresponding to the real-time take-up diameter of the take-up roller and the second friction start torque corresponding to the real-time unwind diameter of the unwind roller (obtained simultaneously with the real-time take-up diameter) are obtained. Then, by combining the take-up tension setting and the first friction start torque, the required rotation mode of the take-up servo motor is confirmed; similarly, by combining the unwind tension setting and the second friction start torque, the required rotation mode of the unwind servo motor is confirmed.

[0109] Furthermore, in this embodiment, the first mechanical friction force can be determined based on the first friction start torque whether the coating machine is rotating forward or reverse. If the winding tension setting is greater than the first mechanical friction force, the required rotation mode of the winding servo motor to meet the tension requirement is determined to be either reverse or stationary. If the winding tension setting is equal to the first mechanical friction force, the required rotation mode of the winding servo motor to meet the tension requirement is determined to be stationary. If the winding tension setting is less than the first mechanical friction force, the required rotation mode of the winding servo motor to meet the tension requirement is determined to be forward. Alternatively, the second mechanical friction force can be determined based on the second friction start torque. If the unwinding tension setting is greater than the second mechanical friction force, the required rotation mode of the unwinding servo motor to meet the tension requirement is determined to be either reverse or stationary. If the unwinding tension setting is equal to the second mechanical friction force, the required rotation mode of the unwinding servo motor to meet the tension requirement is determined to be stationary. If the unwinding tension setting is less than the second mechanical friction force, the required rotation mode of the unwinding servo motor to meet the tension requirement is determined to be forward.

[0110] In the above scheme, the winding and unwinding are driven by winding servo motors and unwinding servo motors, respectively. Correspondingly, the rotation mode of the winding servo motor and the unwinding servo motor is determined, which effectively improves the operational reliability of the winding servo motor and the unwinding servo motor.

[0111] Please see Figure 5 In some embodiments, the tension sampling values ​​include the winding tension sampling values ​​and the unwinding tension sampling values; step 106 includes steps 502 and 504.

[0112] Step 502: With the winding servo motor running in the desired rotation mode, adjust the winding output torque according to the winding tension set value and the winding tension sample value.

[0113] Step 504: With the unwinding servo motor running in the required rotation mode, adjust the unwinding output torque according to the unwinding tension set value and the unwinding tension sampled value.

[0114] Specifically, the winding output torque is the torque output by the magnetic powder tension control device to the winding component; more specifically, it can be the torque output by the magnetic powder controller of the magnetic powder tension control device to the winding roller. The unwinding output torque is also the torque output by the magnetic powder tension control device to the unwinding component; more specifically, it can be the torque output by the magnetic powder controller of the magnetic powder tension control device to the unwinding roller.

[0115] As shown in the above embodiment, winding and unwinding are controlled separately. Tension detectors, servo motors, and magnetic powder controllers are installed at both the winding and unwinding components. The PLC performs PID closed-loop regulation by combining the winding tension setpoint and the winding tension sampled value corresponding to the winding component, and outputs analog signals to the magnetic powder controller of the winding component to realize the winding output torque regulation. Similarly, the PLC performs PID closed-loop regulation by combining the unwinding tension setpoint and the unwinding tension sampled value corresponding to the unwinding component, and outputs analog signals to the magnetic powder controller of the unwinding component to realize the unwinding output torque regulation.

[0116] In the above scheme, the winding and unwinding of the coating machine are controlled by winding servo motors and unwinding servo motors, respectively. Correspondingly, the output torque of winding and unwinding is adjusted separately, which effectively improves the accuracy of the output torque of the coating machine.

[0117] Please see Figure 6 In some embodiments, step 202 includes step 602.

[0118] Step 602: Determine the friction starting torque based on the real-time roll diameter and the correspondence between roll diameter and starting torque.

[0119] Specifically, the relationship between roll diameter and starting torque characterizes the starting torque of the coating machine for different roll diameters. As shown in the above embodiment, the roll diameter includes the take-up roll diameter and the unwind roll diameter. The relationship between roll diameter and starting torque can include the starting torque corresponding to different take-up roll diameters and the starting torque corresponding to different unwind roll diameters.

[0120] Considering that the winding servo motor and the unwinding servo motor can operate in forward, reverse, and stationary modes, in one embodiment, the correspondence between the roll diameter and the starting torque may include: the starting torque corresponding to different winding roll diameters and the starting torque corresponding to different unwinding roll diameters in the three cases of forward, reverse, and stationary operation of the winding servo motor; and the starting torque corresponding to different winding roll diameters and the starting torque corresponding to different unwinding roll diameters in the three cases of forward, reverse, and stationary operation of the unwinding servo motor.

[0121] Furthermore, in one embodiment, the starting torque will differ when the coating machine rotates forward and reverse. The correspondence between roll diameter and starting torque may further include: the starting torque corresponding to different winding roll diameters and the starting torque corresponding to different unwinding roll diameters when the coating machine is rotating forward and the winding servo motor is rotating forward, reversing, and stationary; and the starting torque corresponding to different winding roll diameters and the starting torque corresponding to different unwinding roll diameters when the coating machine is rotating reverse and the unwinding servo motor is rotating forward, reversing, and stationary.

[0122] It should be noted that the relationship between roll diameter and starting torque is not stored in the magnetic powder tension control device in a unique way. It can be stored in the form of graphs, tables, databases, etc., and there is no specific limitation.

[0123] The above scheme, by combining the real-time roll diameter and the correspondence between roll diameter and starting torque, determines the friction starting torque corresponding to different real-time roll diameters, and has a high efficiency in determining the friction starting torque.

[0124] In some embodiments, the method for determining the correspondence between roll diameter and starting torque includes: when the coating machine is running in forward rotation for debugging, determining the first magnetic powder starting torque, the first motor starting torque, and the first friction starting torque corresponding to each roll diameter under different rotation states of the take-up and unwind servo motor; when the coating machine is running in reverse rotation for debugging, determining the second magnetic powder starting torque, the second motor starting torque, and the second friction starting torque corresponding to each roll diameter under different rotation states of the take-up and unwind servo motor; and determining the correspondence between roll diameter and starting torque based on the first magnetic powder starting torque, the first motor starting torque, the first friction starting torque, the second magnetic powder starting torque, the second motor starting torque, and the second friction starting torque.

[0125] Specifically, the forward rotation commissioning of the coating machine means that during the commissioning phase, the coating machine operates in a forward rotation manner; the reverse rotation commissioning of the coating machine means that during the commissioning phase, the coating machine operates in a reverse rotation manner. Forward rotation of the coating machine refers to the drive components moving the conveyor belt or coating rollers forward during the coating process, evenly applying the coating from front to back to form a uniform coating film. Reverse rotation of the coating machine refers to the coating process where the coating is applied from back to front, or the coating rollers, tilting frames, and other components move in the opposite direction.

[0126] The magnetic powder starting torque is the starting torque of the magnetic powder controller; the motor starting torque is the starting torque of the take-up and unwinding servo motors; and the friction starting torque is the starting torque caused by mechanical friction. In practical scenarios, the magnetic powder starting torque, motor starting torque, and friction starting torque can be further subdivided into the magnetic powder starting torque, motor starting torque, and friction starting torque corresponding to take-up, and the magnetic powder starting torque, motor starting torque, and friction starting torque corresponding to unwind.

[0127] When the coating machine is rotating forward, the take-up and unwind servo motors (including the take-up servo motor and the unwind servo motor, which can be collected separately) can be rotating forward, rotating backward, or stationary. When the take-up and unwind servo motors are rotating forward, the first magnetic powder starting torque, the first motor starting torque, and the first friction starting torque are obtained for different roll diameters. When the take-up and unwind servo motors are stationary, the first magnetic powder starting torque, the first motor starting torque, and the first friction starting torque are obtained for different roll diameters. And when the take-up and unwind servo motors are rotating backward, the first magnetic powder starting torque, the first motor starting torque, and the first friction starting torque are obtained for different roll diameters.

[0128] When the coating machine is in reverse, the take-up and unwind servo motor can also rotate forward, reverse, or stand still. When the take-up and unwind servo motor is rotating forward, the second magnetic powder starting torque, the second motor starting torque, and the second friction starting torque are obtained for different roll diameters. When the take-up and unwind servo motor is standing still, the second magnetic powder starting torque, the second motor starting torque, and the second friction starting torque are obtained for different roll diameters. And when the take-up and unwind servo motor is in reverse, the second magnetic powder starting torque, the second motor starting torque, and the second friction starting torque are obtained for different roll diameters.

[0129] Finally, by combining the acquired data, a correspondence between roll diameter and starting torque can be established. In this correspondence, given that the rotation mode of the coating machine and the rotation mode of the servo motor are determined, the magnetic powder starting torque, motor starting torque, and friction starting torque under different winding roll diameters can be obtained; and the magnetic powder starting torque, motor starting torque, and friction starting torque under different unwinding roll diameters can also be obtained.

[0130] In the above scheme, during the debugging phase, the coating machine is controlled to rotate forward and in reverse respectively. In order to obtain the magnetic powder starting torque, motor starting torque and friction starting torque corresponding to different rotation modes and different roll diameters of the winding and unwinding servo motor in the forward or reverse state, the precise correspondence between roll diameter and starting torque can be obtained.

[0131] In some embodiments, determining the first magnetic powder starting torque, the first motor starting torque, and the first friction starting torque corresponding to each roll diameter under different rotation states of the take-up and unwinding servo motor includes: acquiring the first adjustment tension sampling value of the take-up and unwinding servo motor under different rotation states and different roll diameters, as well as the first magnetic powder starting torque and the first motor starting torque, when the adjustment tension setting value is zero; and determining the corresponding first friction starting torque based on the first adjustment tension sampling value, the first magnetic powder starting torque, and the first motor starting torque.

[0132] Specifically, the tension setting value, also known as the debugging stage, refers to the tension value set for the coating machine; the tension sampling value, also known as the tension sampling value, is the tension value collected in real time during debugging operation. In actual scenarios, during the forward rotation debugging operation of the coating machine, the unwinding tension setting value is set to zero. At this time, the coating machine is controlled to simulate coating operation, which can be divided into forward rotation, reverse rotation, and stationary operation of the unwinding and take-up servo motors. The tension value obtained at this time can be converted through the relationship between tension and torque to obtain the comprehensive torque at this time, which is the torque caused by the magnetic powder starting torque, the motor starting torque, and the friction starting torque. The magnetic powder starting torque and the motor starting torque can be measured online. At this time, the friction starting torque is obtained by subtracting the magnetic powder starting torque and the motor starting torque from the comprehensive torque. Through this method, the magnetic powder starting torque, the motor starting torque, and the friction starting torque corresponding to different roll diameters under various rotation states of the unwinding and take-up servo motors can be analyzed.

[0133] It should be noted that during the actual debugging process, the winding and unwinding can be analyzed and calculated simultaneously at the same time. That is, based on the first debugging tension sampling value corresponding to winding, the magnetic powder starting torque, motor starting torque and friction starting torque under different winding diameters can be analyzed; based on the first debugging tension sampling value corresponding to unwinding, the magnetic powder starting torque, motor starting torque and friction starting torque under different unwinding diameters can be analyzed.

[0134] The above scheme controls the tension setting to zero when the coating machine is rotating forward, and collects the first adjustment tension sampling value of the take-up and untake-up servo motor under different rotation states and different roll diameters. Based on this, the first friction start torque corresponding to different rotation states and different roll diameters can be calculated. In this way, a high-precision first friction start torque can be obtained.

[0135] In some embodiments, determining the second magnetic powder starting torque, the second motor starting torque, and the second friction starting torque corresponding to each roll diameter under different rotation states of the take-up and unwinding servo motor includes: acquiring the second adjustment tension sampling value of the take-up and unwinding servo motor under different rotation states and different roll diameters, as well as the second magnetic powder starting torque and the second motor starting torque, when the tension setting value is zero; and determining the corresponding second friction starting torque based on the second adjustment tension sampling value, the second magnetic powder starting torque, and the second motor starting torque.

[0136] Specifically, similar to the method for determining the first friction starting torque mentioned above, when the coating machine is reversed, the magnetic powder starting torque, motor starting torque, and friction starting torque corresponding to different roll diameters can be analyzed under various rotation states of the take-up and untake-up servo motors, which will not be elaborated here.

[0137] The above scheme controls the tension setting to zero when the coating machine is in reverse, and collects the second adjustment tension sampling value of the take-up and untake-up servo motor under different rotation states and different roll diameters. Based on this, the second friction starting torque corresponding to different rotation states and different roll diameters can be calculated. In this way, a high-precision second friction starting torque can be obtained.

[0138] Please see Figure 7 In some embodiments, the coating machine operation method further includes steps 702, 704 and 706.

[0139] Step 702: Based on the tension sampling value and the real-time roll diameter, deduce the current starting torque.

[0140] Step 704: Determine the starting torque error based on the current starting torque, real-time roll diameter, and the correspondence between roll diameter and starting torque.

[0141] Step 706: If the starting torque error meets the alarm conditions, output an alarm message.

[0142] Specifically, during the normal operation of the coating machine, the same method as the above-described debugging process can be used to calculate the current starting torque corresponding to the real-time roll diameter. Then, using the calculated current starting torque, real-time roll diameter, and the correspondence between roll diameter and starting torque, the starting torque error is analyzed and calculated. If the starting torque error meets the alarm conditions, an alarm message is output, thus achieving operation monitoring of the coating machine. The method for calculating the current starting torque is similar to the method for obtaining each starting torque in the debugging state in the above embodiments, and will not be repeated here.

[0143] The above-mentioned solution can also monitor the coating machine during operation by back-calculating the current starting torque in real time. If there is a large error in the current starting torque, an alarm message will be output in a timely manner, which can effectively improve the operational reliability of the coating machine.

[0144] Please see Figure 8 In some embodiments, step 704 includes steps 802 and 804.

[0145] Step 802: Determine the theoretical starting torque based on the real-time roll diameter and the correspondence between roll diameter and starting torque.

[0146] Step 804: Determine the starting torque error based on the current starting torque and the theoretical starting torque.

[0147] Specifically, in this embodiment, the current starting torque, derived from the tension sampling value and real-time roll diameter, can include at least one of the current magnetic powder starting torque, the current motor starting torque, and the current friction starting torque. Similarly, the calculation of the current starting torque can be performed separately during winding and unwinding, which will not be elaborated further here.

[0148] The relationship between roll diameter and starting torque stores the correspondence between the coating machine's rotation mode, the rotation mode of the take-up and untake-up servo motors, the roll diameter, and the starting torque (including magnetic powder starting torque, motor starting torque, and friction starting torque). Therefore, when the rotation mode of the coating machine and the rotation mode of the take-up and untake-up servo motors are determined, the magnetic powder starting torque, motor starting torque, and friction starting torque can be obtained by matching different real-time roll diameters in this relationship, and used as the theoretical starting torque.

[0149] After that, the starting torque error is determined by combining the current starting torque and the theoretical starting torque. Specifically, the error analysis can be performed separately for the magnetic powder starting torque, the motor starting torque, and the friction starting torque, without any limitation here.

[0150] The above scheme determines the theoretical starting torque by using the real-time roll diameter and the correspondence between roll diameter and starting torque, and combines the theoretical starting torque with the current starting torque to determine the starting torque error, thereby improving the accuracy of the starting torque error.

[0151] The method for determining the starting torque error is not unique. In one embodiment, the difference between the current starting torque and the theoretical starting torque under the same roll diameter can be used as the starting torque error. In another embodiment, the starting torque error can be calculated by combining multiple roll diameters, the current starting torque, and the theoretical starting torque.

[0152] Please see Figure 9 In some embodiments, step 804 includes steps 902, 904, 906 and 908.

[0153] Step 902: Obtain the current starting torque and theoretical starting torque corresponding to at least two different roll diameters.

[0154] Step 904: Determine the first variable parameter based on the current starting torque and at least two roll diameters.

[0155] Step 906: Determine the second variation parameter based on the theoretical starting torque and at least two roll diameters.

[0156] Step 908: Determine the starting torque error based on the first and second changing parameters.

[0157] Specifically, the first variable parameter represents the amount by which the current starting torque changes with the roll diameter, and the second variable parameter represents the amount by which the theoretical starting torque changes with the roll diameter. The specific types of the first and second variable parameters are not unique. In one embodiment, the first variable parameter and the second variable parameter are respectively the increase magnitude of the current starting torque with the roll diameter and the increase magnitude of the theoretical starting torque with the roll diameter. For example, when the roll diameter increases by the same value, the increase magnitude of the current starting torque and the theoretical starting torque.

[0158] In another embodiment, the first variation parameter may also be the rate of change of the current starting torque following the roll diameter, and the second variation parameter may also be the rate of change of the theoretical starting torque following the roll diameter. For example, at least two sets of roll diameter, current starting torque and theoretical starting torque are selected, and the roll diameter is used as the abscissa, and the current starting torque and theoretical starting torque are used as the ordinates respectively to fit two straight lines, and the slopes of the two straight lines are used as the first variation parameter and the second variation parameter respectively.

[0159] Furthermore, the difference between the first and second changing parameters, or the ratio of the absolute value of the difference to the first changing parameter, or the ratio of the absolute value of the difference to the second changing parameter, can be used as the starting torque error. This error can be compared with the error thresholds pre-stored in the magnetic powder tension control device (different error thresholds are set for different starting torque errors). If the starting torque error is greater than the error threshold, it is considered that the starting torque error is too large.

[0160] The above scheme combines analysis of at least two roll diameters and their corresponding current starting torques to obtain a first variation parameter of the starting torque relative to the roll diameter, and combines analysis of at least two roll diameters and their corresponding theoretical starting torques to obtain a second variation parameter of the theoretical starting torque relative to the roll diameter. The starting torque error is then determined by the second variation parameter and the first variation parameter, reducing the influence of data measurement errors and further improving the accuracy of the starting torque error.

[0161] In some embodiments, the starting torque error includes at least one of friction starting torque error, motor starting torque error, and magnetic powder starting torque error.

[0162] Specifically, the starting torque can be at least one of the magnetic powder starting torque, the motor starting torque, and the friction starting torque. Correspondingly, the current starting torque can be at least one of the current magnetic powder starting torque, the current motor starting torque, and the current friction starting torque. The theoretical starting torque can be at least one of the theoretical magnetic powder starting torque, the theoretical motor starting torque, and the theoretical friction starting torque. By analyzing the three separately, the magnetic powder starting torque error, the motor starting torque error, and the friction starting torque error can be obtained respectively.

[0163] The above scheme allows the starting torque error to be at least one of friction starting torque error, motor starting torque error, and magnetic powder starting torque error. By using one or more of these errors, the operation monitoring of the coating machine can be achieved, thereby meeting different monitoring needs.

[0164] Please see Figure 10 In some embodiments, step 706 includes step 1002.

[0165] Step 1002: If at least one of the friction starting torque error, motor starting torque error, and magnetic powder starting torque error exceeds a preset error threshold, an alarm message is output.

[0166] Specifically, in the actual analysis process, at least one of the friction starting torque error, motor starting torque error, and magnetic powder starting torque error can be used to analyze whether the alarm condition is met. In the magnetic powder tension control device, corresponding error thresholds are set for the friction starting torque error, motor starting torque error, and magnetic powder starting torque error. These thresholds can be the same or not exactly the same. In a real-world scenario, as long as one of the starting torque errors is detected to be greater than its corresponding error threshold, the alarm condition is considered met.

[0167] The above scheme only requires that at least one of the friction starting torque error, motor starting torque error, and magnetic powder starting torque error is greater than a preset error threshold to be considered to meet the alarm conditions, thus having high alarm reliability.

[0168] In some embodiments, the coating machine operation method further includes: recording the operating parameters of the take-up servo motor and the unwind servo motor respectively during the operation of the coating machine; and changing the operating parameters of the take-up servo motor and the unwind servo motor upon receiving a switching command.

[0169] Specifically, the switching command is the command to switch the rotation mode of the coating machine. During coating machine operation—whether in debugging or normal operation—the operating parameters of the take-up servo motor and the unwind servo motor can be recorded in real time. If a switching command is received, the operating parameters of the take-up and unwind servo motors can be swapped. That is, the operating parameters of the take-up servo motor are configured for the unwind servo motor, and vice versa, thus achieving a one-button switching function for forward and reverse rotation.

[0170] The above solution allows the operating parameters of the winding servo motor and the unwinding servo motor to be recorded separately during the operation of the coating machine. When there is a switching requirement, the operating parameters of the two motors can be directly changed to achieve one-click switching between forward and reverse rotation, which has high operational convenience.

[0171] To facilitate understanding of the technical solution of this application, the following explanation is provided in conjunction with more detailed embodiments.

[0172] First, during the debugging phase, the coating machine is controlled to run in forward rotation. After startup, the real-time unwinding diameter is calculated using the rotation angle of the unwinding servo motor, the travel length of the coating machine recorded by the encoder, and the arc length formula. Similarly, the real-time winding diameter is calculated using the rotation angle of the winding servo motor, the travel length of the winding roller recorded by the encoder, and the arc length formula. Then, the debugging tension setting (which can be the tension setting corresponding to unwinding and / or winding) is set to zero. The unwinding and winding servo motors are operated in three states: forward rotation, reverse rotation, and stationary. The first debugging tension sampling value corresponding to different winding diameters and different unwinding diameters are acquired sequentially under these three states. Using the first debugging tension sampling value and its corresponding online measured first magnetic powder starting torque and first motor starting torque, the first friction starting torque corresponding to different winding diameters and different unwinding diameters under the three states of the unwinding and winding servo motors are analyzed.

[0173] During forward operation, the winding and unwinding parameters are recorded in real time. After forward debugging is completed, the coating machine is switched to reverse mode with one click. Following the same method as in the forward mode, the starting torques of the second magnetic powder, the second motor, and the second friction start torque are obtained for different winding diameters when the winding and unwinding servo motors are running in forward, reverse, and stationary states, respectively. Similarly, the starting torques of the second magnetic powder, the second motor, and the second friction start torque are obtained for different unwinding diameters. Finally, a correspondence between winding diameter and starting torque is established based on the data obtained above.

[0174] During normal operation, the coating machine can rotate forward or backward. Through human-machine interaction devices or interfaces such as touch screens, the winding tension setpoint and unwinding tension setpoint of the coating machine can be set respectively. This process adopts the same calculation method as the debugging stage to obtain the real-time winding diameter and real-time unwinding diameter. Tension sensors are used to collect the winding tension sampling value and unwinding tension sampling value in real time.

[0175] Based on the real-time winding diameter, the PLC can match the corresponding magnetic powder starting torque, motor starting torque, and friction starting torque according to the correspondence between winding diameter and starting torque. Combining the friction starting torque, the PLC can analyze and calculate the first mechanical friction force corresponding to the real-time winding diameter. Similarly, based on the real-time unwinding diameter, the PLC can match the corresponding magnetic powder starting torque, motor starting torque, and friction starting torque according to the correspondence between winding diameter and starting torque. Combining the friction starting torque, the PLC can analyze and calculate the second mechanical friction force corresponding to the real-time unwinding diameter.

[0176] The PLC compares and analyzes the winding tension setpoint and the first mechanical friction force. When the winding tension setpoint is greater than the first mechanical friction force, it controls the winding servo motor to reverse or stop; when the winding tension setpoint is equal to the first mechanical friction force, it controls the winding servo motor to stop; and when the winding tension setpoint is less than the first mechanical friction force, it controls the winding servo motor to rotate forward. Simultaneously, it compares and analyzes the unwinding tension setpoint and the second mechanical friction force. When the unwinding tension setpoint is greater than the second mechanical friction force, it controls the unwinding servo motor to reverse or stop; when the unwinding tension setpoint is equal to the second mechanical friction force, it controls the unwinding servo motor to stop; and when the unwinding tension setpoint is less than the second mechanical friction force, it controls the unwinding servo motor to rotate forward.

[0177] When the take-up and unwinding servo motors rotate in the corresponding manner, the PLC performs closed-loop PID calculation and adjustment based on the take-up tension sampling value and the take-up tension set value, and outputs an analog signal to the magnetic powder controller corresponding to the take-up servo motor to realize the adjustment of the take-up output torque; similarly, it performs closed-loop PID calculation and adjustment based on the unwinding tension sampling value and the unwinding tension set value, and outputs an analog signal to the magnetic powder controller corresponding to the unwinding servo motor to realize the adjustment of the unwinding output torque.

[0178] Furthermore, the PLC can combine the acquired real-time roll diameter and tension sampling values ​​to deduce the current starting torque corresponding to different roll diameters in the actual operating scenario, namely the magnetic powder starting torque (obtained online), the motor starting torque (obtained online), and the friction starting torque (determined by reverse calculation). The real-time roll diameter is matched against the corresponding relationship between roll diameter and starting torque to obtain the theoretical starting torque (which also includes magnetic powder starting torque, motor starting torque, and friction starting torque). For each type of starting torque, the PLC can establish a linear relationship between roll diameter and current starting torque, and a linear relationship between roll diameter and theoretical starting torque, with roll diameter as the horizontal axis and current starting torque and theoretical starting torque as the vertical axes. The slopes of these two linear relationships are used to calculate the error, resulting in the starting torque error (corresponding to friction starting torque error, motor starting torque error, and magnetic powder starting torque error). If at least one of the friction starting torque error, motor starting torque error, and magnetic powder starting torque error is detected to exceed a preset error threshold, an alarm message is output to remind the user to inspect and troubleshoot the cause of the fault.

[0179] It should be understood that although the steps in the flowcharts of the embodiments described above are shown sequentially according to the arrows, these steps are not necessarily executed in the order indicated by the arrows. Unless explicitly stated herein, there is no strict order restriction on the execution of these steps, and they can be executed in other orders. Moreover, at least some steps in the flowcharts of the embodiments described above may include multiple steps or multiple stages. These steps or stages are not necessarily completed at the same time, but can be executed at different times. The execution order of these steps or stages is not necessarily sequential, but can be performed alternately or in turn with other steps or at least some of the steps or stages of other steps.

[0180] Based on the same inventive concept, this application also provides a coating machine operating device for implementing the coating machine operating method described above. The solution provided by this device is similar to the solution described in the above method; therefore, the specific limitations in one or more embodiments of the coating machine operating device provided below can be found in the limitations of the coating machine operating method described above, and will not be repeated here.

[0181] Please see Figure 11 A coating machine operating device includes: a parameter acquisition module 112, a rotation analysis module 114, and a torque adjustment module 116.

[0182] The parameter acquisition module 112 is used to acquire the tension setting value, real-time roll diameter, and tension sampling value of the coating machine; the rotation analysis module 114 is used to determine the required rotation mode of the take-up and unwinding servo motor to meet the tension requirements based on the tension setting value and real-time roll diameter; the torque adjustment module 116 is used to adjust the output torque based on the tension setting value and tension sampling value when the take-up and unwinding servo motor is running in the required rotation mode.

[0183] In some embodiments, the rotation analysis module 114 is further configured to determine the friction start torque based on the real-time roll diameter; and to determine the required rotation mode of the take-up and unwinding servo motor to meet the tension requirements based on the friction start torque and the tension set value.

[0184] In some embodiments, the rotation analysis module 114 is further configured to determine the mechanical friction force of the coating machine based on the friction start torque; when the tension set value is greater than the mechanical friction force, determine whether the required rotation mode of the take-up and unwinding servo motor to meet the tension requirement is reverse rotation or stationary rotation; when the tension set value is equal to the mechanical friction force, determine whether the required rotation mode of the take-up and unwinding servo motor to meet the tension requirement is stationary rotation; and when the tension set value is less than the mechanical friction force, determine whether the required rotation mode of the take-up and unwinding servo motor to meet the tension requirement is forward rotation.

[0185] In some embodiments, the rotation analysis module 114 is further configured to determine the required rotation mode of the winding servo motor to meet the tension requirements based on the first friction start torque and the winding tension setting value; and to determine the required rotation mode of the unwinding servo motor to meet the tension requirements based on the second friction start torque and the unwinding tension setting value.

[0186] In some embodiments, the torque adjustment module 116 is further configured to adjust the winding output torque according to the winding tension setpoint and the winding tension sampled value when the winding servo motor is operating in the desired rotation mode; and to adjust the unwinding output torque according to the unwinding tension setpoint and the unwinding tension sampled value when the unwinding servo motor is operating in the desired rotation mode.

[0187] In some embodiments, the rotation analysis module 114 is further configured to determine the friction starting torque based on the real-time roll diameter and the correspondence between the roll diameter and the starting torque.

[0188] Please see Figure 12 In some embodiments, the coating machine operating device further includes a debugging module 122.

[0189] The debugging module 122 is used to determine the first magnetic powder starting torque, the first motor starting torque, and the first friction starting torque corresponding to each roll diameter under different rotation states of the winding and unwinding servo motors during forward rotation debugging operation of the coating machine; and to determine the second magnetic powder starting torque, the second motor starting torque, and the second friction starting torque corresponding to each roll diameter under different rotation states of the winding and unwinding servo motors during reverse rotation debugging operation of the coating machine; and to determine the correspondence between roll diameter and starting torque based on the first magnetic powder starting torque, the first motor starting torque, the first friction starting torque, the second magnetic powder starting torque, the second motor starting torque, and the second friction starting torque.

[0190] In some embodiments, the debugging module 122 is further configured to acquire, when the debugging tension setting value is zero, the first debugging tension sampling value of the winding and unwinding servo motor under different rotation states and different roll diameters, as well as the first magnetic powder starting torque and the first motor starting torque; and determine the corresponding first friction starting torque based on the first debugging tension sampling value, the first magnetic powder starting torque and the first motor starting torque.

[0191] In some embodiments, the debugging module 122 is further configured to acquire, when the tension setting value is zero, the second debugging tension sampling value of the winding and unwinding servo motor under different rotation states and different roll diameters, as well as the second magnetic powder starting torque and the second motor starting torque; and determine the corresponding second friction starting torque based on the second debugging tension sampling value, the second magnetic powder starting torque and the second motor starting torque.

[0192] Please see Figure 13In some embodiments, the coating machine operating device further includes a torque monitoring module 132.

[0193] The torque monitoring module 132 is used to infer the current starting torque based on the tension sampling value and the real-time roll diameter; to determine the starting torque error based on the current starting torque, the real-time roll diameter, and the correspondence between the roll diameter and the starting torque; and to output an alarm message when the starting torque error meets the alarm conditions.

[0194] In some embodiments, the torque monitoring module 132 is further configured to determine the theoretical starting torque based on the real-time roll diameter and the correspondence between the roll diameter and the starting torque; and to determine the starting torque error based on the current starting torque and the theoretical starting torque.

[0195] In some embodiments, the torque monitoring module 132 is further configured to acquire the current starting torque and the theoretical starting torque corresponding to at least two different roll diameters; determine a first variation parameter based on the current starting torque and at least two roll diameters; determine a second variation parameter based on the theoretical starting torque and at least two roll diameters; and determine the starting torque error based on the first variation parameter and the second variation parameter.

[0196] In some embodiments, the torque monitoring module 132 is further configured to output an alarm message when at least one of the friction starting torque error, motor starting torque error, and magnetic powder starting torque error is greater than a preset error threshold.

[0197] Please see Figure 14 In some embodiments, the coating machine operating device further includes a one-button switching module 142.

[0198] The one-click switching module 142 is used to record the operating parameters of the winding servo motor and the unwinding servo motor respectively during the operation of the coating machine; and to switch the operating parameters of the winding servo motor and the unwinding servo motor when a switching command is received.

[0199] Each module in the aforementioned coating machine operating device can be implemented entirely or partially through software, hardware, or a combination thereof. These modules can be embedded in the processor of a computer device in hardware form or independent of it, or stored in the memory of a computer device in software form, so that the processor can call and execute the operations corresponding to each module.

[0200] The aforementioned coating machine operating device can, during the coating machine's operation, combine the tension setpoint and real-time roll diameter to determine the required rotation mode of the take-up and unwinding servo motors to meet the tension demand. This control of the take-up and unwinding servo motors' rotation is then used to adjust the output torque based on the tension setpoint and sampled tension value. Thus, output torque adjustment can be performed while maintaining the rotation mode of the take-up and unwinding servo motors to meet the tension demand, resulting in high tension control accuracy.

[0201] In some embodiments, a computer device is provided, which may be a terminal, and its internal structure diagram may be as follows: Figure 15 As shown, the computer device includes a processor, memory, input / output interface, communication interface, display unit, and input device. The processor, memory, and input / output interface are connected via a system bus, and the communication interface, display unit, and input device are also connected to the system bus via the input / output interface. The processor provides computing and control capabilities. The memory includes non-volatile storage media and internal memory. The non-volatile storage media stores the operating system and computer programs. The internal memory provides an environment for the operation of the operating system and computer programs in the non-volatile storage media. The input / output interface is used for exchanging information between the processor and external devices. The communication interface is used for wired or wireless communication with external terminals; wireless communication can be achieved through Wi-Fi, mobile cellular networks, NFC (Near Field Communication), or other technologies. When the computer program is executed by the processor, it implements a coating machine operation method. The display unit is used to form a visually visible image and can be a display screen, projection device, or virtual reality imaging device. The display screen can be an LCD screen or an e-ink screen. The input device of the computer device can be a touch layer covering the display screen, or buttons, trackballs, or touchpads set on the casing of the computer device, or external keyboards, touchpads, or mice, etc.

[0202] Those skilled in the art will understand that Figure 15 The structure shown is merely a block diagram of a portion of the structure related to the present application and does not constitute a limitation on the computer device to which the present application is applied. Specific computer devices may include more or fewer components than those shown in the figure, or combine certain components, or have different component arrangements.

[0203] In some embodiments, a computer device is provided, including a memory and a processor, wherein the memory stores a computer program, and the processor executes the computer program to perform the following steps:

[0204] The system acquires the tension setpoint, real-time roll diameter, and tension sample value of the coating machine; based on the tension setpoint and real-time roll diameter, it determines the required rotation mode of the take-up and untake-up servo motors to meet the tension requirements; and when the take-up and untake-up servo motors are operating in the required rotation mode, it adjusts the output torque based on the tension setpoint and tension sample value.

[0205] In some embodiments, when the processor executes the computer program, it further implements the following steps: determining the friction start torque based on the real-time roll diameter; and determining the required rotation mode of the take-up and unwinding servo motor to meet the tension requirements based on the friction start torque and the tension setpoint.

[0206] In some embodiments, when the processor executes the computer program, it further performs the following steps: determining the mechanical friction force of the coating machine based on the friction start torque; when the tension setpoint is greater than the mechanical friction force, determining whether the required rotation mode of the take-up and unwinding servo motor to meet the tension requirement is reverse rotation or stationary rotation; when the tension setpoint is equal to the mechanical friction force, determining whether the required rotation mode of the take-up and unwinding servo motor to meet the tension requirement is stationary rotation; and when the tension setpoint is less than the mechanical friction force, determining whether the required rotation mode of the take-up and unwinding servo motor to meet the tension requirement is forward rotation.

[0207] In some embodiments, when the processor executes the computer program, it further implements the following steps: determining the required rotation mode of the winding servo motor to meet the tension requirement based on the first friction start torque and the winding tension setting value; and determining the required rotation mode of the unwinding servo motor to meet the tension requirement based on the second friction start torque and the unwinding tension setting value.

[0208] In some embodiments, when the processor executes the computer program, it further implements the following steps: when the take-up servo motor is operating in the desired rotation mode, adjusting the take-up output torque according to the take-up tension setpoint and the take-up tension sample value; when the unwinding servo motor is operating in the desired rotation mode, adjusting the unwinding output torque according to the unwinding tension setpoint and the unwinding tension sample value.

[0209] In some embodiments, when the processor executes the computer program, it further performs the following steps: determining the frictional starting torque based on the real-time roll diameter and the correspondence between the roll diameter and the starting torque.

[0210] In some embodiments, when the processor executes the computer program, it further implements the following steps: inferring the current starting torque based on the tension sampling value and the real-time roll diameter; determining the starting torque error based on the current starting torque, the real-time roll diameter, and the correspondence between the roll diameter and the starting torque; and outputting an alarm prompt message if the starting torque error meets the alarm conditions.

[0211] In some embodiments, when the processor executes the computer program, it further performs the following steps: determining the theoretical starting torque based on the real-time roll diameter and the correspondence between the roll diameter and the starting torque; and determining the starting torque error based on the current starting torque and the theoretical starting torque.

[0212] In some embodiments, when the processor executes the computer program, it further performs the following steps: obtaining the current starting torque and the theoretical starting torque corresponding to at least two different roll diameters; determining a first variation parameter based on the current starting torque and at least two roll diameters; determining a second variation parameter based on the theoretical starting torque and at least two roll diameters; and determining the starting torque error based on the first variation parameter and the second variation parameter.

[0213] In some embodiments, when the processor executes the computer program, it further implements the following steps: if at least one of the friction starting torque error, the motor starting torque error, and the magnetic powder starting torque error is greater than a preset error threshold, an alarm message is output.

[0214] In some embodiments, when the processor executes the computer program, it further performs the following steps: during the operation of the coating machine, recording the operating parameters of the take-up servo motor and the unwind servo motor respectively; and, upon receiving a switching instruction, changing the operating parameters of the take-up servo motor and the unwind servo motor.

[0215] In some embodiments, a computer-readable storage medium is provided having a computer program stored thereon, which, when executed by a processor, performs the following steps:

[0216] The system acquires the tension setpoint, real-time roll diameter, and tension sample value of the coating machine; based on the tension setpoint and real-time roll diameter, it determines the required rotation mode of the take-up and untake-up servo motors to meet the tension requirements; and when the take-up and untake-up servo motors are operating in the required rotation mode, it adjusts the output torque based on the tension setpoint and tension sample value.

[0217] In some embodiments, when the computer program is executed by the processor, it further implements the following steps: determining the friction start torque based on the real-time roll diameter; and determining the required rotation mode of the take-up and unwinding servo motor to meet the tension requirements based on the friction start torque and the tension setpoint.

[0218] In some embodiments, when the computer program is executed by the processor, it further performs the following steps: determining the mechanical friction force of the coating machine based on the friction start torque; when the tension setpoint is greater than the mechanical friction force, determining whether the required rotation mode of the take-up and unwinding servo motor to meet the tension requirement is reverse rotation or stationary rotation; when the tension setpoint is equal to the mechanical friction force, determining whether the required rotation mode of the take-up and unwinding servo motor to meet the tension requirement is stationary rotation; and when the tension setpoint is less than the mechanical friction force, determining whether the required rotation mode of the take-up and unwinding servo motor to meet the tension requirement is forward rotation.

[0219] In some embodiments, when the computer program is executed by the processor, it further implements the following steps: determining the required rotation mode of the winding servo motor to meet the tension requirement based on the first friction start torque and the winding tension setting value; and determining the required rotation mode of the unwinding servo motor to meet the tension requirement based on the second friction start torque and the unwinding tension setting value.

[0220] In some embodiments, when the computer program is executed by the processor, it further implements the following steps: when the take-up servo motor is operating in the desired rotation mode, adjusting the take-up output torque according to the take-up tension setpoint and the take-up tension sample value; when the unwinding servo motor is operating in the desired rotation mode, adjusting the unwinding output torque according to the unwinding tension setpoint and the unwinding tension sample value.

[0221] In some embodiments, when the computer program is executed by the processor, it further performs the following steps: determining the frictional starting torque based on the real-time roll diameter and the correspondence between the roll diameter and the starting torque.

[0222] In some embodiments, when the computer program is executed by the processor, it further implements the following steps: inferring the current starting torque based on the tension sampling value and the real-time roll diameter; determining the starting torque error based on the current starting torque, the real-time roll diameter, and the correspondence between the roll diameter and the starting torque; and outputting an alarm prompt message if the starting torque error meets the alarm conditions.

[0223] In some embodiments, when the computer program is executed by the processor, it further performs the following steps: determining the theoretical starting torque based on the real-time roll diameter and the correspondence between the roll diameter and the starting torque; and determining the starting torque error based on the current starting torque and the theoretical starting torque.

[0224] In some embodiments, when the computer program is executed by the processor, it further performs the following steps: obtaining the current starting torque and the theoretical starting torque corresponding to at least two different roll diameters; determining a first variation parameter based on the current starting torque and at least two roll diameters; determining a second variation parameter based on the theoretical starting torque and at least two roll diameters; and determining the starting torque error based on the first variation parameter and the second variation parameter.

[0225] In some embodiments, when the computer program is executed by the processor, it further implements the following steps: when at least one of the friction starting torque error, the motor starting torque error, and the magnetic powder starting torque error is greater than a preset error threshold, an alarm prompt message is output.

[0226] In some embodiments, when the computer program is executed by the processor, it further performs the following steps: during the operation of the coating machine, recording the operating parameters of the take-up servo motor and the unwind servo motor respectively; and, upon receiving a switching instruction, changing the operating parameters of the take-up servo motor and the unwind servo motor.

[0227] In some embodiments, a computer program product is provided, including a computer program that, when executed by a processor, performs the following steps:

[0228] The system acquires the tension setpoint, real-time roll diameter, and tension sample value of the coating machine; based on the tension setpoint and real-time roll diameter, it determines the required rotation mode of the take-up and untake-up servo motors to meet the tension requirements; and when the take-up and untake-up servo motors are operating in the required rotation mode, it adjusts the output torque based on the tension setpoint and tension sample value.

[0229] In some embodiments, when the computer program is executed by the processor, it further implements the following steps: determining the friction start torque based on the real-time roll diameter; and determining the required rotation mode of the take-up and unwinding servo motor to meet the tension requirements based on the friction start torque and the tension setpoint.

[0230] In some embodiments, when the computer program is executed by the processor, it further performs the following steps: determining the mechanical friction force of the coating machine based on the friction start torque; when the tension setpoint is greater than the mechanical friction force, determining whether the required rotation mode of the take-up and unwinding servo motor to meet the tension requirement is reverse rotation or stationary rotation; when the tension setpoint is equal to the mechanical friction force, determining whether the required rotation mode of the take-up and unwinding servo motor to meet the tension requirement is stationary rotation; and when the tension setpoint is less than the mechanical friction force, determining whether the required rotation mode of the take-up and unwinding servo motor to meet the tension requirement is forward rotation.

[0231] In some embodiments, when the computer program is executed by the processor, it further implements the following steps: determining the required rotation mode of the winding servo motor to meet the tension requirement based on the first friction start torque and the winding tension setting value; and determining the required rotation mode of the unwinding servo motor to meet the tension requirement based on the second friction start torque and the unwinding tension setting value.

[0232] In some embodiments, when the computer program is executed by the processor, it further implements the following steps: when the take-up servo motor is operating in the desired rotation mode, adjusting the take-up output torque according to the take-up tension setpoint and the take-up tension sample value; when the unwinding servo motor is operating in the desired rotation mode, adjusting the unwinding output torque according to the unwinding tension setpoint and the unwinding tension sample value.

[0233] In some embodiments, when the computer program is executed by the processor, it further performs the following steps: determining the frictional starting torque based on the real-time roll diameter and the correspondence between the roll diameter and the starting torque.

[0234] In some embodiments, when the computer program is executed by the processor, it further implements the following steps: inferring the current starting torque based on the tension sampling value and the real-time roll diameter; determining the starting torque error based on the current starting torque, the real-time roll diameter, and the correspondence between the roll diameter and the starting torque; and outputting an alarm prompt message if the starting torque error meets the alarm conditions.

[0235] In some embodiments, when the computer program is executed by the processor, it further performs the following steps: determining the theoretical starting torque based on the real-time roll diameter and the correspondence between the roll diameter and the starting torque; and determining the starting torque error based on the current starting torque and the theoretical starting torque.

[0236] In some embodiments, when the computer program is executed by the processor, it further performs the following steps: obtaining the current starting torque and the theoretical starting torque corresponding to at least two different roll diameters; determining a first variation parameter based on the current starting torque and at least two roll diameters; determining a second variation parameter based on the theoretical starting torque and at least two roll diameters; and determining the starting torque error based on the first variation parameter and the second variation parameter.

[0237] In some embodiments, when the computer program is executed by the processor, it further implements the following steps: when at least one of the friction starting torque error, the motor starting torque error, and the magnetic powder starting torque error is greater than a preset error threshold, an alarm prompt message is output.

[0238] In some embodiments, when the computer program is executed by the processor, it further performs the following steps: during the operation of the coating machine, recording the operating parameters of the take-up servo motor and the unwind servo motor respectively; and, upon receiving a switching instruction, changing the operating parameters of the take-up servo motor and the unwind servo motor.

[0239] The aforementioned computer equipment, storage media, and computer program products can, during the operation of the coating machine, determine the required rotation mode of the take-up and unwinding servo motors to meet the tension requirements by combining the tension setpoint and real-time roll diameter. This allows for control of the take-up and unwinding servo motors' rotation, and then adjustment of the output torque based on the tension setpoint and sampled tension value. Thus, output torque adjustment can be performed under the rotation mode of the take-up and unwinding servo motors to meet the tension requirements, resulting in high tension control accuracy.

[0240] Those skilled in the art will understand that all or part of the processes in the above embodiments can be implemented by a computer program instructing related hardware. The computer program can be stored in a non-volatile computer-readable storage medium. When executed, the computer program can include the processes of the embodiments described above. Any references to memory, databases, or other media used in the embodiments provided in this application can include at least one of non-volatile and volatile memory. Non-volatile memory can include read-only memory (ROM), magnetic tape, floppy disk, flash memory, optical memory, high-density embedded non-volatile memory, resistive random access memory (ReRAM), magnetic random access memory (MRAM), ferroelectric random access memory (FRAM), phase change memory (PCM), graphene memory, etc. Volatile memory can include random access memory (RAM) or external cache memory, etc. By way of illustration and not limitation, RAM can take many forms, such as Static Random Access Memory (SRAM) or Dynamic Random Access Memory (DRAM). The databases involved in the embodiments provided in this application may include at least one type of relational database and non-relational database. Non-relational databases may include, but are not limited to, blockchain-based distributed databases. The processors involved in the embodiments provided in this application may be general-purpose processors, central processing units, graphics processing units, digital signal processors, programmable logic devices, quantum computing-based data processing logic devices, etc., and are not limited to these.

[0241] Please see Figure 16 This application also provides a coating machine, including: a magnetic powder tension control device 165, a take-up servo motor 162, a take-up roller 161, an unwinding servo motor 164, and an unwinding roller 163. The take-up servo motor 162 is connected to the take-up roller 161, and the unwinding servo motor 164 is connected to the unwinding roller 163. The take-up servo motor 162 and the unwinding servo motor 164 are respectively connected to the magnetic powder tension control device 165. The magnetic powder tension control device 165 is used to execute the steps of the above-described coating machine operation method.

[0242] Specifically, the operation method of the coating machine is as shown in the above embodiments and accompanying drawings, and will not be repeated here. The magnetic powder tension control device 165 includes a magnetic powder controller, an encoder, and a logic processor (e.g., a PLC). The encoder is connected to the shaft of the take-up and untake-up servo motor, and the logic processor is connected to both the magnetic powder controller and the encoder. During the operation of the coating machine, the travel length is obtained through the encoder, and then, combined with the rotation angle of the take-up and untake-up servo motor, the corresponding roll diameter, i.e., the take-up and untake-up roll diameter, can be calculated using the arc length formula.

[0243] It should be noted that the take-up and unwinding servo motors include a take-up servo motor 162 and an unwinding servo motor 164. The real-time take-up diameter and the real-time unwinding diameter are calculated separately, and the take-up roller 161 and the unwinding roller 163 are controlled separately. Therefore, the take-up servo motor 162 and the unwinding servo motor 164 are respectively equipped with encoders and magnetic powder controllers.

[0244] Furthermore, in some embodiments, in order to acquire tension sampling values, a tension collector can be configured for the coating machine. Specifically, a tension collector is configured at the take-up roller 161 and the unwind roller 163 respectively to acquire unwinding tension sampling values ​​and take-up tension sampling values.

[0245] The aforementioned coating machine, during operation, can determine the required rotation mode of the take-up and unwinding servo motors to meet tension demands by combining the tension setpoint and real-time roll diameter. This control of the servo motor rotation allows for adjustment of the output torque based on the tension setpoint and sampled tension values. Thus, output torque adjustment is achieved under the correct rotation mode of the take-up and unwinding servo motors to meet tension requirements, resulting in high tension control accuracy.

[0246] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and not to limit them. Although this application 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 or all of the technical features therein. These modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this application, and they should all be covered within the scope of the claims and specification of this application. In particular, as long as there is no structural conflict, the various technical features mentioned in the embodiments can be combined in any way. This application is not limited to the specific embodiments disclosed herein, but includes all technical solutions falling within the scope of the claims.

Claims

1. A method for operating a coating machine, characterized in that, include: Obtain the tension setpoint, real-time roll diameter, and tension sample value of the coating machine; Based on the tension setting value and the real-time roll diameter, determine the required rotation mode of the take-up and unwinding servo motor to meet the tension requirements; When the take-up and untake-up servo motor is operating in the desired rotation mode, the output torque is adjusted according to the tension set value and the tension sample value.

2. The coating machine operation method according to claim 1, characterized in that, The step of determining the required rotation mode of the take-up and unwinding servo motor to meet the tension requirement based on the tension set value and the real-time roll diameter includes: The friction start torque is determined based on the real-time roll diameter; Based on the friction start torque and the tension setting value, determine the required rotation mode of the winding and unwinding servo motor to meet the tension requirements.

3. The coating machine operation method according to claim 2, characterized in that, The step of determining the required rotation mode of the take-up and unwinding servo motor to meet the tension requirement based on the friction start torque and the tension set value includes: The mechanical friction force of the coating machine is determined based on the friction start torque. When the tension setting value is greater than the mechanical friction force, it is determined that the required rotation mode for the take-up and unwind servo motor to meet the tension requirement is either reverse rotation or stationary. When the tension setting value is equal to the mechanical friction force, the required rotation mode for the take-up and unwind servo motor to meet the tension requirement is determined to be stationary; When the tension setting value is less than the mechanical friction force, the required rotation mode for the take-up and unwind servo motor to meet the tension requirement is determined to be forward rotation.

4. The coating machine operation method according to claim 2 or 3, characterized in that, The real-time roll diameter includes the real-time take-up roll diameter and the real-time unwind roll diameter; the tension setting value includes the take-up tension setting value and the unwind tension setting value; the take-up and unwind servo motors include the take-up servo motor and the unwind servo motor; and the friction start torque includes the first friction start torque corresponding to the real-time take-up roll diameter and the second friction start torque corresponding to the real-time unwind roll diameter. The step of determining the required rotation mode of the take-up and unwinding servo motor to meet the tension requirement based on the friction start torque and the tension set value includes: Based on the first friction start torque and the winding tension setting value, determine the required rotation mode of the winding servo motor to meet the tension requirements; Based on the second friction start torque and the unwinding tension setting value, determine the rotation mode required for the unwinding servo motor to meet the tension requirements.

5. The coating machine operation method according to claim 4, characterized in that, The tension sampling values ​​include the winding tension sampling values ​​and the unwinding tension sampling values; When the take-up / unwinding servo motor is operating in the desired rotation mode, adjusting the output torque according to the tension set value and the tension sample value includes: When the winding servo motor is operating in the desired rotation mode, the winding output torque is adjusted according to the winding tension set value and the winding tension sampled value; When the unwinding servo motor is operating in the desired rotation mode, the unwinding output torque is adjusted according to the unwinding tension set value and the unwinding tension sampled value.

6. The coating machine operation method according to any one of claims 2-5, characterized in that, The step of determining the friction starting torque based on the real-time roll diameter includes: The friction starting torque is determined based on the real-time roll diameter and the correspondence between roll diameter and starting torque.

7. The coating machine operation method according to claim 6, characterized in that, The method for determining the correspondence between the roll diameter and the starting torque includes: Under the condition of the coating machine rotating in the forward test run, determine the first magnetic powder starting torque, the first motor starting torque and the first friction starting torque corresponding to each roll diameter under different rotation states of the take-up and unwind servo motors; Under the condition of reverse debugging operation of the coating machine, determine the second magnetic powder starting torque, the second motor starting torque and the second friction starting torque corresponding to each roll diameter under different rotation states of the take-up and unwind servo motors. The correspondence between the roll diameter and the starting torque is determined based on the first magnetic powder starting torque, the first motor starting torque, the first friction starting torque, the second magnetic powder starting torque, the second motor starting torque, and the second friction starting torque.

8. The coating machine operation method according to claim 7, characterized in that, The determination of the first magnetic powder starting torque, the first motor starting torque, and the first friction starting torque corresponding to each roll diameter under different rotation states of the take-up and unwinding servo motor includes: With the tension setting set to zero, the first tension sampling value of the winding and unwinding servo motor under different rotation states and different roll diameters, as well as the first magnetic powder starting torque and the first motor starting torque, are obtained. The first friction starting torque is determined based on the first debugging tension sampling value, the first magnetic powder starting torque, and the first motor starting torque.

9. The coating machine operation method according to claim 7 or 8, characterized in that, The determination of the second magnetic powder starting torque, the second motor starting torque, and the second friction starting torque corresponding to each roll diameter under different rotation states of the take-up and unwinding servo motor includes: With the set tension value set to zero, the second set tension sampling value of the take-up and unwind servo motor under different rotation states and different roll diameters is obtained, as well as the second magnetic powder starting torque and the second motor starting torque; The corresponding second friction starting torque is determined based on the second debugging tension sampling value, the second magnetic powder starting torque, and the second motor starting torque.

10. The coating machine operation method according to any one of claims 1-9, characterized in that, Also includes: Based on the tension sampling value and the real-time roll diameter, the current starting torque is calculated backwards; The starting torque error is determined based on the current starting torque, the real-time roll diameter, and the correspondence between roll diameter and starting torque. If the starting torque error meets the alarm conditions, an alarm message will be output.

11. The coating machine operation method according to claim 10, characterized in that, The step of determining the starting torque error based on the current starting torque, the real-time roll diameter, and the correspondence between roll diameter and starting torque includes: Based on the real-time roll diameter and the correspondence between roll diameter and starting torque, the theoretical starting torque is determined; The starting torque error is determined based on the current starting torque and the theoretical starting torque.

12. The coating machine operation method according to claim 11, characterized in that, The step of determining the starting torque error based on the current starting torque and the theoretical starting torque includes: Obtain the current starting torque and theoretical starting torque for at least two different roll diameters; The first variable parameter is determined based on the current starting torque and at least two roll diameters; The second variation parameter is determined based on the theoretical starting torque and at least two roll diameters; The starting torque error is determined based on the first and second changing parameters.

13. The coating machine operation method according to any one of claims 10-12, characterized in that, The starting torque error includes at least one of friction starting torque error, motor starting torque error, and magnetic powder starting torque error.

14. The coating machine operation method according to claim 13, characterized in that, When the starting torque error meets the alarm conditions, an alarm prompt message is output, including: If at least one of the friction starting torque error, the motor starting torque error, and the magnetic powder starting torque error exceeds a preset error threshold, an alarm message will be output.

15. The coating machine operation method according to any one of claims 1-14, characterized in that, Also includes: During the operation of the coating machine, the operating parameters of the take-up servo motor and the unwind servo motor are recorded respectively; Upon receiving a switching command, the operating parameters of the take-up servo motor and the unwind servo motor are adjusted.

16. A coating machine operating device, characterized in that, include: The parameter acquisition module is used to acquire the tension setpoint, real-time roll diameter, and tension sample value of the coating machine; The rotation analysis module is used to determine the required rotation mode of the take-up and unwinding servo motor to meet the tension requirements based on the tension set value and the real-time roll diameter. The torque adjustment module is used to adjust the output torque according to the tension set value and the tension sample value when the take-up and unwind servo motor is running in the desired rotation mode.

17. A computer device comprising a memory and a processor, wherein the memory stores a computer program, characterized in that, When the processor executes the computer program, it implements the steps of the coating machine operation method according to any one of claims 1 to 15.

18. A computer-readable storage medium having a computer program stored thereon, characterized in that, When the computer program is executed by the processor, it implements the steps of the coating machine operation method according to any one of claims 1 to 15.

19. A computer program product, comprising a computer program, characterized in that, When executed by a processor, the computer program implements the steps of the coating machine operation method according to any one of claims 1 to 15.

20. A coating machine, characterized in that, include: The system comprises a magnetic powder tension control device, a take-up servo motor, a take-up roller, an unwinding servo motor, and an unwinding roller. The take-up servo motor is connected to the take-up roller, and the unwinding servo motor is connected to the unwinding roller. The take-up servo motor and the unwinding servo motor are respectively connected to the magnetic powder tension control device. The magnetic powder tension control device is used to perform the steps of the coating machine operation method according to any one of claims 1 to 15.

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