Self-adaptive tension regulation method for precise forming of mirror aluminum foil

Abstract

The present application belongs to the technical field of metal material processing control, and particularly relates to a self-adaptive tension regulation method for mirror surface aluminum foil precision forming, comprising the following steps: S1, obtaining full-element working condition data in the mirror surface aluminum foil forming process, the full-element working condition data comprising a feedback tension value, a linear speed and a driving speed of a main driving motor; S2, evaluating a stability confidence index according to the feedback tension value and the linear speed, and distinguishing whether the tension deviation belongs to systematic error or random interference through the stability confidence index; S3, dynamically mapping bandwidth sensitivity based on the stability confidence index and the driving speed. The present application can effectively eliminate high-frequency noise interference, significantly reduce tension fluctuation between multi-stage roller systems, solve the stress wrinkle problem in ultra-thin aluminum foil forming, eliminate overshoot and reciprocating swing in conventional control, and improve mirror surface flatness.

Description

Technical Field

[0001] This invention belongs to the field of metal material processing and control technology, specifically relating to an adaptive tension control method for precision forming of mirror aluminum foil. Background Technology

[0002] In the precision forming production line of mirror aluminum foil, due to the extremely thin thickness of the aluminum foil, typically between ten and fifty micrometers—equivalent to only a few sheets of ordinary paper—its physical properties exhibit exceptional flexibility and deformability. This characteristic allows the multi-stage tension roller system to form a highly coupled organic whole through the aluminum foil. Even the slightest tension fluctuation in any stage of the roller system, or even a minute deviation in rotational speed or change in force, will be rapidly transmitted to the entire roller system, triggering a chain reaction.

[0003] However, traditional tension control methods have significant limitations when facing high-speed, precise, and complex operating conditions. To filter out high-frequency noise from bearing micro-vibrations, motor vibrations, or electromagnetic interference, existing technologies typically employ filters with fixed parameters. However, this inevitably leads to phase lag in the control system, and the lag time fluctuates slightly with operating speed. At high speeds, this lag effect easily induces low-frequency resonance in the system, causing periodic transverse ripples on the aluminum foil surface. These defects are difficult to repair through subsequent processes, severely affecting the product's flatness and mirror gloss, and reducing the yield of qualified products.

[0004] Furthermore, tension fluctuations propagate through aluminum foil with an inherent physical time delay. Affected by the aluminum foil material, thickness, and operating line speed, it takes a certain amount of time for the disturbance signal from the preceding roller system to reach the subsequent roller system. Existing correction mechanisms, lacking precise perception and real-time calculation of the time-varying relationship between line speed and the physical distance between rollers, often only begin adjustment after the fluctuation has already caused destructive effects and obvious defects have appeared in the aluminum foil. This delayed correction mode is difficult to meet the stringent requirements for aluminum foil flatness in precision forming, thus hindering the improvement of product quality on the production line. Summary of the Invention

[0005] This invention provides an adaptive tension control method for precision forming of mirror aluminum foil, in order to solve the technical problems of resonance ripples caused by tension coupling and surface flatness reduction due to control lag in the forming of ultra-thin aluminum foil in the prior art.

[0006] This invention provides an adaptive tension control method for precision forming of mirror-finish aluminum foil, comprising the following steps:

[0007] S1, acquire all-factor working condition data during the mirror aluminum foil forming process, including feedback tension value, linear velocity and drive speed of main drive motor;

[0008] S2, assess the stability confidence index based on the feedback tension value and linear velocity, and determine whether the tension deviation is a systematic error or random interference through the stability confidence index;

[0009] S3, based on the stability confidence index and the dynamic mapping bandwidth sensitivity of the drive speed, adjusts the sensing bandwidth of the control system through bandwidth sensitivity to achieve mechanical noise suppression in different speed ranges;

[0010] S4 combines the feedback tension value, bandwidth sensitivity, and linear velocity, and uses the phase advance attenuation factor constructed based on the inter-stage physical span to perform decoupling calculations and output tension control commands.

[0011] Its effects are as follows: First, this invention abandons the traditional approach of simply relying on tension values. By integrating all-element data of linear velocity and motor speed, it establishes a multi-dimensional working condition sensing field. Second, it innovatively introduces a stability confidence index, giving the control system a human-like ability to distinguish between random mechanical noise interference and substantial system tension deviations from a mathematical and statistical perspective, thereby avoiding ineffective oscillations caused by the controller blindly following high-frequency noise. Furthermore, this invention dynamically adjusts the bandwidth sensitivity based on stability and speed. When high-speed operation is noisy, it automatically contracts the sensing bandwidth for flexible vibration damping, and instantly expands the bandwidth for rapid response when correction is needed, perfectly solving the contradiction between high sensitivity and strong anti-interference capability. Finally, it uses physical roller gap and linear velocity to construct a phase pre-attenuation factor. By using a space-for-time strategy, it injects compensation before the preceding disturbance reaches the current stage, eliminating tension ripples caused by transmission lag at the source and ensuring the ultimate flatness of mirror aluminum foil forming.

[0012] Furthermore, stability confidence indicators The calculation formula is:

[0013]

[0014] In the formula, To provide feedback on the tension value, The target tension constant is It is the static bias constant. It is a natural constant. The rate of change of tension, For the physical span between classes, is the linear velocity.

[0015] The benefits are as follows: This invention constructs a stability confidence index calculation model that includes a square term for tension deviation and a logarithmic term for the rate of change. This model cleverly utilizes the nonlinear sensitivity of the logarithmic function to numerical changes. Unlike existing technologies that only set simple thresholds, this formula can comprehensively consider both the magnitude and severity of the tension deviation from the target, thus establishing a quantitative standard at the mathematical level to measure the reliability of current tension fluctuations. This provides a solid, physically meaningful basis for subsequent judgments on whether intervention and control are necessary.

[0016] Furthermore, the evaluation logic for the stability confidence index includes:

[0017] In response to the decrease in stability confidence index caused by the increase in the rate of change of tension, the current fluctuation is determined to be a mechanical instantaneous shock, and the correction force is weakened;

[0018] In response to the feedback tension value continuously deviating from the target tension constant and the stability confidence index remaining at a high level, the current fluctuation is determined to be a systemic deviation, and a correction is initiated.

[0019] The benefits are as follows: This invention establishes an intelligent decision-making logic based on a stability confidence index, enabling hierarchical management of control behavior. When a high rate of change caused by mechanical shock leads to a decrease in the confidence index, the system determines it as an invalid disturbance and actively reduces the correction force to prevent the aluminum foil from breaking due to an allergic reaction. Conversely, when a sustained tension deviation is detected while the confidence index remains at a high level, the system determines it as a genuine process drift and immediately initiates correction. This logic effectively avoids the chasing noise phenomenon common in traditional PID control, significantly improving system stability.

[0020] Furthermore, bandwidth sensitivity The calculation formula is:

[0021]

[0022] In the formula, Based on the sensing bandwidth, As a confidence indicator of stability, This is the dynamic damping coefficient. To drive the rotational speed, This is the maximum driving speed.

[0023] The effect is as follows: This invention couples an abstract stability index with a specific physical quantity of motor speed by constructing a dynamic mapping formula for bandwidth sensitivity. This formula uses the speed ratio term in the denominator to simulate the physical law of mechanical vibration frequency increasing with speed, making the controller's sensing bandwidth no longer a fixed value, but an elastic range that changes in real time with the operating conditions. This ensures that the controller can operate in the frequency band with the optimal signal-to-noise ratio at any speed.

[0024] Furthermore, the logic for dynamically mapping bandwidth sensitivity includes:

[0025] Obtain the standardized speed ratio of the main drive motor. If the increase of the standardized speed ratio causes the mechanical noise frequency to enter the control bandwidth, the bandwidth sensitivity is compressed by increasing the denominator term in the calculation formula, so that the controller enters the flexible filtering state.

[0026] If the stability confidence index indicates a systematic deviation, the correction response speed can be improved by increasing the bandwidth sensitivity.

[0027] The benefits are as follows: This invention employs a dual-mode design, combining flexible filtering for high-speed operation and agile response for deviation conditions. When high-speed motor rotation causes mechanical noise frequencies to intrude into the control band, the system automatically increases the sensitivity of the formula denominator, effectively acting as a low-pass filter. Conversely, upon confirming a systematic deviation, the system proactively releases bandwidth limitations, significantly improving response speed. This mechanism ensures that the production line will not be forced to slow down due to resonance during acceleration, guaranteeing a dual improvement in both capacity and quality.

[0028] Furthermore, tension control commands The calculation formula is:

[0029]

[0030] In the formula, For proportional gain, The target tension constant is To provide feedback on the tension value, For bandwidth sensitivity, For the perturbation modes obtained through real-time observation, The phase advance attenuation factor is based on physical distance. For the physical span between classes, Linear velocity, The period is the discrete sampling period.

[0031] Furthermore, the logic for outputting tension control commands includes:

[0032] By using the phase advance attenuation factor to predict the time when the tension change of the preceding roller system will reach the current stage, the disturbance compensation amount is injected into the controller in advance to counteract the impending impact.

[0033] Furthermore, the acquisition process of all-element operating condition data is achieved through synchronous capture via a high-speed data acquisition bus, with a sampling period less than or equal to a preset discrete sampling period.

[0034] Furthermore, the static bias constant in the stability confidence index calculation is used to prevent the calculation formula from generating numerical singularities under steady-state conditions and serves as the fault tolerance threshold of the system.

[0035] Furthermore, the static bias constant is set to 2.

[0036] The beneficial effects are as follows: The core innovation of this invention lies in proposing an adaptive tension control mechanism based on the decoupling of stability confidence index and physical space. Addressing the wrinkling problem caused by tension coupling and filtering lag in the forming of ultra-thin mirror aluminum foil, this invention accurately distinguishes between random noise and systematic errors by constructing a confidence index, and resolves the contradiction between disturbance rejection and sensitivity by dynamically mapping bandwidth sensitivity using rotational speed. Furthermore, it innovatively utilizes the physical span between stages to calculate the phase advance factor, achieving proactive compensation for tension fluctuations, fundamentally eliminating hysteresis resonance, and significantly improving the mirror flatness of the aluminum foil. Attached Figure Description

[0037] Figure 1 This is a flowchart of the adaptive tension control method for precision forming of mirror aluminum foil in this invention.

[0038] Figure 2 This is a comparison diagram of the stability characteristics of the control system in phase space in this invention.

[0039] Figure 3 The residual diagram is used to verify the improvement of tension control accuracy in this invention. Detailed Implementation

[0040] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0041] An embodiment of the adaptive tension control method for precision forming of mirror aluminum foil provided by the present invention:

[0042] like Figure 1 As shown, the adaptive tension control method for precision forming of mirror aluminum foil includes the following steps:

[0043] S1, acquire all-factor working condition data during the mirror aluminum foil forming process, including feedback tension value, linear velocity and drive speed of the main drive motor.

[0044] In its implementation, this adaptive tension control system is built on a high-speed data acquisition bus architecture. By precisely deploying tension sensors, high-precision rotary encoders, and a feedback interface connected to the main drive motor driver among the various tension roller systems, a real-time network for capturing all physical quantities is constructed. The tension sensors collect and feedback tension values, which directly reflect the real-time stress state of the mirror aluminum foil during the forming process and are the core data for determining whether the tension deviates from the target range. The high-precision rotary encoder collects the linear velocity parameters of the aluminum foil in real time, which accurately characterizes the dynamic flow rate and transmission stability of the mirror aluminum foil among the various roller systems. The feedback interface of the main drive motor driver synchronously acquires drive speed data, which is directly related to the fundamental frequency of the main drive motor's mechanical vibration and can intuitively reflect the vibration characteristics and stability of the motor during operation.

[0045] The aforementioned three key data points—feedback tension value, linear velocity, and drive speed—together constitute a three-dimensional operational condition perception space. Within this space, the system can accurately pinpoint the specific operational stage of the current production system through comprehensive analysis and cross-validation of these three types of data. Whether it's the acceleration stage after equipment startup, the high-speed steady-state stage during stable production, or the abnormal oscillation stage caused by mechanical disturbances, all can be quickly identified and determined, providing accurate operational condition prerequisites for the dynamic adaptation of subsequent control logic.

[0046] To ensure the time synchronization and accuracy of the three types of data, the signals acquired by all sensing components are uniformly marked by the system's synchronization clock, achieving timestamp alignment of data acquisition and avoiding misjudgments of operating conditions due to data transmission delays or asynchronous acquisition. Simultaneously, the system is set to a sampling period of less than or equal to ten milliseconds. Through high-frequency discrete sampling, it fully captures the dynamic changes of various physical quantities, ensuring that even instantaneous tension changes, speed fluctuations, or linear velocity anomalies can be captured and recorded promptly.

[0047] This multi-dimensional, highly synchronous, and high-frequency all-element operating condition data perception capability provides a comprehensive, accurate, and real-time physical reference for subsequent adaptive control algorithms, ensuring that the control logic can closely follow the dynamic changes of the real production scenario. It lays a solid underlying data foundation for subsequent stability confidence index assessment, bandwidth sensitivity dynamic mapping, and phase early decoupling control, ensuring the timeliness of response and the accuracy of control of the entire control system.

[0048] S2 assesses the stability confidence index based on the feedback tension value and linear velocity, and determines whether the tension deviation is a systematic error or random interference through the stability confidence index.

[0049] After completing the synchronous acquisition and preprocessing of all-element operating condition data, the core objective of this step is to use precise algorithmic logic to sift through the raw signals, filtering out invalid noise signals caused by factors such as instantaneous mechanical impact and electromagnetic interference, and accurately identifying the systemic tension deviations that truly require regulatory intervention. The core implementation vehicle for this process is the stability confidence index. This indicator, by integrating the static deviation and dynamic change characteristics of the feedback tension value, constructs a core parameter that can quantify the tension stability of the system, providing a scientific basis for subsequent control decisions.

[0050] To more clearly demonstrate the stability confidence indicators The calculation logic and application scenarios are explained in detail below with specific operating parameters:

[0051] Assuming that in the precision forming process of mirror aluminum foil, the system presets a target tension constant based on the aluminum foil material, thickness, and forming process requirements. The static bias constant is 100N, which is set to avoid numerical singularities in the calculation formula under steady-state conditions and to ensure system fault tolerance. The value is 2. At a certain stable production moment, the tension sensors deployed between each level of the roller system provide real-time feedback on the current tension value. The value is 105N. First, calculate the square term of the tension deviation: At this moment, the high-precision rotary encoder collects the linear velocity of the aluminum foil. Given a speed of 2 m / s, the physical span between each stage of the roller system is known. The value is 1m, and the instantaneous rate of change of the current tension is detected through signal differentiation. The value is 10 N / s, which is within the normal range of process fluctuations.

[0052] Substitute the above parameters into the stability confidence index The calculation formula is as follows:

[0053]

[0054] Right now:

[0055] .

[0056] The calculation results indicate that the current stability confidence index The high level indicates that the current tension deviation is a persistent, systematic deviation, rather than a transient noise disturbance.

[0057] If, at another production moment, a sudden event such as a minor vibration in the equipment bearing or an external mechanical collision causes a significant instantaneous impact, leading to a change in the tension rate... The voltage surged to 100 N / s in a short period, while other parameters remained unchanged. Substituting these parameters back into the formula, the resulting stability confidence index... If the value is still greater than 1, it means that the instantaneous impact has not yet reached the strength to make the indicator fall below the threshold. The system will further determine whether to start the correction based on the duration of the fluctuation.

[0058] If the instantaneous impact intensity increases further, the rate of change of tension will increase. At higher values, such as 350 N / s and above, the logarithmic term in the denominator will increase rapidly, leading to a decrease in the stability confidence index. A sudden drop to less than 1 directly reflects the instantaneous and abnormal nature of the current signal fluctuation. At this point, the system will clearly determine it as an invalid instantaneous interference and will not blindly follow the control.

[0059] At the logical judgment level, the stability confidence index The magnitude of the index value directly corresponds to the properties of tension fluctuation: when the index value is low, the system determines that the current tension fluctuation is caused by invalid interference from random factors such as instantaneous mechanical impact and electromagnetic interference. At this time, the controller will actively reduce the correction force to maintain the stability of the control strategy and avoid negative effects such as overshoot and reciprocating oscillation caused by blindly following signal peaks, ensuring that the aluminum foil forming process is not affected by invalid control; when the tension deviation persists, such as the difference between the feedback tension value and the target tension constant remaining within a fixed range for multiple consecutive sampling periods, and the stability confidence index If the tension remains at a high level, the system determines that the current fluctuation is a systematic deviation caused by factors such as equipment parameter drift or changes in process conditions. At this time, a precise correction program needs to be started immediately, and the tension is quickly pulled back to the target range through subsequent bandwidth sensitivity adjustment and control command output.

[0060] Through stability confidence indicators Through its construction and application, this invention enables accurate identification of the true attributes of tension fluctuation signals, effectively distinguishes between systematic errors and random interference, and avoids the over-adjustment problem caused by the inability to identify noise signals in traditional control methods. It provides reliable decision support for the dynamic adaptation of subsequent control strategies and ensures the accuracy and stability of tension control.

[0061] S3, based on the stability confidence index and the dynamic mapping bandwidth sensitivity of the drive speed, adjusts the sensing bandwidth of the control system through bandwidth sensitivity to achieve mechanical noise suppression in different speed ranges.

[0062] Through stability confidence indicators After accurately identifying the true nature of the tension fluctuation signal, the system needs to dynamically adjust the control bandwidth accordingly. The core implementation method is bandwidth sensitivity. The dynamic mapping of bandwidth sensitivity directly determines the controller's response sensitivity to tension deviations and its ability to suppress mechanical noise. Its dynamic adjustment mechanism ensures that the system maintains optimal control performance under different operating conditions, avoiding both over-adjustment and control lag. The following section, using the operating condition examples from the previous text, elaborates on bandwidth sensitivity. The calculation process, control logic, and core function of [the system].

[0063] Following the previous example of stable operating conditions, the current stability confidence index has been calculated using a formula. This value is in the high range, and the system clearly determines that there is a persistent systemic tension deviation. The control bandwidth needs to be increased to accelerate the correction response and ensure that the tension quickly returns to the target range. Based on the process parameters and equipment characteristics of the precision forming of mirror aluminum foil, the relevant basic parameters are set as follows: System preset basic sensing bandwidth... 50Hz; dynamic damping coefficient =1; the drive speed is fed back in real time by a high-precision rotary encoder. The maximum drive speed of the main drive motor is 1500 rpm; this is the system's preset maximum drive speed. The speed parameter is 3000 rpm, which is directly related to the fundamental frequency of the motor's mechanical vibration and is the core reference for the bandwidth compression vibration isolation strategy.

[0064] Substitute the above parameters into the bandwidth sensitivity. The dynamic mapping formula is used for precise calculation, and the specific process is as follows:

[0065] Bandwidth sensitivity dynamic mapping formula:

[0066]

[0067] Substitute specific parameters into the calculation:

[0068] .

[0069] The calculation results show that when the system determines that there is a systematic tension deviation and the motor is in the low to medium speed range, the bandwidth sensitivity is nearly doubled compared to the basic sensing bandwidth of 50Hz. At this time, the controller's control sensitivity is greatly improved, which can quickly capture subtle changes in tension deviation and output precise control commands in a timely manner to ensure that the systematic tension deviation is corrected in the shortest possible time, thus ensuring the tension stability during the aluminum foil forming process and avoiding quality defects such as wrinkling and overstretching of aluminum foil caused by the continuous existence of tension deviation.

[0070] Conversely, when the main drive motor operates at high speeds, its operating characteristics change significantly: increased motor speed leads to a rise in its fundamental mechanical vibration frequency. At this point, the mechanical noise frequency easily overlaps with the controller's bandwidth. If high bandwidth sensitivity is maintained, the controller may mistakenly identify the mechanical noise as tension deviation, triggering unnecessary frequent adjustments—essentially "dancing" with the noise. This not only increases motor energy consumption but may also exacerbate roller vibration, affecting the quality of aluminum foil forming. For this condition, a dynamic mapping mechanism of bandwidth sensitivity plays a vibration-damping role: as the drive speed... rise, As the numerical value increases, the denominator in the bandwidth sensitivity calculation formula increases significantly, while the fractional term decreases accordingly, ultimately affecting the bandwidth sensitivity. It was forcibly compressed.

[0071] This bandwidth compression is essentially a precise vibration damping strategy: when the motor is operating at high speed and high noise, by reducing bandwidth sensitivity, the controller enters a flexible filtering state, actively filtering out mechanical noise signals that overlap with the control bandwidth, reducing ineffective control actions, and preventing the motor from vibrating unnecessarily due to noise, while maintaining basic tension monitoring capabilities; and once the system passes... Once a genuine systemic tension deviation is detected again, the bandwidth sensitivity will quickly rise to a high level, ensuring that the correction speed is not affected, thus achieving the dual goals of vibration avoidance without affecting correction and correction without amplifying noise.

[0072] In summary, through bandwidth sensitivity The system can dynamically map based on stability confidence indicators. By identifying the signal characteristics and combining them with the real-time speed of the main drive motor, the control sensitivity and noise suppression capability are adaptively adjusted to achieve a dynamic balance between the two. This mechanism effectively solves the problem of the incompatibility between sensitivity and noise suppression in traditional control methods. It ensures rapid correction of systematic deviations while avoiding over-adjustment caused by transient interference and mechanical noise, providing stable and reliable control support for the precision forming of mirror aluminum foil.

[0073] S4 combines the feedback tension value, bandwidth sensitivity, and linear velocity, and uses the phase advance attenuation factor constructed based on the inter-stage physical span to perform decoupling calculations and output tension control commands.

[0074] The core of this step is to comprehensively decouple the real-time tension deviation from the predicted disturbance from the preceding stage, and ultimately output the tension control command. To address the lag problem in the transmission of upstream fluctuations in multi-stage roller systems, the control law specifically introduces a phase advance attenuation factor based on physical distance. The fluctuations of the preceding roller system will occur at a linear velocity. Along the physical span between levels There will inevitably be a certain physical time delay when the signal is transmitted to this level. This factor can compensate for delayed predictions by trading space for time.

[0075] Tension control command The calculation formula is:

[0076]

[0077] In the formula, For proportional gain, The target tension constant is To provide feedback on the tension value, For bandwidth sensitivity, For the perturbation modes obtained through real-time observation, The phase advance attenuation factor is based on physical distance. For the physical span between classes, For linear velocity, The period is the discrete sampling period.

[0078] Calculation example: Assume that the following is known , The perturbation mode was observed in the pre-stage. Current inter-level physical span linear velocity Then physical delay The phase advance decay factor is At this point, the predicted compensation item is calculated as follows: By combining the instantaneous deviation correction term, the final control command can be obtained. This means that before the fluctuation reaches the current stage, the system has already adjusted the output current in advance based on the predicted value, actively preparing for the impending impact and completely solving the oscillation problem caused by lag in multi-stage systems.

[0079] By introducing a phase advance factor for decoupling control, it is possible to achieve advance compensation for tension fluctuations.

[0080] For the effects of this embodiment, refer to Figure 2 In the phase space diagram, the existing technology trajectory exhibits large areas of chaotic patches, indicating continuous oscillation; while the trajectory of this invention displays a clear centripetal spiral shape and rapidly converges towards the origin, proving a very strong steady-state tendency. (Reference) Figure 3 The residual plots show that the coverage area of ​​the region covered by this invention is extremely small, and the average residual value tends to be 0.1%. Compared with the large number of random peaks in the region of the prior art, this invention significantly avoids aluminum foil scratches and wrinkles caused by tension fluctuations. The above experimental results fully verify the significant advantages of this solution in improving the flatness of mirror aluminum foil.

[0081] The above are all preferred embodiments of the present invention and are not intended to limit the scope of protection of the present invention. Therefore, all equivalent changes made in accordance with the structure, shape and principle of the present invention should be covered within the scope of protection of the present invention.

Claims

1. An adaptive tension control method for precision forming of mirror-finish aluminum foil, characterized in that, Includes the following steps: S1, acquire all-factor working condition data during the mirror aluminum foil forming process, including feedback tension value, linear velocity and drive speed of main drive motor; S2, assess the stability confidence index based on the feedback tension value and linear velocity, and determine whether the tension deviation is a systematic error or random interference through the stability confidence index; Stability Confidence Index The calculation formula is: , To provide feedback on the tension value, The target tension constant is It is the static bias constant. It is a natural constant. The rate of change of tension, For the physical span between classes, Linear velocity; S3, based on stability confidence indicators and dynamic mapping bandwidth sensitivity of drive speed, adjusts the sensing bandwidth of the control system through bandwidth sensitivity to achieve mechanical noise suppression in different speed ranges; bandwidth sensitivity The calculation formula is: , Based on the sensing bandwidth, This is the dynamic damping coefficient. To drive the rotational speed, This is the maximum driving speed; S4 combines the feedback tension value, bandwidth sensitivity, and linear velocity, and uses the phase advance attenuation factor constructed based on the inter-stage physical span to perform decoupling calculations and output tension control commands.

2. The adaptive tension control method for precision forming of mirror aluminum foil according to claim 1, characterized in that, The evaluation logic for the stability confidence index includes: In response to the decrease in stability confidence index caused by the increase in the rate of change of tension, the current fluctuation is determined to be a mechanical instantaneous shock, and the correction force is weakened; In response to the feedback tension value continuously deviating from the target tension constant and the stability confidence index remaining at a high level, the current fluctuation is determined to be a systemic deviation, and a correction is initiated.

3. The adaptive tension control method for precision forming of mirror aluminum foil according to claim 1, characterized in that, The logic for dynamically mapping bandwidth sensitivity includes: Obtain the standardized speed ratio of the main drive motor. If the increase of the standardized speed ratio causes the mechanical noise frequency to enter the control bandwidth, the bandwidth sensitivity is compressed by increasing the denominator term in the calculation formula, so that the controller enters the flexible filtering state. If the stability confidence index indicates a systematic deviation, the correction response speed can be improved by increasing the bandwidth sensitivity.

4. The adaptive tension control method for precision forming of mirror aluminum foil according to claim 1, characterized in that, Tension control command The calculation formula is: In the formula, For proportional gain, The target tension constant is To provide feedback on the tension value, For bandwidth sensitivity, For the perturbation modes obtained through real-time observation, The phase advance attenuation factor is based on physical distance. For the physical span between classes, For linear velocity, The period is the discrete sampling period.

5. The adaptive tension control method for precision forming of mirror aluminum foil according to claim 4, characterized in that, The logic for outputting tension control commands includes: By using the phase advance attenuation factor to predict the time when the tension change of the preceding roller system will reach the current stage, the disturbance compensation amount is injected into the controller in advance to counteract the impending impact.

6. The adaptive tension control method for precision forming of mirror aluminum foil according to claim 1, characterized in that, The acquisition of all-element operating condition data is achieved through synchronous capture via a high-speed data acquisition bus, with a sampling period less than or equal to the preset discrete sampling period.

7. The adaptive tension control method for precision forming of mirror aluminum foil according to claim 1, characterized in that, The static bias constant in the stability confidence index calculation is used to prevent numerical singularities from occurring in the calculation formula under steady-state conditions and serves as the fault tolerance threshold of the system.

8. The adaptive tension control method for precision forming of mirror aluminum foil according to claim 7, characterized in that, The static bias constant is 2.

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