Abnormality treatment method for improving copper foil wrinkles

Abstract

The invention relates to the technical field of metal foil processing, and discloses an abnormity processing method for improving copper foil wrinkles, and the method comprises the steps: monitoring the microscopic stress distribution of the surface of a copper foil in real time to recognize the wrinkle precursor characteristics, and immediately applying active preventive intervention such as asymmetric tension fine adjustment after the recognition for inhibition; if the intervention is invalid, the formed macroscopic wrinkle form is diagnosed on line, and according to the diagnosis result, one functional lightweight guide roller is matched and selected from various functional lightweight guide rollers such as a middle convex roller or a flattening roller to be replaced; after replacement, the system automatically loads control parameters matched with the rotational inertia of the new guide roller, and cooperation of hardware and control is achieved. By establishing a'prevention-diagnosis-matching-cooperation 'closed-loop control system, active prevention of wrinkles is realized, the defect occurrence rate is remarkably reduced, and meanwhile, the processing efficiency and the finished product yield are improved.

Description

Technical Field

[0001] This invention relates to the field of metal foil processing technology, specifically to a method for improving the abnormal treatment of copper foil wrinkles. Background Technology

[0002] With the rapid development of the server and consumer electronics industries, the market demand for high-frequency, high-speed copper foil, a core material for printed circuit boards, is evolving towards thinner specifications (e.g., 4-35μm). However, the reduction in copper foil thickness poses a severe challenge to the stability of the production process. In continuous production stages, from cathode roll deposition to winding and subsequent surface treatment, ultra-thin copper foil, due to its extremely low bending stiffness and mechanical strength, is highly susceptible to wrinkling defects caused by uneven local stress, which directly leads to a decrease in yield and an increase in production costs.

[0003] Currently, industry-standard methods for handling such wrinkle problems have significant limitations. A common approach is to passively adjust the system based on operator experience after macroscopic wrinkles are detected, such as adjusting the guide roller slide position or stopping the machine to measure the guide roller's level and check the tension control system. This method is slow to respond and lacks precise data guidance during the adjustment process, often failing to effectively eliminate wrinkles and leading to recurring problems. Another tentative improvement is through hardware modifications, such as replacing traditional steel guide rollers with larger outer diameter ones to increase the copper foil's wrapping angle and stabilize the foil path. However, while increasing the guide roller diameter, this approach also drastically increases its weight and rotational inertia, not only increasing the energy burden on the drive system but also making the tension control system sluggish during high-speed start-stop or dynamic speed-changing conditions, potentially introducing new tension fluctuations. Therefore, its improvement effect is not ideal.

[0004] In summary, existing technologies lack a systematic solution that can proactively prevent, accurately diagnose, and efficiently correct wrinkle defects in ultrathin copper foil. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides an abnormal handling method for improving copper foil wrinkles. It aims to solve the complex technical problems of existing wrinkle handling methods, such as slow response, lack of targeted adjustment methods, low processing efficiency, and the introduction of dynamic tension instability due to the inherent defects of traditional hardware improvement schemes.

[0006] This invention provides a method for improving the abnormal treatment of copper foil wrinkles, employing the following technical solution: An abnormality treatment method for improving copper foil wrinkles includes the following steps: S1. Monitor the micro-stress distribution on the surface of copper foil in real time to identify early signs of wrinkling; S2. When the precursor features of the wrinkles are identified, active preventive intervention is applied to the copper foil to inhibit its development; S3. If the proactive preventive intervention fails to suppress the early signs of wrinkles within a preset time, the macroscopic wrinkle morphology that has been formed will be diagnosed online. S4. Based on the diagnostic results of the macroscopic wrinkle morphology, select one from a variety of preset functional lightweight guide rollers; S5. Replace the existing guide rollers on the production line with the selected functional lightweight guide rollers, and automatically load control parameters that match the rotational inertia of the functional lightweight guide rollers.

[0007] By adopting the above technical solution, this invention establishes a multi-level closed-loop control system from "prevention" to "correction," and its innovative mechanism and beneficial effects are reflected in: Early intervention: Steps S1 and S2 constitute a proactive prevention module. By identifying the physical precursors (abnormal evolution of microscopic stress distribution) before macroscopic wrinkle nucleation and propagation, the system can intervene at the nascent stage of defect formation. This intervention actively counteracts the localized stress concentrations that cause wrinkles by constructing a compensating stress field, thereby preventing most wrinkling events from occurring at their physical root without interrupting production.

[0008] Precision of the treatment method: Steps S3 and S4 constitute a precise diagnosis and matching module. This solution abandons the traditional "one-size-fits-all" adjustment that relies on manual experience, and instead uses an online diagnostic system to objectively and quantitatively classify the formed wrinkles morphologically. Based on the classification results, the system selects the guide roller that is mechanically most suitable for handling this specific type of wrinkle from a "tool library" containing various functional guide rollers. This achieves a precise mapping between defect types and optimal physical intervention methods, ensuring the effectiveness of the treatment.

[0009] System Response Coordination: Step S5 ensures the synchronous matching of hardware replacement and software control. Lightweight guide rollers, due to their significantly reduced moment of inertia, exhibit physical response characteristics completely different from traditional heavy-duty guide rollers. This solution automatically loads control parameters that match the moment of inertia of the new guide roller, ensuring that the dynamic response characteristics of the control system (command issuer) and the physical actuator (guide roller) are matched. This avoids control overshoot or oscillation caused by inertia mismatch, thus fully utilizing the rapid response advantage of the lightweight guide roller and achieving system-level stability after replacement.

[0010] Preferably, the wrinkle precursor features in step S1 include at least one of the following: a continuous increase in the amplitude of a specific frequency fluctuation in the transverse tension distribution of the copper foil, or the slope of the tension difference between the center and edge regions of the copper foil exceeding a preset threshold. By adopting the above technical solution, the abstract "precursor features" are defined as specific physical quantities that can be accurately measured by sensors. The fluctuation at a specific frequency is directly related to the periodic relaxation of the copper foil, while the slope of the tension difference characterizes the degree of non-uniformity of transverse stress; both are direct causes of wrinkle formation. Using these parameters as criteria improves the sensitivity and reliability of precursor identification.

[0011] Preferably, the spatial frequency of the specific frequency fluctuation is 0.05–0.2 cycles / mm; the time rate of change of the tension differential slope is greater than 0.5–2.0 µm / s. By adopting the above technical solution, an effective threshold range for the aforementioned physical quantities, verified experimentally, is provided. This range setting can effectively avoid false alarms caused by normal production fluctuations while ensuring a high detection rate, thus optimizing the performance of the monitoring system.

[0012] Preferably, the active preventative intervention in step S2 is implemented by applying an asymmetric speed command to the driving systems on both sides of the copper foil while maintaining a constant overall average tension, thereby generating an instantaneous speed difference. This technical solution provides a specific and efficient intervention method. This asymmetric drive can generate a small shear stress field within the copper foil, which can directly act on the area where wrinkles are about to form, reconstructing the local stress balance. Simultaneously, since the overall average tension remains constant, the disturbance to the entire production process is minimized.

[0013] Preferably, the instantaneous velocity difference is 0.01 to 0.1% of the average linear velocity of the copper foil. By adopting the above technical solution, the intensity range of the intervention measure is defined. The velocity difference within this range is sufficient to generate an effective compensating stress field, while being small enough not to cause new damage to the copper foil or introduce other unstable factors.

[0014] Preferably, the roller body of the functional lightweight guide roller is made of 7075-T6 aluminum alloy. By adopting the above technical solution, the core material of the guide roller is clearly defined. 7075-T6 aluminum alloy combines low density and high strength, making it an ideal choice for achieving a balance between lightweight and high rigidity in the guide roller, providing a physical basis for subsequent rapid response and stable control.

[0015] Preferably, step S4, which involves selecting a functional lightweight guide roller based on the wrinkle morphology, includes: selecting a micro-volume convex roller when the wrinkle is diagnosed as a center-relaxation type; and selecting a micro-spiral groove flattening roller when the wrinkle is diagnosed as a diagonal oblique type. By employing the above technical solution, the mechanical correspondence between different functional guide rollers and specific wrinkle types is revealed. The micro-volume convex roller, with its slightly larger diameter in the middle, applies a small additional stretch to the center of the copper foil, thereby eliminating center relaxation. The micro-spiral groove flattening roller utilizes its surface spiral structure to generate a lateral force from the center to both sides during copper foil movement, effectively flattening oblique wrinkles.

[0016] Preferably, the control parameters matched with the guide roller in step S5 include: servo motor drive parameters set for the rotational inertia of the guide roller, and specially optimized PID control model parameters. By adopting the above technical solution, the content of the control parameters that need to be adaptively adjusted is specifically specified. The servo drive parameters directly determine the motor's ability to execute commands, while the PID parameters define the response speed, stability, and steady-state error of the closed-loop control system. The coordinated optimization of both is key to achieving compatibility between the control system and the new hardware.

[0017] Preferably, the surface of the functional lightweight guide roller is treated with either hard anodizing or hard chrome plating. By employing the above technical solution, the surface properties of the lightweight guide roller are improved. Although the aluminum alloy substrate is lightweight and high-strength, its surface hardness and wear resistance are insufficient. Through hard anodizing or hard chrome plating, a high-hardness, wear-resistant, and corrosion-resistant ceramic or metal layer can be formed on its surface, significantly extending the service life of the guide roller.

[0018] Preferably, the process parameters for the hard anodizing treatment include: using an electrolyte with a sulfuric acid concentration of 180–220 g / L, at a temperature of -2–5°C, and at a flux of 2.0–3.5 A / dm³. 2 By applying a high cathode current density, a hard oxide film with a thickness of 25–50 µm is obtained. This technical solution provides a set of specific process conditions for stably obtaining high-performance oxide films. The combination of low temperature and high current density helps to generate a dense and hard oxide film, ensuring the effectiveness of the surface treatment.

[0019] This invention provides a method for improving the treatment of abnormalities such as wrinkles in copper foil. It has the following beneficial effects: 1. This invention significantly reduces the incidence of macroscopic wrinkle defects, achieving online proactive prevention in the production process. By real-time monitoring of wrinkle precursor characteristics and applying proactive preventative intervention, this method transforms the abnormality handling mode from the traditional "passive correction after defect formation" to "proactive prevention before defect formation," suppressing most wrinkle events at their source without interrupting production.

[0020] 2. This invention improves the efficiency and accuracy of anomaly handling, significantly reducing production downtime caused by wrinkle issues. The method uses an online diagnostic system to quickly classify wrinkle morphology and precisely match the optimal solution from modular functional guide roller sets. Combined with the easy-to-replace nature of the lightweight guide rollers, it transforms the traditional time-consuming manual troubleshooting and adjustment process into a standardized, rapid response procedure.

[0021] 3. This invention enhances the stability of tension control during the production process, thereby improving the consistency and yield of the final copper foil product. After replacing the guide rollers with low-inertia functional lightweight rollers, the system automatically loads matching control parameters, achieving synergy between control commands and the dynamic response characteristics of the physical actuator, avoiding tension overshoot and oscillations that may be caused by inertia mismatch. Especially under dynamic conditions such as production line start-up, shutdown, or speed changes, this solution can maintain more stable tension, ensuring the surface quality of the copper foil. Detailed Implementation

[0022] Preparation example: Preparation of functional lightweight guide rollers This section describes the preparation methods of the core components used in subsequent embodiments and comparative examples—lightweight guide rollers with different functions. The raw materials used, such as 7075-T6 aerospace-grade seamless aluminum alloy tubing and various chemical reagents, are all commercially available industrial-grade products and do not require separate preparation.

[0023] Preparation Example 1: Preparation of High-Precision, Straight, and Lightweight Guide Rollers Machining: Seamless 7075-T6 aluminum alloy tubing with an outer diameter of Ø220mm and a wall thickness of 20mm was selected as the roller body.

[0024] Rough machining: The tube is turned using a CNC lathe, with a grinding allowance of 1.0mm.

[0025] Finishing: Precision grinding is performed using an external cylindrical grinder until the outer diameter reaches Ø220mm±0.005mm. After machining, ensure that the surface roughness Ra≤0.2µm and the circular runout error≤0.01mm.

[0026] Dynamic balancing test: The finished roller body is subjected to dynamic balancing test at a speed of 2000 rpm and corrected to dynamic balancing accuracy level G1.0.

[0027] Surface hard anodizing treatment: Pretreatment: The roller body is etched in sodium hydroxide solution (50g / L) at 50℃ for 2min, and then polished in nitric acid solution (180g / L) at room temperature for 1min.

[0028] Anodizing: The roller is immersed in an electrolyte solution for treatment. The electrolyte composition is: sulfuric acid (200 g / L) and oxalic acid (3 g / L). The process parameters are: electrolyte temperature 0℃, cathode current density 2.5 A / dm³. 2 Processing time: 60 minutes.

[0029] Post-treatment: Boiling water sealing was performed in deionized water at 98℃ for 25 minutes. After the treatment, a high-precision, flat, and lightweight guide roller with a hard oxide film of 45μm thickness and HV450 hardness was obtained, denoted as G-1.

[0030] Preparation Example 2: Preparation of a Miniature Medium-Convex Lightweight Guide Roller The same tubing and roughing, dynamic balancing, and surface treatment processes as in Example 1 were used. The difference lies in the finishing steps: Finishing: A parabolic convex profile is ground using a CNC cylindrical grinding machine according to a preset CNC program. Based on different degrees of convexity, the following three types of guide rollers are manufactured: Preparation Example 2-1: The increase in the diameter of the roller's center compared to the diameters at both ends is 0.05 mm. The resulting guide roller is designated G-2A.

[0031] Preparation Example 2-2: The increase in the diameter of the roller's center compared to the diameters at both ends is 0.15 mm. The resulting guide roller is designated G-2B.

[0032] Preparation Example 2-3: The increase in the diameter of the roller's center compared to the diameters at both ends is 0.20 mm. The resulting guide roller is designated G-2C.

[0033] Preparation Example 3: Preparation of a micro-spiral groove flattening lightweight guide roller The same tube material and machining (straight roll processing) and surface treatment process as in Example 1 were used. The difference lies in the addition of a spiral groove processing step after finishing. Spiral groove machining: The precision-machined straight roller body is fixed on a five-axis CNC machining center, and a micro ball end mill is used to machine symmetrical double spiral microgrooves on the roller surface. Based on different spiral groove parameters, the following three types of guide rollers are prepared: Preparation Example 3-1: The helix angle was 5°, the groove depth was 15 μm, and the groove width was 0.8 mm. The resulting guide roller is designated G-3A.

[0034] Preparation Example 3-2: The helix angle was 10°, the groove depth was 30 μm, and the groove width was 1.0 mm. The resulting guide roller is designated G-3B.

[0035] Preparation Example 3-3: The helix angle was 15°, the groove depth was 50 μm, and the groove width was 1.2 mm. The resulting guide roller is designated G-3C.

[0036] Example: Specific application of the method of the present invention This section describes the specific process of applying the method of this invention on the same ultrathin copper foil production line. The experimental object was an electrolytic copper foil with a thickness of 8 μm and a width of 1350 mm. The basic setpoint of the production line was 60 m / min, and the setpoint of the tension control system was 50 N / m. The threshold for judging the precursor characteristics of the online monitoring system was: the amplitude of a specific frequency fluctuation exceeded the reference value by 20%, and the tension difference slope exceeded 1.0 µm / s.

[0037] Example 1:

[0038] This embodiment provides a method for preventing and correcting type C (diagonal oblique type) wrinkles, specifically including the following steps: During normal production line operation, the online monitoring system detected that the tension difference slope of the copper foil reached 1.2µm / s, exceeding the threshold and indicating a precursor to wrinkling. The system immediately initiated the asymmetric tension fine-tuning program to intervene.

[0039] After 3.0 seconds of intervention, the tension differential slope remained at 1.1 µm / s, and the precursor characteristics were not effectively suppressed. At this point, slightly slanted wrinkles, visible to the naked eye and forming an angle of approximately 45° with the direction of operation, began to appear on the surface of the copper foil.

[0040] The detection system diagnosed the wrinkle as Class C and issued an alarm. Operators stopped the production line.

[0041] According to the system instructions, the flat guide roller at the current station was replaced with the micro-spiral groove flattening guide roller (G-3B) with a helix angle of 10° prepared in Preparation Example 3-2. The entire replacement process took 8 minutes.

[0042] After the replacement is confirmed in the control system, the system automatically calls up the PID parameters (P=2.0, I=0.3s, D=0.03s) and servo motor drive parameters that match the G-3B guide roller.

[0043] The production line was restarted and restored to a linear speed of 60 m / min. After the restart, the original slanted wrinkles were completely eliminated after passing through the new flattening guide rollers, and no similar wrinkles appeared in subsequent production processes.

[0044] Example 2:

[0045] This embodiment provides a method for preventing and correcting type A (central relaxation type) wrinkles, specifically including the following steps: During production line operation, the online monitoring system detected a spatial frequency fluctuation of 0.1 cycles / mm in the central area of ​​the copper foil, with the amplitude exceeding the baseline value by 25% for 1.5 seconds consecutively, which was determined to be a precursor to wrinkling. The system initiated the asymmetric tension fine-tuning program.

[0046] The intervention failed, and noticeable wavy wrinkles appeared in the middle of the copper foil. The system diagnosed these wrinkles as Class A.

[0047] The production line was paused, and according to system instructions, the guide rollers were replaced with micro-convex guide rollers (G-2B) with a convexity of 0.15 mm prepared in Preparation Example 2-2. The replacement process took 7 minutes.

[0048] The system automatically loads control parameters that match the G-2B guide roller.

[0049] The production line was restarted, the central loose wrinkles were effectively flattened, and the surface of the copper foil was restored to smoothness.

[0050] Example 3:

[0051] This embodiment provides a method for successfully suppressing early signs of wrinkles through preventative intervention at higher production speeds, specifically including the following steps: The production line speed was increased to 80m / min to simulate higher-load production conditions.

[0052] After running for about 15 minutes, the online monitoring system detected that the tension differential slope reached 1.3µm / s, which exceeded the threshold.

[0053] The system immediately initiated the asymmetric tension fine-tuning program, applying an instantaneous speed difference of 0.05% to both sides of the copper foil.

[0054] After 2.5 seconds of intervention, the monitoring system showed that the tension differential slope dropped back to 0.4µm / s, returning to within the safe threshold.

[0055] Throughout the process, no macroscopic wrinkles visible to the naked eye formed on the copper foil surface. The production line did not need to be stopped, nor was any hardware replacement required, thus achieving proactive online prevention of problems.

[0056] Example 4:

[0057] This embodiment provides a method for processing corresponding wrinkles using functional guide rollers with different parameters, in order to verify the effectiveness of the parameter range covered by the present invention.

[0058] Scenario 1 (Addressing minor C-type wrinkles): When minor C-type wrinkles with a small wrinkle angle (approximately 30°) occur, replace the roller with the micro-spiral groove flattening guide roller (G-3A) prepared in Preparation Example 3-1 with a helix angle of 5°. After restarting production, the wrinkles are eliminated.

[0059] Scenario 2 (Addressing Severe Type A Wrinkles): When severe Type A wrinkles with large wrinkle peak heights occur, the roller is replaced with a micro-convex guide roller (G-2C) prepared in Examples 2-3, with a convexity of 0.20 mm. After restarting production, the wrinkles are effectively smoothed out.

[0060] This embodiment demonstrates that by selecting guide rollers with different parameters and specifications in the preparation example, wrinkling problems of different degrees can be specifically solved, indicating that the technical solution claimed in this invention has wide applicability and effectiveness.

[0061] Comparative Example: Compared with existing and conventional technologies Comparative Example 1 The difference from Example 1 is that this comparative example uses a conventional operating method. The production line uses heavy-duty stainless steel straight guide rollers and no online monitoring system is installed. When the same type C (diagonal oblique type) wrinkles as in Example 1 occur during production, they are visually detected by the inspection personnel, the machine is stopped immediately, and maintenance personnel manually adjust the mechanical and tension settings based on their personal experience. All other production parameters are the same.

[0062] Comparative Example 2 Compared to Example 1, the difference lies in that this comparative example simply replaces the guide roller material with lightweight aluminum alloy. The production line was initially equipped with the high-precision, flat, lightweight guide roller (G-1) prepared in Example 1, but it was not equipped with an online diagnostic system or modular functional guide roller assembly. When type C wrinkles appeared, the handling method was the same as in Comparative Example 1, i.e., manual adjustment was performed after stopping the machine. Everything else was the same.

[0063] Comparative Example 3 The difference compared to Example 1 is that this comparative example uses a fixed functional guide roller to attempt to solve all problems. The production line was initially equipped with the micro-convex guide roller (G-2B) prepared in Preparation Example 2-2. When the same type C wrinkles as in Example 1 occurred during production, the system did not perform any replacement operations, and production continued. Everything else was the same.

[0064] Comparative Example 4 Compared to Example 1, the difference lies in that this comparative example employs the diagnostic and replacement process of the present invention, but disables the preventative intervention function in step one. The system only issues an alarm and instructs the operator to replace the micro-spiral groove flattening guide roller (G-3B) of Preparation Example 3-2 after detecting that macroscopic C-type wrinkles have fully formed. Everything else is the same.

[0065] Comparative Example 5 The difference from Example 1 is that, in this comparative example, after replacing the functional guide roller, no matching adaptive control parameters were applied. After replacing it with the micro-spiral groove flattening guide roller (G-3B) of Preparation Example 3-2, the control system continued to use the general PID parameters (P=1.0, I=0.8s, D=0.08s) suitable for standard flat guide rollers for tension control. Everything else was the same.

[0066] Test Example 1: Validation of the effectiveness of preventive interventions Experimental objective: This test aims to quantitatively verify the effectiveness of the "asymmetric tension fine-tuning" intervention measure in the method of this invention, that is, to evaluate whether the system can restore the micro-stress distribution of copper foil to a stable state without forming macro-wrinkles after identifying the precursor features of wrinkles.

[0067] Experimental equipment and conditions: Production line configuration: The ultra-thin copper foil production line described in the examples is used, and the high-precision flat and lightweight guide roller (G-1) prepared in Preparation Example 1 is initially installed.

[0068] Experimental materials: Electrolytic copper foil with a thickness of 8μm and a width of 1350mm.

[0069] Operating parameters: The production line speed is constant at 80m / min, and the tension setting is 50N / m.

[0070] System settings: Enable online monitoring and preventative intervention functions. The trigger threshold for early signs of wrinkling is set to: tension difference slope > 1.0 µm / s. The recovery threshold for a safe state is set to: tension difference slope < 0.5 µm / s.

[0071] Experimental steps: 1. Start the production line and ensure it operates stably under the established experimental equipment and conditions.

[0072] 2. Start the data recording program and continuously record the full-width tension differential slope value calculated by the online monitoring system at a frequency of 10Hz.

[0073] 3. The system operates automatically. When the tension differential slope value is detected to exceed the trigger threshold of 1.0µm / s for the first time, the data logging program automatically marks the event as an "intervention event".

[0074] 4. Record the peak slope at the moment the intervention event occurs, and confirm that the preventive intervention function (asymmetric tension fine-tuning) has been automatically executed by the control system.

[0075] 5. Continuously record the changes in the tension differential slope. Record the time when the slope value first drops below the safe recovery threshold of 0.5µm / s.

[0076] 6. Calculate the "recovery time" required from triggering intervention to returning to the safety threshold.

[0077] 7. During a continuous 1-hour production cycle, repeat steps 3 to 6 and record all intervention events and their related data.

[0078] Experimental data: Table 1: Data Recording of Functional Response to Preventive Intervention

[0079] in conclusion: The test data in Table 1 show that the preventive intervention function proposed in this invention is effective. After detecting the early signs of wrinkling (i.e., the peak value of the tension difference slope is in the range of 1.08 to 1.48 µm / s), the system is able to suppress the feature back below the safe threshold within 1.6 to 2.9 seconds.

[0080] The mechanism of this method lies in its ability to advance the treatment process by monitoring the dynamic evolution of the micro-stress field of the copper foil in real time, rather than waiting for macroscopic defects to form. The applied asymmetric tension fine-tuning actively constructs a compensating stress field within the copper foil. This stress field can counteract the localized stress concentrations that lead to wrinkle formation, thereby physically preventing the nucleation and propagation of wrinkles.

[0081] This test verifies that the method can transform anomaly handling from the traditional "passive correction" to "active prevention," providing a feasible technical path to maintain the stability of copper foil surface quality without interrupting production.

[0082] Test Example 2: Response Performance Verification of Control Parameter Adaptation Function Experimental objective: This test aims to quantitatively evaluate the performance of the adaptive loading function of the control parameters in the method of this invention. It compares the ability to suppress tension fluctuations under dynamic conditions (step changes in production line speed) by using adaptive control parameters matched to lightweight guide rollers and general control parameters.

[0083] Experimental equipment and conditions: Production line configuration: Use the production line in Example 1 and install the micro-spiral groove flattening lightweight guide roller (G-3B) prepared in Preparation Examples 3-2.

[0084] Experimental materials: Electrolytic copper foil with a thickness of 8μm and a width of 1350mm.

[0085] Operating parameters: The initial speed of the production line is 60m / min, and the tension setting is 50N / m.

[0086] Test conditions: Apply a speed step command to the production line, linearly increasing the linear speed from 60m / min to 70m / min within 1.0 second.

[0087] Data acquisition: A high-precision tension sensor (response frequency 1kHz) is used to record the real-time tension value during the speed change process.

[0088] Experimental steps: 1. Load adaptive parameters: Switch the control system to the adaptive control parameters used in Example 1 (PID parameters: P=2.0, I=0.3s, D=0.03s).

[0089] 2. Perform test conditions: After the production line is running stably at a speed of 60m / min, apply a speed step command.

[0090] 3. Data Recording (Adaptive Group): Record the maximum tension value monitored by the tension sensor during this process and calculate the maximum tension overshoot. Simultaneously, record the time required from the speed reaching 70 m / min until the tension value recovers and stabilizes within ±2% of the set value, i.e., the stabilization time.

[0091] 4. Repeat steps 2-3 for a total of 5 independent tests.

[0092] 5. Load general parameters: Switch the control system to the general control parameters used by the comparative proportional 5 (PID parameters: P=1.0, I=0.8s, D=0.08s).

[0093] 6. Perform test conditions: After the production line is running stably at a speed of 60m / min, apply the same speed step command.

[0094] 7. Data Records (General Group): Record the same performance metrics as in step 3.

[0095] 8. Repeat steps 6-7 for a total of 5 independent tests.

[0096] Experimental data: Table 2: Comparison of dynamic response performance under different control parameters

[0097] in conclusion: The data comparison in Table 2 shows that, using adaptive control parameters matched to the lightweight guide rollers, the dynamic tension control performance differs significantly from that of general parameters. Specifically, under the same speed step disturbance, the maximum tension overshoot is significantly reduced from the range of 18.42%–24.15% to the range of 5.38%–7.91%; the tension stabilization time is shortened from 2.85–3.47 seconds to 0.72–0.94 seconds.

[0098] The mechanism behind this result lies in the fact that the lightweight guide roller, due to its significantly reduced moment of inertia, exhibits reduced response lag in the physical system, thus possessing the potential for rapid response to control commands. The adaptive control parameters of this invention (with higher proportional gain and faster response characteristics) are optimized specifically for this low inertia characteristic, enabling the control commands to be executed quickly and accurately by the physical system, thereby achieving rapid suppression of tension fluctuations.

[0099] Conversely, general control parameters are typically designed for high-inertia systems, and their control strategies are relatively conservative. When applied to low-inertia systems, this results in a mismatch between control and execution, leading to severe overshoot and prolonged oscillations under disturbances.

[0100] This test verifies the necessity of the "hardware-control" synergy in this invention. That is, simply replacing the lightweight hardware is insufficient to achieve optimal performance; it must be combined with a matching adaptive control algorithm to fully utilize its low inertia advantage and achieve precise tension control under high-speed dynamic conditions.

[0101] Test Example 3: Comparison of the Incidence and Severity of Wrinkle Events Experimental objective: This test aims to comprehensively evaluate the effectiveness of the method of this invention and various comparative methods in suppressing macroscopic wrinkling events during long-term continuous production. Evaluation indicators include the total frequency of wrinkle occurrence and the average severity of wrinkles.

[0102] Experimental equipment and conditions: Production line and materials: The same production line and 8μm electrolytic copper foil as in the example were used.

[0103] Test cycle: Each test method is run continuously for a full 8-hour production shift under the same environmental conditions.

[0104] Test group: Example 1 group: The entire process of "prevention-diagnosis-replacement-synergy" described in this invention is fully adopted.

[0105] Comparative Example 1: Using traditional stainless steel guide rollers and manual adjustment during machine stop.

[0106] Comparative Example 2: Lightweight straight guide rollers and manual adjustment during machine stop were used.

[0107] Comparative Example 3: Pre-installed micro-sized convex guide rollers (G-2B) and continuously running.

[0108] Comparative Group 4: The diagnostic replacement process was adopted, but the preventive intervention function was disabled.

[0109] Data Acquisition and Evaluation: An online detection system automatically records all macroscopic folding events that occur within 8 hours. The system automatically assesses the severity of each fold based on its maximum height (amplitude), classifying it into a level 1-5 (level 1 being the mildest and level 5 the most severe), and calculates the average value.

[0110] Experimental steps: 1. Configure the production line for Comparative Example 1, using traditional stainless steel flat guide rollers. Start production and begin 8 hours of timing and data recording.

[0111] 2. After the test cycle is completed, save the data. Change the production line configuration to the state of comparative group 2 (replace with G-1 guide rollers).

[0112] 3. Repeat steps 1-2 to complete the 8-hour continuous test for Comparative Example 2, Comparative Example 3, Comparative Example 4 and Example 1 in sequence.

[0113] 4. Compile the data from all test groups and conduct comparative analysis.

[0114] Experimental data: Table 3: Comparison of wrinkle suppression performance of different methods within an 8-hour production cycle

[0115] in conclusion: Table 3 clearly shows the gradient differences in wrinkle suppression performance among different techniques. The method of this invention (Example 1) is significantly superior to all comparative methods in both the frequency and severity of wrinkle events.

[0116] The underlying mechanism of this result is analyzed as follows: The results of Comparative Examples 1 and 2 show that simple passive adjustments or simple hardware weight reduction cannot fundamentally solve the problem; wrinkling events remain frequent and severe.

[0117] The results of Comparative Example 3 reveal the limitations of fixed functional guide rollers. Although the total number of events was reduced, the average severity level was the highest. This indicates that when the roller type does not match the actual type of wrinkles produced (e.g., using a convex roller to deal with oblique wrinkles), it not only fails to solve the problem but may also exacerbate local stress distortion, leading to more severe defects. This, in turn, demonstrates the necessity of the "online diagnosis and modular matching" step in this invention.

[0118] The comparison between Comparative Example 4 and Example 1 is most illustrative. Both employed the correct diagnostic and matching replacement procedures; the only difference was whether the preventative intervention function was enabled. The total number of wrinkle events was drastically reduced from 8 to 2, directly demonstrating the effectiveness of the core "proactive prevention" step of this invention. It can eliminate most wrinkles before they form a macroscopic shape.

[0119] In summary, this test verifies the systematic advantages of this invention. Its high performance does not stem from improvements in a single technology, but rather from the organic integration of proactive prevention, precise diagnosis, and rapid response, forming a multi-level closed-loop control system. This system overcomes the fundamental shortcomings of traditional methods in terms of timeliness and specificity, and is key to achieving high-quality and stable production of ultra-thin copper foil.

[0120] Test Example 4: Comparison of Production Efficiency and Yield Experimental objective: This test aims to quantitatively evaluate the overall efficiency of the method of this invention relative to different comparative methods in a continuous production process from the perspective of production economics. The evaluation indicators are the cumulative downtime caused by wrinkling issues and the final yield of copper foil products.

[0121] Experimental equipment and conditions: Production line and materials: The same production line and 8μm electrolytic copper foil as in the example were used.

[0122] Test cycle: Each test method is run continuously for a full 8-hour production shift under the same environmental conditions.

[0123] Test group: Example 1 group: The entire process method described in this invention is adopted.

[0124] Comparative Example 1: Using traditional stainless steel guide rollers and manual adjustment during machine stop.

[0125] Comparative Example 2: Lightweight flat guide rollers (G-1) and manual adjustment method during machine shutdown were used.

[0126] Comparative Group 4: The diagnostic replacement process was adopted, but the preventive intervention function was disabled.

[0127] Data Acquisition: Automatically records the total downtime of the production line due to handling wrinkle issues during the test cycle. After the test cycle, the total production length is calculated using the meter counter data, and the length of qualified products is determined through the quality inspection process, thereby calculating the finished product yield. Finished Product Yield (%) = (Length of Qualified Products / Total Production Length) × 100%.

[0128] Experimental steps: 1. Configure a production line for Comparative Example 1. Start production and begin 8 hours of timing and data recording. For this group, any downtime caused by wrinkles will last from the time the production line speed drops to zero until it returns to normal production speed.

[0129] 2. After the test cycle ends, save the cumulative downtime and production length data.

[0130] 3. Change the production line configuration to the state of comparative group 2.

[0131] 4. Repeat steps 1-3 to complete the 8-hour continuous test for Comparative Example 2, Comparative Example 4 and Example 1 in sequence.

[0132] Data from all test groups were compiled and compared.

[0133] Experimental data: Table 4: Comparison of Production Efficiency of Different Methods within an 8-Hour Production Cycle

[0134] in conclusion: The test data in Table 4, from the perspectives of production efficiency and finished product output, verify the comprehensive advantages of the method of the present invention.

[0135] Comparing Comparative Examples 1 and 2 with Comparative Example 4 and Example 1, there is a difference in cumulative downtime by orders of magnitude. The fundamental reason lies in the change in processing mode. Comparative Examples 1 and 2 rely on passive manual intervention, and their processes include uncertain fault diagnosis time and long mechanical adjustment time. In contrast, the present invention (and Comparative Example 4) uses automated diagnosis and modular rapid replacement, which reduces the processing time of a single event from hours to minutes.

[0136] Compared to Comparative Example 4 and Example 1, the downtime was further reduced from 42 minutes to 15 minutes. This improvement stems directly from the introduction of the preventative intervention function in this invention. As shown in Test Example 3, this function effectively reduced the total number of macro-wrinkle events, thereby fundamentally reducing the frequency of downtime intervention.

[0137] Finished product yield data is highly correlated with downtime data. Longer downtime and more frequent production start-ups and shutdowns inevitably lead to more scrap. This invention minimizes the scrap rate by maximizing continuous stable operating time.

[0138] In summary, this test demonstrates that the present invention is not merely an improvement on a single technical point, but rather a systematic process optimization solution. It reduces downtime requirements through "proactive prevention" and shortens necessary downtime through "rapid response." The combined effect of these two approaches ultimately maximizes effective production time and minimizes material loss, demonstrating clear industrial application value.

Claims

1. A method for improving the abnormality treatment of copper foil wrinkles, characterized in that, Includes the following steps: S1. Monitor the micro-stress distribution on the surface of copper foil in real time to identify early signs of wrinkling; S2. When the precursor features of the wrinkles are identified, active preventive intervention is applied to the copper foil to inhibit its development; S3. If the proactive preventive intervention fails to suppress the early signs of wrinkles within a preset time, the macroscopic wrinkle morphology that has been formed will be diagnosed online. S4. Based on the diagnostic results of the macroscopic wrinkle morphology, select one from a variety of preset functional lightweight guide rollers; S5. Replace the existing guide rollers on the production line with the selected functional lightweight guide rollers, and automatically load control parameters that match the rotational inertia of the functional lightweight guide rollers.

2. The method for improving the abnormality treatment of copper foil wrinkles according to claim 1, characterized in that, The wrinkle precursor features in step S1 include at least one of the following: the amplitude of a specific frequency fluctuation in the transverse tension distribution of the copper foil continuously increases, or the slope of the tension difference between the center and edge regions of the copper foil exceeds a preset threshold.

3. The method for improving the abnormality treatment of copper foil wrinkles according to claim 2, characterized in that, The spatial frequency of the specific frequency fluctuation is 0.05 to 0.2 cycles / mm; the time rate of change of the tension differential slope is greater than 0.5 to 2.0 µm / s.

4. The method for improving the abnormality treatment of copper foil wrinkles according to claim 1, characterized in that, The specific method of the active preventive intervention in step S2 is as follows: while keeping the overall average tension of the copper foil constant, apply an asymmetric speed command to the drive system on both sides of the copper foil to generate an instantaneous speed difference.

5. The method for improving the abnormality treatment of copper foil wrinkles according to claim 4, characterized in that, The instantaneous velocity difference is 0.01 to 0.1% of the average linear velocity of the copper foil.

6. The method for improving the abnormality treatment of copper foil wrinkles according to claim 1, characterized in that, The functional lightweight guide roller is made of 7075-T6 aluminum alloy.

7. A method for improving the abnormality treatment of copper foil wrinkles according to claim 1 or 6, characterized in that, The step S4, which involves selecting a functional lightweight guide roller based on the fold morphology, includes: When diagnosed with a central relaxation type of wrinkle, select a micro-volume convex roller; When diagnosed as diagonal slant wrinkles, select a micro-spiral groove flattening roller.

8. The method for improving the abnormality treatment of copper foil wrinkles according to claim 1, characterized in that, The control parameters matched with the guide roller in step S5 include: servo motor drive parameters set for the rotational inertia of the guide roller, and specially optimized PID control model parameters.

9. The method for improving the abnormality treatment of copper foil wrinkles according to claim 6, characterized in that, The surface of the functional lightweight guide roller is treated with either hard anodizing or hard chrome plating.

10. The method for improving the abnormality treatment of copper foil wrinkles according to claim 9, characterized in that, The process parameters for the hard anodizing treatment include: using an electrolyte with a sulfuric acid concentration of 180–220 g / L, at a temperature of -2–5°C, and at a flux of 2.0–3.5 A / dm³. 2 The cathode current density was processed to obtain a hard oxide film with a thickness of 25–50 µm.

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