Aluminum foil thickness deviation control method and system for electrolytic capacitor

Abstract

The invention relates to a method and a system for controlling the thickness deviation of an aluminum foil for an electrolytic capacitor, which are used for rolling and processing an aluminum plate strip foil. A re-measurement control step is carried out after the thickness gauge is calibrated; thickness calculation parameters are collected for real-time thickness calculation; and various early warning and intervention steps are combined, so that the thickness deviation control of the aluminum foil for producing the electrolytic capacitor is finally realized. The system comprises a measurement deviation regulation and control device based on environment temperature deviation correction, a thickness calculation parameter acquisition device and a real-time thickness calculation and production intervention regulation and control device which are arranged on an actual production site. The method can effectively solve the key technical problems of aluminum foil thickness deviation fluctuation and ultra-thickness and ultra-thickness always existing in the rolling process of the aluminum foil rolling mill, and can realize high-quality thickness detection control, so that the rolling efficiency and the thickness quality of the aluminum foil reach the advanced level of the industry.

Description

Technical Field

[0001] This invention belongs to the field of aluminum sheet, strip and foil rolling processing, specifically a method and system for controlling the thickness deviation of aluminum foil for electrolytic capacitors. Background Technology

[0002] With the high-quality and rapid development and upgrading of the aluminum foil industry for electrolytic capacitors, higher requirements have been placed on the high-precision rolling and thickness quality control of aluminum foil. The thickness control of electronic aluminum foil is the core control indicator of the product. Thickness deviation causes performance and quality problems such as capacity and bending of aluminum electrolytic capacitors.

[0003] The aluminum foil processing for electrolytic capacitors includes 15 steps such as melting, casting, milling, homogenization, hot rolling, cold rolling, rewinding, alkaline washing, foil rolling, intermediate annealing, tension leveling, cleaning, shearing, heat treatment, and rewinding. Foil rolling is the key core process in aluminum foil processing, and the thickness deviation control of electronic aluminum foil is the core control indicator of the foil rolling mill.

[0004] Currently, in my country's aluminum foil rolling process, the thickness of aluminum foil is mainly detected and controlled online using an X-ray thickness gauge. During the calibration of the X-ray thickness gauge, a standard sample is used as a reference for alloy coefficient linear curve compensation to ensure that the thickness measured by the thickness gauge matches the nominal thickness of the standard sample. However, the following problems exist:

[0005] 1. The X-ray source of a thickness gauge mainly consists of a high-voltage source and an X-ray tube. The stability of the operating temperature directly affects the stability of the X-ray source output, thus affecting the measurement accuracy of the thickness gauge. The filament of the X-ray tube emits electrons through heating with current. Temperature changes directly affect the electron emission frequency of the filament. When the operating temperature rises, the filament overheats, increasing the electron emission and resulting in a higher intensity of X-rays penetrating the aluminum foil, leading to a lower measured thickness value. During the aluminum foil rolling process, the thickness gauge is affected by changes in ambient temperature and oil / gas temperature, causing variations in the X-ray source's operating temperature. This leads to changes in the measured aluminum foil thickness, and ultimately, feedback control causes deviations in the actual aluminum foil thickness value.

[0006] 2. The X-ray thickness gauge is calibrated using a standard sample to ensure that the thickness measured by the gauge matches the nominal thickness of the standard sample. Errors in the standard sample and deviations in the calibration process can cause thickness deviations during aluminum foil rolling, resulting in large quantities of excessively thick or thin aluminum coils as waste.

[0007] 3. During the aluminum foil rolling process, there is only one method to detect the thickness of aluminum foil. When a thickness detection deviation occurs, it is not easy to detect, which leads to the actual aluminum foil thickness deviation during thickness feedback control, resulting in aluminum foil waste. Summary of the Invention

[0008] In view of the above-mentioned deficiencies and defects in the prior art, this application provides a method and system for controlling the thickness deviation of aluminum foil for electrolytic capacitors. The main innovation in solving the technical problem is: measurement deviation control based on ambient temperature correction; re-measurement control after calibration of the thickness gauge; real-time thickness calculation by collecting thickness calculation parameters, and combining various early warning and intervention strategies to ultimately achieve thickness deviation control of aluminum foil for electrolytic capacitor production.

[0009] The technical solution adopted by the present invention to achieve the above objectives is as follows:

[0010] A method for controlling the thickness deviation of aluminum foil for electrolytic capacitors includes the following steps:

[0011] Measurement deviation control based on ambient temperature correction: The temperature control device is used to detect the ambient temperature of the thickness gauge in real time and control the ambient temperature to limit it within the target temperature threshold range, which is used to correct the measurement deviation of the thickness gauge.

[0012] Thickness calculation parameter acquisition: The control module for measuring the winding diameter and the pulse measurement module located on the winding side of the aluminum sheet, strip and foil rolling mill unit are used to detect the number of winding turns m and the winding diameter R of aluminum sheet, strip and foil in real time;

[0013] Real-time thickness calculation and production intervention control: The real-time thickness T of aluminum sheet and foil is calculated based on the real-time detection of the number of turns m and the winding diameter R. On-site production early warning and intervention control are carried out based on the measurement deviation of the thickness gauge and the real-time thickness T of aluminum sheet and foil.

[0014] The control environment is limited to the target temperature threshold range, which includes: outputting commands to control the temperature sensor to detect the ambient temperature, and controlling the compressed air refrigeration unit or electric heating equipment to start and stop working according to the target temperature and threshold range, thereby changing the ambient temperature of the thickness gauge.

[0015] The winding diameter measurement module is a high-precision laser rangefinder, and the pulse measurement module includes a metal stop block located on the rotating shaft of the aluminum plate, strip and foil rolling mill and a pulse proximity switch near the rotation path of the metal stop block during the production process.

[0016] The control module for measuring the winding diameter and the pulse measurement module, located on the winding side of the aluminum sheet, strip, and foil rolling mill, real-time detects the number of winding turns m and the winding diameter R of the aluminum sheet, strip, and foil, including:

[0017] Control the operation of the high-precision laser rangefinder, and calculate the distance S1 between the aluminum coil surface and the high-precision laser rangefinder by combining the laser speed, laser emission time, and laser echo time;

[0018] Based on the installation positions of the high-precision laser rangefinder and the scroll, the distance S2 from the high-precision laser rangefinder to the rotation center line of the scroll is obtained;

[0019] Calculate the real-time roll diameter R = S2 - S1;

[0020] The control pulse proximity switch counts the number of turns (m) of aluminum sheet / strip foil in real time.

[0021] The method of conducting on-site production early warning and intervention control based on the measurement deviation of the thickness gauge and the real-time thickness calculation value T of the aluminum sheet, strip and foil includes: production parameters based on measurement deviation correction, production parameters based on the real-time thickness calculation value T of the aluminum sheet, strip and foil, or a weighted fusion of the two to achieve production early warning and intervention control.

[0022] The formula for calculating the real-time thickness T of the aluminum sheet / strip foil is: T=K[(Rd) / 2] / m, where d is the diameter of the rotating shaft sleeve, R is the real-time winding diameter, m is the real-time number of turns, and k is the winding density.

[0023] in:

[0024] a. The production early warning and intervention control based on measurement deviation correction production parameters includes comparing the thickness value of aluminum sheet, strip and foil measured by the thickness gauge with the target set thickness value to obtain the first thickness deviation, outputting an alarm command according to the first thickness deviation limit, and adjusting the roll gap and rolling force of the aluminum foil rolling mill to realize thickness deviation correction and compensation; outputting an instruction according to the second thickness deviation limit and adjusting the automatic stop of the aluminum foil rolling mill;

[0025] b. The production early warning and intervention control based on the real-time thickness calculation value T of aluminum sheet, strip and foil includes comparing the real-time thickness calculation value T of the sheet, strip and foil with the target set thickness value to obtain the first thickness deviation, outputting an alarm command according to the first thickness deviation limit, and adjusting the roll gap and rolling force of the aluminum foil rolling mill to realize thickness deviation correction and compensation; outputting an instruction according to the second thickness deviation limit and adjusting the automatic stop of the aluminum foil rolling mill;

[0026] c. The weighted fusion of these two factors to correct production parameters and achieve production early warning and intervention control includes calculating the fused thickness value = the thickness value of the aluminum plate, strip, and foil measured by the thickness gauge. + Real-time thickness calculation value of sheet / strip foil T ;

[0027] The thickness value is compared with the target set thickness value. An alarm command is output according to the first thickness deviation limit, and the roll gap and rolling force of the aluminum foil rolling mill are adjusted to achieve thickness deviation correction and compensation. An alarm command is output according to the second thickness deviation limit, and the aluminum foil rolling mill is automatically stopped.

[0028] The method also includes measuring the deviation using a calibrated thickness gauge and performing retesting control after calibration: before aluminum foil rolling, the thickness gauge is calibrated and alloy coefficient compensated using a standard sample, and then a standard sample with a thickness close to the thickness of the calibrated sample is tested with the thickness gauge. If the average value of several measurements of the thickness deviation between the thickness measured by the thickness gauge and the thickness of the standard sample does not meet the threshold range, then recalibration and verification are performed.

[0029] A thickness deviation control system for aluminum foil used in electrolytic capacitors includes a measurement deviation control device based on ambient temperature correction, a thickness calculation parameter acquisition device, and a real-time thickness calculation and production intervention control device installed at the actual production site.

[0030] The measurement deviation control device based on ambient temperature correction includes a thickness gauge and a temperature control device located in its detection environment. The thickness gauge is used to detect the thickness of aluminum sheet, strip, and foil. The temperature control device adopts one or more of the following methods, including but not limited to air cooling, water cooling, or electric heating, to control the real-time temperature of the detection environment, thereby correcting the measurement deviation.

[0031] The thickness calculation parameter acquisition device includes a winding diameter measurement module and a pulse measurement module located on the winding side of the aluminum sheet, strip and foil rolling mill, which are used to detect the number of winding turns m and the winding diameter R of aluminum sheet, strip and foil in real time.

[0032] The real-time thickness calculation and production intervention control device adopts a field controller, which is connected to the temperature control equipment, thickness gauge, winding diameter measurement module and pulse measurement module to control the operation of each device. The field controller is also connected to the aluminum plate, strip and foil rolling mill to control its start and stop operation. The field controller is equipped with a memory with a pre-set program module. When the field controller loads the program, it executes the method steps described above to realize real-time thickness calculation of aluminum plate, strip and foil based on measurement deviation correction, as well as on-site production correction early warning and intervention control.

[0033] The temperature control device includes a temperature sensor, a compressed air refrigeration unit, and pipelines. The pipelines are arranged near the thickness gauge. The temperature sensor detects the ambient temperature. The compressed air refrigeration unit starts and stops working according to the target temperature and threshold range, delivering air at the target temperature into the pipeline, thereby changing the ambient temperature of the thickness gauge.

[0034] The winding diameter measurement module located on the winding side of the aluminum sheet, strip and foil rolling mill is a high-precision laser rangefinder, placed opposite the winding machine of the aluminum sheet, strip and foil rolling mill; the pulse measurement module includes a metal stop block located on the rotating shaft of the aluminum sheet, strip and foil rolling mill and a pulse proximity switch near the rotation path of the metal stop block during the production process.

[0035] The system also includes a host computer located in the field control room or in a remote cloud, the host computer including a control backend and a frontend interface;

[0036] The control backend is equipped with a memory and a processor. The memory stores the program. When the processor loads the program, it interacts with the front-end interface to collect the production parameters and control commands input by the user, adjusts the program logic to generate an algorithm program, and sends it down to the field controller. The field controller then coordinates the field equipment to perform on-site production early warning and intervention control, and collects the production data uploaded by the field controller in real time to construct a twin historical production process and generate early warning and intervention strategies. The early warning and intervention strategies are the aluminum foil rolling mill roll gap and rolling force.

[0037] The front-end interface is used for human-computer interaction, collecting production parameters and control commands input by the user. The production parameters include, but are not limited to, the target set thickness value of aluminum sheet, strip and foil, the ambient temperature threshold of the thickness gauge, the real-time thickness calculation value T formula of aluminum sheet, strip and foil, and the fusion thickness calculation formula; as well as the twin visualization display of the operating status of each piece of equipment, historical production process and early warning and intervention strategies during the production process.

[0038] By researching and applying a method for controlling the thickness deviation of aluminum foil used in electrolytic capacitors, this invention effectively solves the key technical problems of thickness deviation fluctuations and ultra-thickness / ultra-thinness that have always existed in the aluminum foil rolling process. It achieves high-quality thickness detection and control capabilities, and the aluminum foil rolling efficiency and thickness quality reach industry-leading levels. Specific advantages are as follows:

[0039] 1. Improved accuracy of aluminum foil thickness detection: By developing and designing a closed-loop temperature feedback control system for the thickness gauge, stable control of the working temperature of the thickness gauge has been achieved, effectively solving the problem of aluminum foil thickness variation caused by changes in the working temperature of the X-ray source, and improving the accuracy and stability of aluminum foil thickness detection.

[0040] 2. Improved stability of aluminum foil thickness measurement calibration: By establishing control standards for retesting after calibration of the thickness gauge, the problem of thickness deviation during aluminum foil rolling caused by deviations in the standard sample of the aluminum foil thickness gauge and deviations in the calibration process is effectively solved, thus improving the stability of aluminum foil thickness measurement calibration.

[0041] 3. Improved Aluminum Foil Thickness Control Accuracy: An online aluminum foil thickness detection and early warning control system was developed. This system incorporates a laser-based measurement device for the winding diameter and a pulse-based measurement device for the number of winding turns. It accurately detects and calculates the aluminum foil thickness in real time and compares it with the thickness measured by a thickness gauge. When the thickness deviation is too large, an automatic over-limit alarm is triggered, and the roll gap and rolling force of the aluminum foil rolling mill are adjusted accordingly to achieve effective thickness deviation compensation and control. Attached Figure Description

[0042] Figure 1 This is a flowchart of a preferred embodiment of the present invention.

[0043] Figure 2 This is a system composition block diagram of a preferred embodiment of the present invention.

[0044] Figure 3 This is a schematic diagram of the temperature control device for the X-ray emission end of the C-frame thickness gauge in a preferred embodiment of the present invention.

[0045] Figure 4 This is a pulse measurement winding turn count device in a preferred embodiment of the present invention.

[0046] Figure 5 This is a laser measurement device for winding diameter in a preferred embodiment of the present invention. Detailed Implementation

[0047] To make the above-mentioned objects, features, and advantages of the present invention more apparent and understandable, the specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a thorough understanding of the present invention. However, the present invention can be implemented in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of the invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0048] 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 invention pertains. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention.

[0049] Thickness control in aluminum foil rolling mills for electrolytic capacitors mainly includes thickness detection, thickness control, and adjustment and control by the actuator. This invention is used for thickness control of electronic aluminum foil ranging from 0.06 to 0.15 mm. Addressing the key technical problems of thickness deviation fluctuations and ultra-thickness / ultra-thinness in aluminum foil rolling processes, this invention designs a method for controlling thickness deviation in aluminum foil for electrolytic capacitors.

[0050] like Figure 1 As shown, a method for controlling the thickness deviation of aluminum foil for electrolytic capacitors includes the following steps:

[0051] Measurement deviation control steps based on ambient temperature correction: Control the temperature control equipment to detect the ambient temperature of the thickness gauge in real time and control the ambient temperature to limit it within the target temperature threshold range, in order to correct the measurement deviation of the thickness gauge.

[0052] The deviation is measured using a calibrated thickness gauge, and a re-measurement control step is performed after calibration: Before aluminum foil rolling, the thickness gauge is calibrated and alloy coefficient is compensated using a standard sample. Then, a standard sample with a thickness close to the calibrated sample thickness is tested with the thickness gauge. The average value of several measurements of the thickness deviation between the thickness measured by the thickness gauge and the thickness of the standard sample is checked. If it does not meet the threshold range, the calibration is repeated and verified.

[0053] Thickness calculation parameter acquisition steps: Control the winding diameter measurement module and pulse measurement module located on the winding side of the aluminum sheet, strip and foil rolling mill to detect the number of winding turns m and the winding diameter R of aluminum sheet, strip and foil in real time;

[0054] Real-time thickness calculation and production intervention control steps: Calculate the real-time thickness T of aluminum sheet / strip foil based on the real-time detection of the number of turns m and the roll diameter R. Based on the measurement deviation of the thickness gauge and the real-time thickness T, conduct on-site production early warning and intervention control.

[0055] like Figure 2 As shown, the present invention also provides a thickness deviation control system for aluminum foil for electrolytic capacitors, including a measurement deviation control device based on ambient temperature correction, a thickness calculation parameter acquisition device, and a real-time thickness calculation and production intervention control device installed at the actual production site.

[0056] The measurement deviation control device based on ambient temperature correction includes a thickness gauge and a temperature control device located in its detection environment. The thickness gauge is used to detect the thickness of aluminum sheet, strip, and foil. The temperature control device adopts one or more of the following methods, including but not limited to air cooling, water cooling, or electric heating, to control the real-time temperature of the detection environment, thereby correcting the measurement deviation.

[0057] The thickness calculation parameter acquisition device includes a winding diameter measurement module and a pulse measurement module located on the winding side of the aluminum sheet, strip and foil rolling mill, which are used to detect the number of winding turns m and the winding diameter R of aluminum sheet, strip and foil in real time.

[0058] The real-time thickness calculation and production intervention control device adopts a field controller, which is connected to the temperature control equipment, thickness gauge, winding diameter measurement module and pulse measurement module to control the operation of each device. The field controller is also connected to the aluminum plate, strip and foil rolling mill to control its start and stop operation. The field controller is equipped with a memory with a pre-set program module. When the field controller loads the program, it executes the method steps described above to realize real-time thickness calculation of aluminum plate, strip and foil based on measurement deviation correction, as well as on-site production correction early warning and intervention control.

[0059] The main innovative points of this invention are described in detail below:

[0060] Innovation Point 1: Development and design of a closed-loop temperature feedback control device for thickness gauges. This device controls the temperature regulation equipment to monitor the ambient temperature of the thickness gauge in real time and regulate it to limit the ambient temperature within the target temperature threshold range, thereby correcting measurement deviations in the thickness gauge.

[0061] A temperature sensor is installed inside the X-ray emitting end of the thickness gauge's C-frame, and a compressed air cooling unit and piping are added to control the temperature of the X-ray emitting end. The operating temperature of the thickness gauge's X-ray emitting end is set at 25 degrees Celsius. When the temperature sensor detects a temperature higher or lower than the set temperature, the compressed air temperature and flow rate are adjusted in real time to stabilize the operating temperature of the thickness gauge's X-ray emitting end, effectively solving the problem of aluminum foil thickness variations caused by changes in the X-ray source's operating temperature. Practical verification has shown no customer complaints regarding thickness deviations, proving the effectiveness of this method. Figure 3 As shown.

[0062] Innovation Point 2: Research and application of thickness gauge calibration and retest control. The calibration of the thickness gauge is used to measure deviations, and retest control is performed after calibration.

[0063] Before rolling each roll of aluminum foil, the thickness gauge is calibrated and alloy coefficient compensated using a standard sample. Then, another standard sample with a thickness close to the calibrated sample must be tested with the thickness gauge to check if the thickness measured by the thickness gauge matches the thickness of the standard sample. This effectively verifies the accuracy of the thickness gauge after calibration. If the average deviation between the thickness measured by the thickness gauge and the thickness measured by the standard sample exceeds ±0.15%, recalibration and verification are necessary. This effectively solves the problem of thickness deviation during aluminum foil rolling caused by deviations in the standard sample and the calibration process. Practical verification has shown no customer complaints regarding thickness deviations, proving the effectiveness of this method.

[0064] Innovation Point 3: By adding a laser measurement device for the winding diameter and a pulse measurement device for the number of winding turns, combined with real-time detection of the aluminum foil winding diameter and the number of winding turns.

[0065] like Figure 4 As shown, a positioning pulse detection module added to the winding side of the aluminum sheet, strip, and foil rolling mill is used to detect the number of aluminum sheet, strip, and foil winding turns m in real time; a high-precision laser rangefinder added to the winding side of the aluminum sheet, strip, and foil rolling mill is used to detect the aluminum sheet, strip, and foil winding diameter R in real time; a PLC controller connected to the positioning pulse detection device and the high-precision laser rangefinder is used to calculate the real-time thickness T of the aluminum sheet, strip, and foil based on the real-time detected number of aluminum sheet, strip, and foil winding turns m and the aluminum sheet, strip, and foil winding diameter R.

[0066] The positioning pulse detection module includes a metal stop and a pulse proximity switch. The metal stop is welded to the rotating shaft on the drive side of the coiler of the aluminum plate, strip and foil rolling mill. The pulse proximity switch is installed on the housing of the coiler. Each time the coiler rotates, when the metal stop enters the sensing range of the pulse proximity switch, the pulse proximity switch will be triggered once, generating a rising edge of a pulse signal. When the metal stop moves away from the sensing range of the pulse proximity switch, a falling edge of a pulse signal will be generated. Thus, one pulse signal will be generated for each rotation of the coiler.

[0067] like Figure 5 As shown, a pulse measurement device for the number of coil turns is installed directly opposite the coiling machine of the aluminum sheet, strip, and foil rolling mill. In this invention, the pulse measurement device for the number of coil turns uses a high-precision laser rangefinder. By measuring the time it takes for the laser to travel from emission to reflection from the surface of the aluminum coil, and combining this with the laser speed, the distance S1 between the surface of the aluminum coil and the high-precision laser rangefinder is calculated (S1 = (speed)). (Time) / 2), and then according to the installation position of the high-precision laser rangefinder and the roll, the distance S2 from the high-precision laser rangefinder to the rotation center line of the roll is obtained, and the real-time winding diameter R=S2-S1 is calculated. The high-precision laser rangefinder sends R to the PLC controller to realize real-time dynamic high-precision detection of the roll diameter during the aluminum coil rolling process.

[0068] Innovation Point 4: The PLC controller accurately detects and calculates the aluminum foil thickness in real time. The system compares the set target thickness, the thickness measured by a thickness gauge, and the thickness calculated by laser diameter measurement. When the deviation exceeds ±2%, the aluminum foil rolling mill control system issues a thickness over-limit alarm and adjusts the roll gap and rolling force accordingly to effectively compensate for the thickness deviation. When the deviation exceeds ±3%, the transmission control system automatically stops the machine to prevent the aluminum sheet / foil roll from being too thick or too thin. This effectively solves the problem of actual aluminum foil thickness deviation caused by thickness detection deviation feedback control during aluminum foil rolling. Practical verification shows a reduction of 200 tons / year in aluminum foil thickness difference waste, proving the effectiveness of this method.

[0069] The pulse proximity switch sends the pulse signal to the PLC controller. In the PLC program, a complete cycle of "rising edge + falling edge" is used as the criterion for judging one revolution of the coiler. The count is incremented by 1 in the program to realize the automatic accumulation calculation of the number of revolutions during the aluminum coil rolling process.

[0070] The PLC controller is specifically used to calculate the real-time thickness of the aluminum sheet foil according to the online real-time thickness calculation formula. The online real-time thickness calculation formula is T=K[(Rd) / 2] / m, where d is the diameter of the rotating shaft sleeve, R is the real-time winding diameter, m is the real-time number of turns, and k is the winding density (the value of k needs to take into account the influence of oil film, air gap, tension, speed, surface pressure, etc. In this embodiment of the invention, k is set to 0.97791).

[0071] Table 1

[0072]

[0073] Specifically, the on-site production early warning and intervention control based on the measurement deviation of the thickness gauge and the real-time calculated thickness T of the aluminum sheet, strip, and foil includes: production parameters based on measurement deviation correction, production parameters based on the real-time calculated thickness T of the aluminum sheet, strip, and foil, or a weighted fusion of both, to achieve production early warning and intervention control; including:

[0074] a. Production early warning and intervention control based on measurement deviation correction production parameters include: comparing the thickness value of aluminum sheet, strip and foil measured by the thickness gauge with the target set thickness value, outputting an alarm command according to the first thickness deviation limit ±2%, and adjusting the roll gap and rolling force of the aluminum foil rolling mill to achieve thickness deviation correction and compensation; outputting an instruction according to the second thickness deviation limit ±3%, and adjusting the automatic stop of the aluminum foil rolling mill;

[0075] b. Production early warning and intervention control based on the real-time thickness calculation value T of aluminum sheet, strip and foil includes: comparing the real-time thickness calculation value T of sheet, strip and foil with the target set thickness value, outputting an alarm command according to the first thickness deviation limit ±2%, and adjusting the roll gap and rolling force of the aluminum foil rolling mill to achieve thickness deviation correction and compensation; outputting an instruction according to the second thickness deviation limit ±3%, and adjusting the automatic stop of the aluminum foil rolling mill;

[0076] c. The weighted fusion of these two factors to correct production parameters and achieve production early warning and intervention control includes: calculating the fused thickness value = the thickness value of the aluminum sheet, strip, and foil measured by the thickness gauge. + Real-time thickness calculation value of sheet / strip foil T ;

[0077] The thickness value is compared with the target set thickness value. An alarm is output according to the first thickness deviation limit of ±2%, and the roll gap and rolling force of the aluminum foil rolling mill are adjusted to achieve thickness deviation correction and compensation. An alarm is output according to the second thickness deviation limit of ±3%, and the aluminum foil rolling mill is automatically stopped.

[0078] Furthermore, based on the existing system composition, the present invention also includes a host computer located in the field control room or remote cloud, the host computer including a control backend and a front-end interface;

[0079] The control backend is equipped with a memory and a processor. The memory stores the program. When the processor loads the program, it interacts with the front-end interface to collect the production parameters and control commands input by the user, adjusts the program logic to generate an algorithm program, and sends it down to the field controller. The field controller then coordinates the field equipment to perform on-site production early warning and intervention control, and collects the production data uploaded by the field controller in real time to construct a twin historical production process and generate early warning and intervention strategies. The early warning and intervention strategies are the aluminum foil rolling mill roll gap and rolling force.

[0080] The front-end interface is used for human-computer interaction, collecting production parameters and control commands input by the user. The production parameters include, but are not limited to, the target set thickness value of aluminum sheet, strip and foil, the ambient temperature threshold of the thickness gauge, the real-time thickness calculation value T formula of aluminum sheet, strip and foil, and the fusion thickness calculation formula; as well as the twin visualization display of the operating status of each piece of equipment, historical production process and early warning and intervention strategies during the production process.

[0081] The above descriptions are merely specific embodiments of this application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of this application. Therefore, this application is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features claimed herein.

Claims

1. An aluminum foil thickness deviation control method for an electrolytic capacitor, characterized by, The method comprises the following steps: controlling the temperature adjusting device to detect the environment temperature of the thickness gauge in real time and adjusting the environment temperature to be within the target temperature threshold range, so as to correct the measurement deviation of the thickness gauge; controlling the measurement winding diameter module and the pulse measurement module arranged on the winding side of the aluminum plate strip foil rolling mill set to detect the winding number m and the winding diameter R of the aluminum plate strip foil in real time; calculating the real-time thickness calculation value T of the aluminum plate strip foil according to the winding number m and the winding diameter R of the aluminum plate strip foil, and performing on-site production early warning and intervention control according to at least one of the measurement deviation of the thickness gauge and the real-time thickness calculation value T of the aluminum plate strip foil.

2. The aluminum foil thickness deviation control method for an electrolytic capacitor according to claim 1, characterized by, The adjustment of the environment to be within the target temperature threshold range comprises: outputting an instruction to control the temperature sensor to detect the environment temperature, and controlling the compressed air refrigeration unit or the electric heating device to start or stop working according to the target temperature and the threshold range, so as to change the environment temperature of the thickness gauge.

3. The method for controlling thickness deviation of an aluminum foil for an electrolytic capacitor according to claim 1, characterized by, The measurement winding diameter module is a high-precision laser range finder, and the pulse measurement module comprises a metal block arranged on the rotating shaft of the aluminum plate strip foil rolling mill set and a pulse proximity switch near the rotating path of the metal block in the production process; the control of the measurement winding diameter module and the pulse measurement module arranged on the winding side of the aluminum plate strip foil rolling mill set to detect the winding number m and the winding diameter R of the aluminum plate strip foil in real time comprises: controlling the high-precision laser range finder to work, and calculating the distance S1 between the aluminum coil surface and the high-precision laser range finder according to the laser speed, the laser light emission time and the laser echo time; obtaining the distance S2 from the high-precision laser range finder to the rotating center line of the winding shaft according to the installation positions of the high-precision laser range finder and the winding shaft; calculating the real-time winding diameter R=S2-S1; controlling the pulse proximity switch to count the winding number m of the aluminum plate strip foil in real time.

4. The method for controlling thickness deviation of an aluminum foil for electrolytic capacitors according to claim 1, characterized by, The on-site production early warning and intervention control according to at least one of the measurement deviation of the thickness gauge and the real-time thickness calculation value T of the aluminum plate strip foil comprises: correcting the production parameters based on the measurement deviation, correcting the production parameters based on the real-time thickness calculation value T of the aluminum plate strip foil, or weighted fusion of the two to correct the production parameters, so as to realize the production early warning and intervention control; The formula of the real-time thickness calculation value T of the aluminum plate strip foil is: T=K[(R-d) / 2] / m, wherein d is the diameter of the rotating shaft sleeve, R is the real-time winding diameter, m is the real-time winding number, and k is the winding density.

5. The method of controlling thickness deviation of an aluminum foil for an electrolytic capacitor according to claim 4, wherein Wherein: a. The production early warning and intervention control based on the measurement deviation to correct the production parameters comprises: comparing the aluminum plate strip foil thickness value measured by the thickness gauge with the target set thickness value to obtain a first thickness deviation, outputting an instruction to alarm according to the first thickness deviation limit value, and adjusting the aluminum foil rolling mill roll gap and rolling force to realize thickness deviation correction compensation; outputting an instruction according to the second thickness deviation limit value, and adjusting the aluminum foil rolling mill to automatically stop; b. The aluminum strip foil real-time thickness calculation value T is used for realizing production early warning and intervention control of the production parameter based on the aluminum strip foil real-time thickness calculation value T, including: comparing the aluminum strip foil real-time thickness calculation value T with the target set thickness value to obtain a first thickness deviation, outputting an instruction alarm according to the first thickness deviation limit value, adjusting the aluminum foil rolling mill roll gap and rolling force to realize thickness deviation correction compensation, and outputting an instruction according to the second thickness deviation limit value and adjusting the aluminum foil rolling mill automatic stop; c. The weighted fusion of the two rectification production parameters realizes production early warning and intervention control, including: calculating the fusion thickness value = the aluminum plate strip foil thickness value measured by the thickness gauge + the real-time thickness calculation value T of the plate strip foil ; The thickness value is compared with the target set thickness value, an instruction alarm is output according to the first thickness deviation limit value, the aluminum foil rolling mill roll gap and rolling force are adjusted to realize thickness deviation correction compensation, and an instruction is output according to the second thickness deviation limit value and the aluminum foil rolling mill automatic stop is adjusted.

6. The method for controlling thickness deviation of an aluminum foil for an electrolytic capacitor according to claim 1, characterized in that, It also includes measuring the deviation by using the calibrated thickness gauge, and re-measuring and controlling after calibration: before aluminum foil rolling, the thickness gauge is calibrated and alloy coefficient compensation is performed by using a standard sample, then the thickness gauge is used to detect a standard sample with a thickness close to the thickness of the calibration sample, and the average of several measurements of the thickness deviation of the thickness measured by the thickness gauge from the thickness of the standard sample is checked; if the average does not meet the threshold range, recalibration and verification are performed.

7. An aluminum foil thickness deviation control system for electrolytic capacitors, characterized by comprising: a foil thickness measuring device; a foil thickness deviation calculating device; a foil thickness deviation correcting device; and a foil thickness deviation correcting device control device. It includes a measurement deviation control device based on environmental temperature correction, a thickness calculation parameter acquisition device, a real-time thickness calculation and production intervention control device arranged in an actual production site; The measurement deviation control device based on environmental temperature correction includes a thickness gauge and a temperature adjusting device arranged in the detection environment of the thickness gauge, the thickness gauge is used to detect the thickness of the aluminum plate strip foil, and the temperature adjusting device is used to adjust the real-time temperature of the detection environment by using one or a combination of multiple modes including but not limited to air cooling, water cooling or electric heating, so as to correct the measurement deviation; The thickness calculation parameter acquisition device includes a measurement coiling diameter module and a pulse measurement module arranged on the coiling side of the aluminum plate strip foil rolling mill unit, which are used to detect the aluminum plate strip foil coiling turns m and the aluminum plate strip foil coiling diameter R in real time; The real-time thickness calculation and production intervention control device uses a field controller which is connected with the temperature adjusting device, the thickness gauge, the measurement coiling diameter module and the pulse measurement module respectively to control the work of each device; the field controller is also connected with the aluminum plate strip foil rolling mill unit to control the start and stop of the work of the aluminum plate strip foil rolling mill unit; the field controller is provided with a memory, and a program module is pre-stored in the memory; when the field controller loads the program, the method steps of any one of claims 1-6 are executed to realize the real-time thickness calculation of the aluminum plate strip foil based on the measurement deviation correction, and the production early warning and intervention control in the field.

8. The aluminum foil thickness deviation control system for an electrolytic capacitor according to claim 7, characterized by The temperature control device includes a temperature sensor and a compressed air refrigeration unit and a pipeline, the pipeline is arranged near the thickness gauge, the temperature sensor detects the environmental temperature, the compressed air refrigeration unit starts and stops work according to the target temperature and the threshold range, and delivers air with the target temperature into the pipeline to change the environmental temperature of the thickness gauge.

9. The aluminum foil thickness deviation control system for an electrolytic capacitor according to claim 7, wherein The measurement coiling diameter module arranged on the coiling side of the aluminum plate strip foil rolling mill unit is a high-precision laser range finder which is placed opposite to the coiling machine of the aluminum plate strip foil rolling mill unit; the pulse measurement module includes a metal block arranged on the rotating shaft of the aluminum plate strip foil rolling mill unit and a pulse proximity switch near the rotating path of the metal block in the production process.

10. The aluminum foil thickness deviation control system for an electrolytic capacitor according to claim 7, characterized by Also include the host computer set in the field control room or remote cloud, the host computer includes control background and front-end interface; The control background is provided with a memory and a processor, the memory stores a program, when the processor loads the program, interacts with the front-end interface to collect the production parameters and control instructions input by the user, adjusts the program logic to generate an algorithm program and sends it to the field controller, adjusts the field equipment to carry out the field production early warning and intervention control, and collects the production data uploaded by the field controller in real time, constructs a twin historical production process, and generates an early warning and intervention strategy; The early warning and intervention strategy is the aluminum foil rolling mill roll gap and rolling force; The front-end interface is used for man-machine interaction, collects the production parameters and control instructions input by the user, and the production parameters include but are not limited to the aluminum plate strip foil target set thickness value, the thickness gauge environment temperature threshold value, the aluminum plate strip foil real-time thickness calculation value T formula, the fusion thickness value calculation formula, and the twin visual display of the running state of each device in the production process, the historical production process and the early warning and intervention strategy.

Images