Intelligent discharging system for positive electrode foil of capacitor winding machine and control method

Abstract

The invention discloses an intelligent anode foil discharging system of a capacitor winding machine and a control method, and relates to the technical field of capacitor winding machines, the intelligent anode foil discharging system comprises a machine body, the front end of the machine body is rotatably connected with a discharging shaft, the outer surface of the discharging shaft is sleeved with an anode foil material roll, and the outer surface of the discharging shaft is provided with a speed encoder; a laser distance measuring sensor is arranged at the left end of the positive electrode foil material roll, a monitoring shaft is rotationally connected to the front end of the machine body, two fixing plates are fixedly connected to the outer surface of the monitoring shaft, and a tension roller is rotationally connected to the side, away from the monitoring shaft, between the two fixing plates. The rotational inertia is calculated, three working stages of starting, running and ending are identified, control instructions matched with the stages are output through the embedded microprocessor, the problems of foil loosening and deformation caused by rotating speed sudden change and inertia are avoided, material waste is reduced, and production continuity is guaranteed.

Description

Technical Field

[0001] This invention relates to the field of capacitor winding machine technology, specifically to an intelligent feeding system and control method for the positive electrode foil of a capacitor winding machine. Background Technology

[0002] A capacitor winding machine is a specialized piece of equipment used to wind electrode materials such as aluminum foil and electrolytic paper separators into capacitor cores. Its core function is to achieve efficient production of capacitors through precise tension control and winding processes. It is widely used in new energy, electronic components and other fields.

[0003] Traditional capacitor winding machines, when used with long rolls of positive electrode foil, often experience difficulties in braking due to inertia after startup. This results in continuous rotation, causing the foil to loosen and deform, rendering it unusable. This not only wastes materials but also disrupts the production process, reducing efficiency and product yield. Furthermore, the foil surface easily attracts dust during storage and handling. If it is wound directly without effective cleaning, contaminants can be drawn into the core package, creating internal micro-short circuits and reducing capacitor withstand voltage and lifespan. Existing dust removal devices, such as brushes or ionizers, offer limited dust removal and are prone to secondary pollution. Therefore, this paper proposes an intelligent positive electrode foil feeding system and control method for capacitor winding machines to address the aforementioned problems. Summary of the Invention

[0004] To address the aforementioned technical problems, this paper provides an intelligent feeding system and control method for positive electrode foil in capacitor winding machines. This solution solves the problem mentioned in the background section regarding the challenges faced by traditional capacitor winding machines with long positive electrode foil rolls. The inertia of the rolls after startup makes it difficult to brake in time, leading to continuous rotation, loosening and deformation of the positive electrode foil, ultimately rendering it unusable. This not only wastes materials but also interrupts the production process, reducing production efficiency and product qualification rate. Furthermore, the foil surface easily absorbs dust during storage and handling. If it is wound directly without effective cleaning, contaminants will be drawn into the core package, creating a potential internal micro-short circuit, reducing the capacitor's withstand voltage and lifespan. Existing dust removal devices are mostly single-point cleaning methods, such as brushes or ion bars, which have limited dust removal effects and are prone to causing secondary pollution.

[0005] To achieve the above objectives, the technical solution adopted by the present invention is as follows: A capacitor winding machine positive electrode foil intelligent feeding system includes a machine body, a feeding shaft rotatably connected to the front end of the machine body, a positive electrode foil roll sleeved on the outer surface of the feeding shaft, a speed encoder on the outer surface of the feeding shaft, a laser range sensor on the left end of the positive electrode foil roll, a monitoring shaft rotatably connected to the front end of the machine body, two fixing plates fixedly connected to the outer surface of the monitoring shaft, a tension roller rotatably connected between the two fixing plates on the side away from the monitoring shaft, an angle encoder on the outer surface of the tension roller, a through groove opened at the front end of the machine body, a connecting shaft slidably connected inside the groove, an adjusting roller rotatably connected to the outer surface of the connecting shaft, a composite dust removal component at the front end of the machine body, and a controller at the left end of the machine body. The composite dust removal assembly includes a dust removal box, with two rotating shafts rotatably connected between the inner walls of the front and rear sides of the dust removal box. Dust removal rollers are fixedly connected to the outer surfaces of the rotating shafts, and the outer surfaces of the dust removal rollers are covered with a nylon fleece layer. Electrostatic dust removal plates are fixedly connected to the inner walls of the front and rear sides of the dust removal box on the left side of the dust removal rollers. Dust collection hoods are fixedly connected to the bottom and top inner sides of the dust removal box.

[0006] Preferably, a drive motor is fixedly installed on the front inner wall of the machine body. The output end of the drive motor passes through the front inner wall of the machine body and is fixedly connected to the rear end of the feeding shaft. A limit plate is fixedly connected between the speed encoder and the positive electrode foil roll on the outer surface of the feeding shaft. An external thread is provided on the outer surface of the feeding shaft. A fastening plate is threaded to the outer surface of the feeding shaft through the external thread. The positive electrode foil roll is clamped between the limit plate and the fastening plate. A fixed seat is fixedly connected to the front end of the machine body on the left side of the positive electrode foil roll. A laser range sensor is set at the bottom inner side of the fixed seat. The measuring end of the laser range sensor is directly opposite the positive electrode foil roll.

[0007] Preferably, the rear end of the monitoring shaft passes through the front end of the machine body and is fixedly connected to a rotation damper. A torsion spring is fixedly connected to the inner wall of the front side of the machine body. The other end of the torsion spring is fixedly connected to the outer surface of the monitoring shaft. A support plate is fixedly connected to the inner wall of the front side of the machine body. A bearing is fixedly connected to the upper end of the support plate. The monitoring shaft passes through the inner side of the bearing.

[0008] Preferably, a fixed frame is fixedly connected to the rear end of the machine body, a ball screw is rotatably connected to the inner side of the fixed frame, a slide is threadedly connected to the outer surface of the ball screw, the front end of the slide is fixedly connected to the rear end of the connecting shaft, and a second drive motor for driving the ball screw to rotate is fixedly installed at the right end of the fixed frame.

[0009] Preferably, the dust collector has an outlet and an inlet through the left and right ends, respectively. A dust collection box is fixedly connected to the front end of the dust collector. The ends of the two dust collection hoods that are far apart from each other are connected to negative pressure pipes. The other ends of the two negative pressure pipes pass through the upper and lower ends of the dust collector and are connected to the upper end of the dust collection box.

[0010] Preferably, negative pressure fans are provided at both the left and right ends of the dust collection box, a partition is fixedly connected to the top of the inner side of the dust collection box, L-shaped screens are fixedly connected to the inner walls of both the left and right sides of the dust collection box, and a dust collection box is inserted into the front end of the dust collection box below the L-shaped screens.

[0011] Preferably, a guide roller 1 is provided above the laser ranging sensor, a guide roller 2 is provided to the right of the adjusting roller, a guide roller 4 and a guide roller 3 are provided on the left and right sides of the composite dust removal component, respectively, and a guide roller 5, a guide roller 6 and a guide roller 7 are provided above the composite dust removal component from left to right. The guide roller 5 and the guide roller 7 are located on the same horizontal line, and the height of the guide roller 6 is lower than the height of the guide roller 5 and the guide roller 7. A winding machine feed port is provided to the right of the guide roller 7. The guide roller 1, guide roller 2, guide roller 3, guide roller 4, guide roller 5, guide roller 6 and guide roller 7 are all rotatably connected to the front end of the machine body, and the winding machine feed port is fixedly connected to the front end of the machine body.

[0012] Preferably, one end of the positive electrode foil roll is fed into the winding machine feed port via guide roller 1, tension roller, adjusting roller, guide roller 2, guide roller 3, feed port, discharge port, guide roller 4, guide roller 5, guide roller 6 and guide roller 7 in sequence.

[0013] Preferably, the controller integrates an embedded microprocessor, which is electrically connected to a signal receiving module, a data processing module, and an instruction output module. The signal receiving module is electrically connected to a speed encoder, a laser rangefinder, and an angle encoder. The drive motor one, the rotary damper, the drive motor two, the electrostatic dust removal plate, and the negative pressure fan are all electrically connected to the instruction output module.

[0014] Furthermore, a smart feeding control method for the positive electrode foil of a capacitor winding machine is proposed to realize the feeding system as described above, including the following steps: S1. After the feeding system is started, the embedded microprocessor calls the preset parameter library to complete the initial configuration, calibrates the correspondence between the diameter, length and rotational inertia of the positive electrode foil roll, presets the tension threshold range adapted to production requirements, initializes the communication protocol of each module, and ensures smooth adaptation of each signal. S2. The signal receiving module collects high-frequency synchronous data, the laser rangefinder collects the instantaneous diameter data of the positive electrode foil roll, the speed encoder collects the actual rotation speed data of the feeding shaft, and the angle encoder converts the real-time tension value of the foil. The collected data is then transmitted to the embedded microprocessor. S3. The data processing module uses a moving average filtering algorithm to process the raw data, remove interference signals, and calculate the remaining length and moment of inertia of the current positive electrode foil roll based on the pre-processed diameter data. The system is identified as being in the start-up, operation or end-of-life stage based on the moment of inertia status. S4. The embedded microprocessor generates control commands based on the identified working stage and real-time acquired data. During the startup stage, the command output module sends a smooth acceleration curve command to the drive motor and an initial braking force command to the rotary damper to ensure that the feeding speed is synchronized with the winding machine's feeding speed. During operation, the command output module sends commands to the rotary damper to dynamically adjust the braking force of the rotary damper. At the same time, the drive motor drives the adjusting roller to slide along the slide groove to fine-tune the tension and maintain the tension within the preset threshold range. In the final stage, switch to a low-tension control mode with a stable speed, and simultaneously generate start and stop commands for the composite dust removal components. S5. The command output module sends the generated control commands to each actuator, drives the motor to adjust the output speed, and controls the feeding speed of the feeding shaft; A rotary damper, in conjunction with a torsion spring, maintains the force balance of the tension roller, while an adjusting roller compensates for tension fluctuations through positional offset. When the composite dust removal component is working, the electrostatic dust removal plate adsorbs dust, the negative pressure fan creates a negative pressure environment, and the dust is sucked into the dust collection box through the dust collection hood and negative pressure pipe. After being filtered by the L-shaped screen, the dust is collected in the dust collection box. S6. Real-time acquisition of feedback data from the actuator, comparison with the preset threshold, when the tension deviation exceeds the preset tension threshold range, only fine adjustment of the braking force of the rotary damper, and pull the tension back to the preset threshold range within the time of adapting to the production rhythm; if the speed deviation exceeds the set speed adaptation range, the speed of the drive motor and the braking force of the rotary damper are adjusted synchronously and the data is fed back to the embedded microprocessor to realize dynamic iterative optimization of algorithm parameters. S7. The embedded microprocessor monitors the device status in real time. If abnormal sensor data, abnormal tension, or loss of speed control occurs, the emergency mechanism is immediately triggered, a shutdown command is sent, and an alarm is triggered. S8. When the diameter of the foil detected by the laser rangefinder drops to near the diameter of the feeding shaft body, the instruction output module sends a stop command, all actuators stop working, the electrostatic dust removal plate is de-energized, and the feeding process is completed.

[0015] The beneficial effects of this invention compared to the prior art are: This solution adopts an integrated composite structure of physical dust removal, electrostatic dust removal, and negative pressure dust collection. Large dust particles are adsorbed by the nylon plush layer of the dust removal roller, fine dust particles are adsorbed by the electrostatic dust removal plate, and the negative pressure system collects the dust into the dust collection box, avoiding secondary pollution and effectively eliminating the risk of micro-short circuits caused by dust being drawn into the core package, thereby improving the voltage withstand performance and service life of the capacitor.

[0016] In this solution, the rotary damper dynamically adjusts the basic braking force according to the working stage, and the adjusting roller achieves precise position fine adjustment through ball screw transmission to compensate for tension fluctuations. In conjunction with the angle encoder, tension data is fed back in real time to form a closed-loop control, ensuring that the foil tension is always stable within the preset threshold range, avoiding excessive tension stretching or insufficient tension loosening, which helps to improve winding accuracy.

[0017] This solution uses a laser rangefinder to monitor the roll diameter in real time, calculate the moment of inertia, and identify the three working stages: start-up, operation, and termination. An embedded microprocessor outputs control commands adapted to each stage, avoiding sudden changes in rotational speed and problems such as foil loosening and deformation caused by inertia, reducing material waste, and ensuring production continuity. Attached Figure Description

[0018] Figure 1 This is a three-dimensional structural diagram of the present invention; Figure 2 This is a three-dimensional structural diagram of the present invention from another perspective; Figure 3 This is a schematic diagram of the connection of the fixing frame in this invention; Figure 4 for Figure 3 A magnified view of a portion of point A in the middle; Figure 5 for Figure 3 A magnified view of a portion of point B in the middle; Figure 6 This is a cross-sectional view of the present invention; Figure 7 for Figure 6 A magnified view of a portion of point C in the middle; Figure 8 This is a schematic diagram of the composite dust removal component in this invention; Figure 9 This is a schematic diagram of the dust collection box in this invention; Figure 10 This is a schematic diagram of the dust collection box in this invention; Figure 11 This is a schematic diagram of the controller in this invention; Figure 12 This is a block diagram illustrating the principle of the control method in this invention.

[0019] The numbers on the map are: 1. Machine body; 2. Drive motor one; 3. Feeding shaft; 4. Positive foil roll; 5. Speed ​​encoder; 6. Mounting base; 7. Laser rangefinder; 8. Monitoring shaft; 9. Mounting plate; 10. Tension roller; 11. Angle encoder; 12. Rotation damper; 13. Torsion spring; 14. Slide groove; 15. Mounting frame; 16. Drive motor two; 17. Ball screw; 18. Slide; 19. Connecting shaft; 20. Adjusting roller; 21. Composite dust removal assembly; 2101. Dust collector box; 2102. Feed inlet; 2103. Discharge outlet; 2104. Rotating shaft; 2105. Dust removal roller; 2106. Electrostatic dust removal plate; 2107. Dust collection hood; 2108. Negative pressure pipe; 2109. Dust collection box; 2110. Negative pressure fan; 2111. Partition plate; 2112. L-shaped screen; 2113. Dust collection box; 22. Winding machine feed port; 23. Controller; 24. Limit plate; 25. Fastening plate; 26. Support plate; 27. Bearing; 28. Guide roller one; 29. ​​Guide roller two; 30. Guide roller three; 31. Guide roller four; 32. Guide roller five; 33. Guide roller six; 34. Guide roller seven. Detailed Implementation

[0020] The following description is intended to disclose the invention and enable those skilled in the art to implement it. The preferred embodiments described below are merely examples, and other obvious variations will occur to those skilled in the art.

[0021] Reference Figure 1 , Figure 3 and Figure 6 As shown, an intelligent feeding system for positive electrode foil of a capacitor winding machine includes a machine body 1. A feeding shaft 3 is rotatably connected to the front end of the machine body 1. A positive electrode foil roll 4 is sleeved on the outer surface of the feeding shaft 3. A speed encoder 5 is installed on the outer surface of the feeding shaft 3. A drive motor 2 is fixedly installed on the front inner wall of the machine body 1. The output end of the drive motor 2 passes through the front inner wall of the machine body 1 and is fixedly connected to the rear end of the feeding shaft 3. A limit plate 24 is fixedly connected to the outer surface of the feeding shaft 3 between the speed encoder 5 and the positive electrode foil roll 4. The outer surface of the feeding shaft 3 is provided with an external thread, and the outer surface of the feeding shaft 3 is connected to the fastening plate 25 through the external thread. The positive electrode foil roll 4 is clamped between the limiting plate 24 and the fastening plate 25. A laser range sensor 7 is provided at the left end of the positive electrode foil roll 4. A fixing seat 6 is fixedly connected to the front end of the machine body 1 on the left side of the positive electrode foil roll 4. The laser range sensor 7 is located at the bottom inner side of the fixing seat 6. The measuring end of the laser range sensor 7 is directly opposite the positive electrode foil roll 4. A controller 23 is provided at the left end of the machine body 1.

[0022] Specifically, the feeding shaft 3 serves as the mounting carrier for the positive electrode foil roll 4. Its external thread engages with the fastening disc 25 to form a clamping structure. The limiting disc 24 is the fixed end. By rotating the fastening disc 25 and moving it along the external thread, the positive electrode foil roll 4 can be clamped between the two, preventing axial displacement or relative slippage of the roll during feeding and ensuring accurate foil conveying path. The drive motor 2 is a servo drive motor with adjustable speed, providing power for the rotation of the feeding shaft 3. It can achieve various operating modes such as smooth acceleration, stable speed, and smooth deceleration, avoiding sudden changes in feeding speed that could cause foil to stretch. Whether it stretches or loosens, the speed encoder 5 is fitted on the outer surface of the feeding shaft 3 to collect the actual rotational speed data of the feeding shaft 3 in real time. It can be combined with the diameter of the foil roll to calculate the actual feeding speed of the foil, providing feedback basis for speed closed-loop control and ensuring that the feeding speed matches the feeding speed of the winding machine. The laser range sensor 7 is used to collect the instantaneous diameter data of the foil roll in real time. As the foil is released, the diameter of the foil roll gradually decreases. The sensor captures the diameter change through the laser range principle, which can further calculate the remaining length and moment of inertia of the foil roll, providing the core basis for adjusting the control parameters at different working stages.

[0023] Reference Figures 1-7 As shown, a monitoring shaft 8 is rotatably connected to the front end of the machine body 1. Two fixing plates 9 are fixedly connected to the outer surface of the monitoring shaft 8. A tension roller 10 is rotatably connected between the two fixing plates 9 on the side away from the monitoring shaft 8. An angle encoder 11 is provided on the outer surface of the tension roller 10. A rotation damper 12 is fixedly connected to the rear end of the monitoring shaft 8 through the front end of the machine body 1. A torsion spring 13 is fixedly connected to the inner wall of the front side of the machine body 1. The other end of the torsion spring 13 is fixedly connected to the outer surface of the monitoring shaft 8. A support plate 26 is fixedly connected to the inner wall of the front side of the machine body 1. A bearing 27 is fixedly connected to the upper end of the support plate 26. The monitoring shaft 8 passes through the inner side of the bearing 27.

[0024] Specifically, the tension roller 10 is connected to the monitoring shaft 8 via the fixed plate 9. When the foil passes over the outer surface of the tension roller 10, it exerts pressure on the tension roller 10 and drives the monitoring shaft 8 to rotate, forming a tension and angle conversion structure. The greater the tension, the greater the rotation angle of the monitoring shaft 8, and vice versa. The angle encoder 11 collects the rotation data of the monitoring shaft 8 in real time, providing feedback signals for the tension closed-loop control. The torsion spring 13 is used to provide a reset spring force for the monitoring shaft 8, which can offset part of the foil tension and prevent the tension roller 10 from rotating excessively. The rotation damper 12 can adjust the braking force. By changing the damping magnitude, a reverse constraint tension is formed to achieve coarse tension adjustment and adapt to the basic tension requirements of different working stages. The support plate 26 and the bearing 27 cooperate to provide rotational support for the monitoring shaft 8, reduce the vibration of the monitoring shaft 8 during rotation, and ensure accurate angle acquisition.

[0025] Furthermore, a slide groove 14 is provided through the front end of the machine body 1. A connecting shaft 19 is slidably connected inside the slide groove 14. An adjusting roller 20 is rotatably connected to the outer surface of the connecting shaft 19. A fixed frame 15 is fixedly connected to the rear end of the machine body 1. A ball screw 17 is rotatably connected to the inner side of the fixed frame 15. A slide seat 18 is threadedly connected to the outer surface of the ball screw 17. The front end of the slide seat 18 is fixedly connected to the rear end of the connecting shaft 19. A drive motor 16 for driving the ball screw 17 to rotate is fixedly installed at the right end of the fixed frame 15.

[0026] Specifically, drive motor 16 drives ball screw 17 to rotate. Ball screw 17 drives slide block 18 to move along the screw axis through thread engagement, which in turn drives connecting shaft 19 and adjusting roller 20 to slide along groove 14. The position change of adjusting roller 20 can change the length of foil conveying path and realize tension fine adjustment. When the foil is loose, adjusting roller 20 can slide to the left to lengthen the conveying path and increase tension. When the tension is too large, sliding to the right can shorten the path and reduce tension. Groove 14 is used to provide sliding guide for adjusting roller 20.

[0027] Reference Figure 1 , Figure 8 , Figure 9 and Figure 10 As shown, a composite dust removal assembly 21 is provided at the front end of the machine body 1. The composite dust removal assembly 21 includes a dust removal box 2101. Two rotating shafts 2104 are rotatably connected between the inner walls of the front and rear sides of the dust removal box 2101. Dust removal rollers 2105 are fixedly connected to the outer surface of the rotating shafts 2104. The outer surface of the dust removal rollers 2105 is covered with a nylon fleece layer. Electrostatic dust removal plates 2106 are fixedly connected to the inner walls of the front and rear sides of the dust removal box 2101 on the left side of the dust removal rollers 2105. Dust collection hoods 2107 are fixedly connected to the bottom and top inner sides of the dust removal box 2101. The left and right ends of the dust removal box 2101 are respectively provided with a discharge port 2103 and an inlet port. The dust collection box 2109 is fixedly connected to the front end of the dust collection box 2101 and the material inlet 2102. The ends of the two dust collection hoods 2107 that are far apart from each other are connected to negative pressure pipes 2108. The other ends of the two negative pressure pipes 2108 pass through the upper and lower ends of the dust collection box 2101 and are connected to the upper end of the dust collection box 2109. Negative pressure fans 2110 are installed at both ends of the dust collection box 2109. A partition 2111 is fixedly connected to the top of the inner side of the dust collection box 2109. L-shaped screens 2112 are fixedly connected to the inner walls of the left and right sides of the dust collection box 2109. A dust collection box 2113 is inserted into the front end of the dust collection box 2109 below the L-shaped screen 2112.

[0028] Specifically, two dust removal rollers 2105 are symmetrically arranged vertically. When the foil passes between them, the nylon fleece layer on the outer surface adsorbs larger dust particles on the foil surface through contact friction, while loosening smaller dust particles. The dust removal rollers 2105 can rotate synchronously with the foil conveyor via the rotating shaft 2104, reducing frictional damage to the foil surface. The electrostatic dust removal plate 2106 generates an electrostatic field when energized. When the foil passes through the electrostatic field, the fine dust remaining on the surface is electrostatically adsorbed, achieving fine dust removal and compensating for the inadequacy of physical dust removal in removing fine dust. The power supply of the electrostatic dust removal plate 2106 is controlled by the controller 23, and the electrostatic intensity can be adjusted according to the foil cleaning requirements. After the negative pressure fan 2110 is started, a negative pressure is formed in the dust removal box 2101 and the dust collection box 2109. The dust collection hood 2107 is positioned to target the dust-generating area of ​​the dust removal roller 2105 and the electrostatic dust removal plate 2106. The detached dust is drawn into the dust collection box 2109 through the negative pressure pipe 2108, preventing secondary pollution from dust dispersion. The partition 2111 prevents the negative pressure airflow on the left and right sides from interfering with each other. The L-shaped screen 2112 filters the drawn-in dust, preventing fine dust from entering the negative pressure fan 2110 and causing damage. The filtered dust falls into the dust collection box 2113. The dust collection box 2113 adopts a plug-in design, which is convenient for regular removal and cleaning, and easy maintenance. The inlet 2102 and outlet 2103 of the dust collection box 2101 are foil material inlet and outlet channels. The channel size is adapted to the width of common positive electrode foil, ensuring smooth passage of foil material while reducing negative pressure leakage and ensuring dust removal effect.

[0029] Reference Figure 1 As shown, a guide roller 28 is positioned above the laser rangefinder 7, and a guide roller 29 is positioned to the right of the adjusting roller 20. Guide rollers 31 and 30 are positioned on the left and right sides of the composite dust removal assembly 21, respectively. From left to right, guide rollers 32, 33, and 34 are positioned above the composite dust removal assembly 21. Guide rollers 32 and 34 are on the same horizontal line, and guide roller 33 is positioned below guide rollers 32 and 34. A winding machine feed port 2 is positioned to the right of guide roller 34. 2. Guide roller 1 28, guide roller 29, guide roller 30, guide roller 4 31, guide roller 5 32, guide roller 6 33 and guide roller 7 34 are all rotatably connected to the front end of the machine body 1. The feed port 22 of the winding machine is fixedly connected to the front end of the machine body 1. One end of the positive electrode foil roll 4 is fed into the feed port 22 of the winding machine in sequence through guide roller 1 28, tension roller 10, adjusting roller 20, guide roller 29, guide roller 30, feed port 2102, discharge port 2103, guide roller 4 31, guide roller 5 32, guide roller 6 33 and guide roller 7 34.

[0030] Specifically, each guide roller is rotatably connected to the front end of the machine body 1 and can rotate synchronously with the foil material conveying to reduce conveying resistance. Guide roller 1 28 guides the foil material to accurately wind around the tension roller 10 after being output from the roll. Guide roller 2 29 and guide roller 3 30 connect the adjusting roller 20 and the feed inlet 2102 of the dust removal box 2101 to ensure that the foil material enters the composite dust removal component 21 smoothly. Guide roller 4 31 guides the dust-removed foil material to wind around the subsequent guide roller group. Guide roller 5 32, guide roller 6 33 and guide roller 7 34 adopt a staggered layout of two flat and one flat, which can further tighten the foil material, eliminate wrinkles that may be generated during the conveying process, and ensure that the foil material is fed flat into the winding machine feed inlet 22. The winding machine feed inlet 22 is the connecting component between the system and the winding machine. Its feed inlet diameter is adapted to the foil material width and can perform final positioning of the foil material to ensure that the foil material enters the winding station of the winding machine accurately and ensures the winding quality.

[0031] Reference Figure 11 As shown, the controller 23 integrates an embedded microprocessor, which is electrically connected to a signal receiving module, a data processing module, and an instruction output module. The signal receiving module is electrically connected to the speed encoder 5, the laser rangefinder 7, and the angle encoder 11. The instruction output module is electrically connected to the electrostatic dust removal plate 2106, the drive motor 2, the rotary damper 12, the drive motor 16, and the negative pressure fan 2110.

[0032] Specifically, the embedded microprocessor integrates a preset parameter library and dynamic control algorithm, which can automatically match control parameters according to different foil specifications and production requirements to achieve personalized feeding control. The signal receiving module is responsible for high-frequency synchronous acquisition of data from various sensors and transmitting the data to the embedded microprocessor, ensuring the real-time and synchronous nature of data acquisition and providing data support for decision-making. The data processing module uses a moving average filtering algorithm to filter the raw data, eliminating signal fluctuations caused by mechanical vibration and environmental interference, improving data accuracy. At the same time, it completes the calculation of derived parameters based on the processed data, such as based on the diameter. The remaining length and moment of inertia are calculated from the data. The tension value is converted based on the rotation data, and the system working stage is identified. The instruction output module issues precise control instructions to each actuator based on the decision results of the embedded microprocessor to achieve coordinated control. For example, the speed adjustment instruction is issued to drive motor 12, the braking force adjustment instruction is issued to the rotary damper 12, the position adjustment instruction is issued to drive motor 26, the power supply instruction is issued to the electrostatic dust removal plate 2106, and the start and stop instruction is issued to the negative pressure fan 2110. At this time, by receiving feedback data from the actuators, a closed-loop control can be formed to ensure accurate control effect.

[0033] It should be noted that the working phase is divided into the start-up phase, the running phase, and the finishing phase, which correspond to the initial state of rotational inertia, the dynamic change of rotational inertia, and the rotational inertia approaching the body of the feeding shaft 3, respectively.

[0034] Reference Figures 1-12 As shown, a method for intelligent feeding control of positive electrode foil in a capacitor winding machine, used to implement the feeding system as described above, includes the following steps: S1. After the feeding system is started, the embedded microprocessor calls the preset parameter library to complete the initial configuration. Based on the foil thickness, density and the body parameters of the feeding shaft of the positive electrode foil roll, the corresponding relationship between the diameter, length and moment of inertia of the positive electrode foil roll is calibrated. According to the foil material and width, the tension threshold range adapted to the production requirements is preset to avoid the foil stretching or loosening. The feeding speed is set to match the feeding speed of the winding machine feed port. At the same time, the communication protocol of the signal receiving module, data processing module and instruction output module is initialized to ensure smooth signal adaptation between each module and each sensor and actuator. S2. The signal receiving module performs high-frequency synchronous acquisition of multi-source sensor data. The laser rangefinder acquires the instantaneous diameter data of the positive electrode foil roll, the speed encoder acquires the actual rotation speed data of the feeding shaft, and the angle encoder acquires the rotation data of the monitoring shaft and converts it into the real-time tension value of the foil. All acquired data are transmitted to the embedded microprocessor through wires. S3. The data processing module uses a moving average filtering algorithm to filter the collected raw data, eliminating signal fluctuations caused by mechanical vibration and environmental interference, ensuring the accuracy of diameter measurement. Based on the pre-processed diameter data, it calculates the remaining length and moment of inertia of the current positive electrode foil roll. According to the dynamic state of the moment of inertia, it determines the working stage of the system. When the moment of inertia is in the initial state of adapting to the long foil feeding, it is the start-up stage. When the moment of inertia is in the intermediate state of continuous dynamic change with the release of the foil, it is the running stage. When the moment of inertia decays to a low level close to the feeding shaft body, it is the finishing stage. S4. The embedded microprocessor generates control commands through dynamic algorithms based on the identified working stage and real-time collected data. During the start-up stage, the rotational inertia is in the initial state. The command output module sends a smooth acceleration curve command to the drive motor to avoid inertial overshoot of the feeding shaft. At the same time, it sends an initial braking force command to the rotary damper that is adapted to the rotational inertia of the initial stage. The tension roller forms a reverse constraint to ensure that the feeding speed is synchronized with the winding machine feeding speed. During operation, the moment of inertia changes continuously and dynamically, and the control parameters are updated dynamically. The braking force of the rotary damper is gradually adjusted according to the diameter reduction. At the same time, the ball screw is driven by the second drive motor to rotate, which drives the slide, connecting shaft and adjusting roller to slide along the slide groove, finely adjusting the tension of the foil conveying path and maintaining the real-time tension within the preset threshold range. During the final stage, the moment of inertia is at a low level. Switch to a low-tension, stable-speed control mode to reduce the starting torque fluctuation of the drive motor. At the same time, adjust the braking force of the rotary damper to match the moment of inertia during the final stage to avoid sudden changes in speed due to insufficient foil material. Simultaneously, generate power supply commands for the electrostatic dust removal plate and start / stop commands for the negative pressure fan to ensure continuous dust removal during foil material conveying. S5. The command output module sends the generated control commands to each actuator to realize the coordinated action of each component. The drive motor adjusts the output speed according to the acceleration curve or the steady speed command to accurately control the feeding speed of the feeding shaft. The rotary damper adjusts the braking force according to the tension command, and works in conjunction with the reset action of the torsion spring to maintain the force balance of the tension roller; the drive motor 2 adjusts the rotation direction and angle of the ball screw according to the tension deviation, and compensates for tension fluctuations by adjusting the position offset of the roller. When the composite dust removal component is working, the electrostatic dust removal plate generates static electricity to adsorb dust on the surface of the foil. The negative pressure fan starts to create a negative pressure environment, and the dust is sucked into the dust collection box through the dust collection hood and negative pressure pipe. After being filtered by the L-shaped screen, it is collected in the dust collection box. S6. Real-time acquisition of feedback data from the actuator, including the actual speed of the drive motor and the real-time tension feedback from the angle encoder. The feedback data is compared with the preset threshold. When the tension deviation exceeds the preset tension threshold range and the foil shows a loosening or stretching trend, the braking force of the rotary damper is only slightly adjusted to pull the tension back to the preset threshold range within a time that matches the production rhythm. If the speed deviation exceeds the set speed adaptation range, and the feeding speed and the unloading speed are mismatched, the speed of the drive motor and the braking force of the rotary damper will be adjusted synchronously to ensure that the two quickly return to the matching state. The deviation correction command is fed back to the embedded microprocessor through the data processing module to realize the dynamic iterative optimization of the algorithm parameters. S7. The embedded microprocessor monitors sensor data and the working status of the actuator in real time. If abnormal situations occur, such as sudden changes or no change in laser range sensor data, sudden drop in tension from angle encoder to zero (i.e., foil breakage or tension exceeding the safety threshold), or loss of speed control from speed encoder feedback, the emergency mechanism is immediately triggered. The command output module sends a stop command to all drive motors and rotary dampers to prevent the equipment from running idle or further damage to the foil. The controller triggers an alarm prompt through an external alarm device. S8. When the laser rangefinder detects that the diameter of the positive electrode foil roll is close to the diameter of the feeding shaft body, that is, when the foil is completely fed, the instruction output module sends a stop instruction. Drive motor 1, drive motor 2, rotary damper, and negative pressure fan all stop working, the electrostatic dust removal plate is de-energized, and a complete feeding process is completed.

[0035] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the claimed invention. The scope of protection claimed by the appended claims and their equivalents is defined.

Claims

1. An intelligent feeding system for the positive electrode foil of a capacitor winding machine, characterized in that, The machine includes a body (1), a feeding shaft (3) is rotatably connected to the front end of the body (1), a positive electrode foil roll (4) is sleeved on the outer surface of the feeding shaft (3), a speed encoder (5) is provided on the outer surface of the feeding shaft (3), a laser range sensor (7) is provided on the left end of the positive electrode foil roll (4), a monitoring shaft (8) is rotatably connected to the front end of the body (1), two fixing plates (9) are fixedly connected to the outer surface of the monitoring shaft (8), a tension roller (10) is rotatably connected between the two fixing plates (9) on the side away from the monitoring shaft (8), an angle encoder (11) is provided on the outer surface of the tension roller (10), a sliding groove (14) is opened through the front end of the body (1), a connecting shaft (19) is slidably connected inside the sliding groove (14), an adjusting roller (20) is rotatably connected to the outer surface of the connecting shaft (19), a composite dust removal component (21) is provided at the front end of the body (1), and a controller (23) is provided on the left end of the body (1). The composite dust removal assembly (21) includes a dust removal box (2101). Two rotating shafts (2104) are rotatably connected between the inner walls of the front and rear sides of the dust removal box (2101). A dust removal roller (2105) is fixedly connected to the outer surface of the rotating shaft (2104). The outer surface of the dust removal roller (2105) is covered with a nylon fleece layer. An electrostatic dust removal plate (2106) is fixedly connected to the inner walls of the front and rear sides of the dust removal box (2101) on the left side of the dust removal roller (2105). A dust collection hood (2107) is fixedly connected to the bottom and top of the inner side of the dust removal box (2101).

2. The intelligent feeding system for positive electrode foil of a capacitor winding machine according to claim 1, characterized in that: A drive motor (2) is fixedly installed on the front inner wall of the machine body (1). The output end of the drive motor (2) passes through the front inner wall of the machine body (1) and is fixedly connected to the rear end of the feeding shaft (3). The outer surface of the feeding shaft (3) is fixedly connected to the limit plate (24) between the speed encoder (5) and the positive foil roll (4). The outer surface of the feeding shaft (3) is provided with an external thread. The outer surface of the feeding shaft (3) is connected to the fastening plate (25) through the external thread. The positive foil roll (4) is clamped between the limit plate (24) and the fastening plate (25). The front end of the machine body (1) is fixedly connected to the left side of the positive foil roll (4) with a fixed seat (6). The laser range sensor (7) is set at the inner bottom of the fixed seat (6). The measuring end of the laser range sensor (7) is directly opposite to the positive foil roll (4).

3. The intelligent feeding system for positive electrode foil of a capacitor winding machine according to claim 1, characterized in that: The rear end of the monitoring shaft (8) passes through the front end of the body (1) and is fixedly connected to a rotation damper (12). A torsion spring (13) is fixedly connected to the inner wall of the front side of the body (1). The other end of the torsion spring (13) is fixedly connected to the outer surface of the monitoring shaft (8). A support plate (26) is fixedly connected to the inner wall of the front side of the body (1). A bearing (27) is fixedly connected to the upper end of the support plate (26). The monitoring shaft (8) passes through the inner side of the bearing (27).

4. The intelligent feeding system for positive electrode foil of a capacitor winding machine according to claim 1, characterized in that: The rear end of the body (1) is fixedly connected to a fixed frame (15), the inner side of the fixed frame (15) is rotatably connected to a ball screw (17), the outer surface of the ball screw (17) is threadedly connected to a slide (18), the front end of the slide (18) is fixedly connected to the rear end of the connecting shaft (19), and the right end of the fixed frame (15) is fixedly installed with a second drive motor (16) for driving the ball screw (17) to rotate.

5. The intelligent feeding system for positive electrode foil of a capacitor winding machine according to claim 1, characterized in that: The dust collector (2101) has an outlet (2103) and an inlet (2102) through its left and right ends, respectively. A dust collection box (2109) is fixedly connected to the front end of the dust collector (2101). The ends of the two dust collection hoods (2107) that are far apart from each other are connected to negative pressure pipes (2108). The other ends of the two negative pressure pipes (2108) pass through the upper and lower ends of the dust collector (2101) and are connected to the upper end of the dust collection box (2109).

6. The intelligent feeding system for positive electrode foil of a capacitor winding machine according to claim 5, characterized in that: Negative pressure fans (2110) are provided at both the left and right ends of the dust collection box (2109). A partition (2111) is fixedly connected to the top inner side of the dust collection box (2109). L-shaped screens (2112) are fixedly connected to the inner walls of both the left and right sides of the dust collection box (2109). A dust collection box (2113) is inserted into the front end of the dust collection box (2109) below the L-shaped screen (2112).

7. The intelligent feeding system for positive electrode foil of a capacitor winding machine according to claim 1, characterized in that: A guide roller 1 (28) is provided above the laser rangefinder (7), a guide roller 2 (29) is provided to the right of the adjusting roller (20), a guide roller 4 (31) and a guide roller 3 (30) are provided on the left and right sides of the composite dust removal assembly (21) respectively, and a guide roller 5 (32), a guide roller 6 (33) and a guide roller 7 (34) are provided above the composite dust removal assembly (21) from left to right. The guide roller 5 (32) and the guide roller 7 (34) are located on the same horizontal line. The height of guide roller six (33) is lower than that of guide roller five (32) and guide roller seven (34). A winding machine feed port (22) is provided on the right side of guide roller seven (34). Guide roller one (28), guide roller two (29), guide roller three (30), guide roller four (31), guide roller five (32), guide roller six (33) and guide roller seven (34) are all rotatably connected to the front end of the machine body (1). The winding machine feed port (22) is fixedly connected to the front end of the machine body (1).

8. The intelligent feeding system for positive electrode foil of a capacitor winding machine according to claim 1, characterized in that: One end of the positive electrode foil roll (4) is fed into the winding machine feed port (22) in sequence through guide roller 1 (28), tension roller (10), adjustment roller (20), guide roller 2 (29), guide roller 3 (30), feed port (2102), discharge port (2103), guide roller 4 (31), guide roller 5 (32), guide roller 6 (33) and guide roller 7 (34).

9. The intelligent feeding system for positive electrode foil of a capacitor winding machine according to claim 1, characterized in that: The controller (23) integrates an embedded microprocessor. The embedded microprocessor is electrically connected to a signal receiving module, a data processing module, and an instruction output module. The signal receiving module is electrically connected to the speed encoder (5), the laser range sensor (7), and the angle encoder (11). The drive motor one (2), the rotary damper (12), the drive motor two (16), the electrostatic dust removal plate (2106), and the negative pressure fan (2110) are all electrically connected to the instruction output module.

10. A method for intelligent feeding control of positive electrode foil in a capacitor winding machine, used to implement the feeding system as described in any one of claims 1-9, characterized in that, Includes the following steps: S1. After the feeding system is started, the embedded microprocessor calls the preset parameter library to complete the initial configuration, calibrates the correspondence between the diameter, length and rotational inertia of the positive electrode foil roll, presets the tension threshold range adapted to production requirements, initializes the communication protocol of each module, and ensures smooth adaptation of each signal. S2. The signal receiving module collects high-frequency synchronous data, the laser rangefinder collects the instantaneous diameter data of the positive electrode foil roll, the speed encoder collects the actual rotation speed data of the feeding shaft, and the angle encoder converts the real-time tension value of the foil. The collected data is then transmitted to the embedded microprocessor. S3. The data processing module uses a moving average filtering algorithm to process the raw data, remove interference signals, and calculate the remaining length and moment of inertia of the current positive electrode foil roll based on the pre-processed diameter data. The system is identified as being in the start-up, operation or end-of-life stage based on the moment of inertia status. S4. The embedded microprocessor generates control commands based on the identified working stage and real-time acquired data. During the startup stage, the command output module sends a smooth acceleration curve command to the drive motor and an initial braking force command to the rotary damper to ensure that the feeding speed is synchronized with the winding machine's feeding speed. During operation, the command output module sends commands to the rotary damper to dynamically adjust the braking force of the rotary damper. At the same time, the drive motor drives the adjusting roller to slide along the slide groove to fine-tune the tension and maintain the tension within the preset threshold range. In the final stage, switch to a low-tension control mode with a stable speed, and simultaneously generate start and stop commands for the composite dust removal components. S5. The command output module sends the generated control commands to each actuator, drives the motor to adjust the output speed, and controls the feeding speed of the feeding shaft; A rotary damper, in conjunction with a torsion spring, maintains the force balance of the tension roller, while an adjusting roller compensates for tension fluctuations through positional offset. When the composite dust removal component is working, the electrostatic dust removal plate adsorbs dust, the negative pressure fan creates a negative pressure environment, and the dust is sucked into the dust collection box through the dust collection hood and negative pressure pipe. After being filtered by the L-shaped screen, the dust is collected in the dust collection box. S6. Real-time acquisition of feedback data from the actuator, comparison with the preset threshold, and when the tension deviation exceeds the preset tension threshold range, only fine adjustment of the braking force of the rotary damper is made to pull the tension back to the preset threshold range within a time that matches the production rhythm. If the speed deviation exceeds the set speed adaptation range, the speed of the drive motor and the braking force of the rotary damper are adjusted synchronously and the data is fed back to the embedded microprocessor to realize dynamic iterative optimization of the algorithm parameters. S7. The embedded microprocessor monitors the device status in real time. If abnormal sensor data, abnormal tension, or loss of speed control occurs, the emergency mechanism is immediately triggered, a shutdown command is sent, and an alarm is triggered. S8. When the diameter of the foil detected by the laser rangefinder drops to near the diameter of the feeding shaft body, the instruction output module sends a stop command, all actuators stop working, the electrostatic dust removal plate is de-energized, and the feeding process is completed.

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