A production process control method and system for a lightweight high-conductivity FFC flexible flat cable for vehicles

Abstract

The application discloses a kind of production process control method and system of lightweight high-conductive FFC soft cable for vehicle.The method obtains process parameters including conductor thickness, insulating layer thickness, laminating temperature and pressure through production control system;Calculate the weight and resistance value of FFC soft cable per unit length;According to the deviation of weight parameter and conductive parameter from the preset lightweight and high-conductive condition, generate and execute targeted control strategy.The application covers automatic determination and real-time compensation for production deviations such as uneven conductor arrangement and uneven lamination, through closed-loop adjustment of workstation instructions, synchronous optimization of lightweight performance and conductive performance in the production process is realized, ensuring the high performance consistency of finished products in automotive application environment.The application improves the intelligent level of FFC production, effectively reduces material loss and product failure rate.

Description

Technical Field

[0001] This invention relates to the field of flexible flat cable (FFC) manufacturing technology, specifically to a method and system for controlling the production process of lightweight, high-conductivity FFC flexible flat cables for automotive applications. Background Technology

[0002] With the rapid development of the new energy vehicle industry, automotive internal wiring systems have placed almost stringent demands on weight reduction and conductivity efficiency. Flexible flat cables (FFCs) are widely used in vehicle electrical connections due to their space-saving and flexible advantages. However, traditional FFC production processes mostly rely on manual sampling or single process parameter settings, lacking efficient industrial control systems to coordinate and control key parameters such as conductor thickness, insulation thickness, lamination temperature, and pressure in real time. This leads to a tendency to sacrifice conductivity stability in the pursuit of lightweighting, or to make the cables too heavy to ensure current load. Especially in high-speed continuous production processes, factors such as material density fluctuations, uneven hot roller pressure, or conductor alignment drift can easily cause quality defects such as inconsistent weight per unit length and excessive resistance. Existing industrial control systems often struggle to dynamically compensate and perform closed-loop optimization based on the deviation between real-time output data and target values ​​in complex and variable process environments, failing to achieve the optimal balance between lightweighting and high conductivity. Therefore, there is an urgent need for a production process control method that can automatically acquire parameters from multiple workstations and generate intelligent control strategies to improve the overall competitiveness and production yield of automotive FFC cables. Summary of the Invention

[0003] The purpose of this invention is to overcome the shortcomings of existing FFC (Flexible Cushion) flexible flat cable production processes, such as low precision in process parameter control, difficulty in balancing lightweight design and high conductivity, and lack of real-time closed-loop adjustment mechanisms. This invention provides a method and system for controlling the production process of lightweight, high-conductivity FFC flexible flat cables for automotive applications. The invention aims to integrate multi-station parameter acquisition into an industrial control system, establishing a dynamic compensation mechanism based on weight and resistance deviations. By adjusting conductor thickness, insulation layer thickness, and lamination process parameters in real time, the invention minimizes the weight per unit length of the FFC flexible flat cable while meeting stringent conductivity standards. Simultaneously, this invention aims to address the issues of uneven physical arrangement and lamination consistency during production. Through automated execution of control strategies, it improves the performance stability of the finished product under high-frequency vibrations and complex electrical environments in automotive applications, ultimately achieving the goals of improving product quality, reducing material costs, and enhancing the intelligent level of precision manufacturing in flexible cables.

[0004] To achieve the above objectives, the present invention provides a method and system for controlling the production process of lightweight, high-conductivity FFC flexible flat cables for automotive applications. The method includes: At least one set of process parameters is acquired in the production control system during the production of the FFC flexible flat cable, wherein the process parameters include at least conductor thickness, insulation layer thickness, lamination temperature and lamination pressure. In the production control system, the weight parameters and conductivity parameters of the FFC flexible flat cable are calculated according to the process parameters, wherein the weight parameters include weight per unit length and the conductivity parameters include resistance value. Based on the deviations of the weight parameters and conductivity parameters from the preset lightweight and high conductivity conditions, a control strategy for the production process is generated and executed in the production control system to optimize the lightweight and high conductivity performance of the FFC flexible flat cable.

[0005] Optionally, the step of obtaining the process parameters in the production control system during the production of the FFC flexible flat cable includes: In the conductor alignment station, the thickness and parallel spacing of the flat conductors are recorded by sensors as the first set of process parameters; In the lamination station, lamination temperature, lamination pressure, and lamination speed are recorded by the control unit as a second set of process parameters. In the testing station, the insulation layer thickness is monitored in real time and recorded as a third set of process parameters, which are then fed back to the production control system.

[0006] Optionally, the step of calculating the weight and conductivity parameters of the FFC flexible flat cable based on the process parameters in the production control system includes: The total thickness is obtained by adding the conductor thickness and the insulation layer thickness, and the weight per unit length is calculated based on the density as a weight parameter. The conductor cross-sectional area is calculated based on the conductor thickness and parallel spacing, and the resistance value is calculated based on the material resistivity as a conductivity parameter.

[0007] Optionally, the preset lightweight and high conductivity conditions are that the weight parameter is lower than a preset weight threshold and the conductivity parameter is lower than a preset resistance threshold, and the step of generating and executing a control strategy for the production process based on the deviation includes: If the weight parameter is higher than a preset weight threshold, an instruction is generated to reduce the conductor thickness or insulation layer thickness and correspondingly increase the lamination pressure. If the conductivity parameter is higher than a preset resistance threshold, an instruction is generated to increase the conductor thickness or optimize the conductor material; The generated control commands are sent to the corresponding workstations for execution, thereby achieving optimization in terms of lightweight design and high conductivity.

[0008] Optionally, the process parameters further include process data corresponding to multiple sets of parallel spacings, the deviations include inconsistencies in weight parameters corresponding to multiple sets of parallel spacings, and the generation and execution of the production process control strategy includes: Determine whether the weight parameters corresponding to multiple sets of parallel spacings are consistent; If there is a discrepancy, the production deviation is determined to be uneven conductor arrangement, and an adjustment instruction is generated to the conductor arrangement equipment to improve the consistency of parallel spacing, thereby stabilizing the lightweight performance.

[0009] Optionally, the process parameters include lamination pressure and lamination speed for at least two sets of lamination processes, the deviation includes inconsistencies in the corresponding conductivity parameters for each set, and the control strategy for generating and executing the production process includes: Determine whether the conductivity parameters corresponding to at least two lamination processes are consistent; If there is a discrepancy, the production deviation is determined to be uneven lamination. The optimized values ​​of lamination pressure and lamination speed for each group are calculated in the production control system, and control commands are generated to apply the optimized lamination pressure and speed to the production process, so as to simultaneously improve lightweight and high conductivity.

[0010] Optionally, the conductor material is tin-plated flat copper wire or high-conductivity aluminum alloy wire, the insulating layer material is PET or PI film, and the lamination process adopts hot rolling or hot pressing process. The production control system adjusts the corresponding process parameter thresholds according to the material type.

[0011] Optionally, after optimizing the lightweight and high conductivity of the FFC flexible flat cable, the following features are also included: In the production control system, the optimized process parameters, along with the corresponding weight and conductivity parameters, are recorded in the database. The generated instructions control the detection device to perform resistance testing and weight measurement on the finished FFC flexible flat cable, and feed the test results back to the production control system to verify performance consistency.

[0012] Optionally, the method further includes: The acquisition module is used to acquire process parameters in the production control system during the production of the FFC flexible flat cable, wherein the process parameters include at least conductor thickness, insulation layer thickness, lamination temperature and lamination pressure. The calculation module is used to calculate the weight parameters and conductivity parameters of the FFC flexible flat cable according to the process parameters in the production control system, wherein the weight parameters include weight per unit length and the conductivity parameters include resistance value; The control module is used to generate and execute a control strategy for the production process in the production control system based on the deviation of the weight parameters and the conductivity parameters from the preset lightweight and high conductivity conditions, so as to optimize the lightweight and high conductivity performance of the FFC flexible flat cable.

[0013] Optionally, it also includes a detection feedback module for real-time monitoring of process parameters and finished product performance during the production process, and feeding back the monitoring data to the acquisition module and control module to achieve closed-loop control of the production process and overall plant control.

[0014] Compared with existing technologies, this invention, by constructing a highly integrated industrial control system, achieves real-time and precise control of conductors, insulation layers, and lamination processes during the production of FFC flexible flat cables. This effectively solves the problem of balancing lightweight design and conductivity performance caused by insufficient parameter coordination in traditional production. By introducing a deviation feedback mechanism, the system can automatically compensate for quality deviations caused by factors such as uneven conductor arrangement and lamination pressure fluctuations. This not only ensures high consistency in product resistance values ​​to meet high conductivity requirements but also achieves extreme weight reduction of the cable through precise control of insulation and conductor thickness, perfectly meeting the dual requirements of weight reduction and efficiency improvement in new energy vehicle wiring systems. Furthermore, the implementation of the closed-loop control strategy significantly reduces the defect rate caused by delays in manual intervention or material fluctuations. While improving production efficiency, it ensures the performance stability of finished products in complex automotive environments, providing scientific and efficient technical support for the large-scale precision manufacturing of automotive FFC flat cables. Attached Figure Description

[0015] Figure 1 Flowchart of the production process control method for lightweight, high-conductivity FFC flexible flat cable for automotive applications provided by this invention; Figure 2 Flowchart of the FFC flexible flat cable performance parameter mapping method provided by the present invention; Figure 3 A schematic diagram of the production process control system for lightweight, high-conductivity FFC flexible flat cable for automobiles provided by the present invention. Detailed Implementation

[0016] To make the objectives, technical solutions, and advantages of this application clearer, the technical solutions of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0017] The terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature; in the description of this application, unless otherwise stated, "multiple" means two or more.

[0018] To more clearly illustrate the technical solution of the present invention, the present invention will be described in detail below with reference to specific embodiments, but it should not be construed as a limitation on the scope of protection of the present invention.

[0019] like Figure 1 As shown, this embodiment achieves precise performance control of FFC flexible flat cable in high-speed production environment by constructing a real-time calculation and dynamic feedback mechanism under the industrial control system. It can effectively eliminate quality risks caused by raw material fluctuations or slight equipment deviations. While ensuring high-standard conductivity performance in vehicles, it achieves the optimal balance of material utilization and significant weight reduction of cables, greatly improving the intelligent management level of the production line and the consistency of finished products.

[0020] Specifically, step S01: Obtain at least one set of process parameters in the production control system during the production of the FFC flexible flat cable, wherein the process parameters include at least conductor thickness, insulation layer thickness, lamination temperature and lamination pressure; The industrial control system connects to various monitoring nodes on the production line in real time via a pre-defined communication protocol. High-precision contact displacement sensors or non-contact laser thickness gauges are used to detect the thickness of continuously passing flat conductors, ensuring millisecond-level response times for the acquired conductor thickness data. Furthermore, at the insulation layer lamination station, an infrared thickness gauge acquires the thickness of the PET or PI film covering the conductor surface. Combined with thermistors and pressure sensors in the lamination station, the instantaneous values ​​of lamination temperature and pressure during the lamination process are collected in real time. Understandably, these process parameters are aggregated into the system's intermediate memory, forming interconnected data packets that provide raw data support for subsequent performance fitting.

[0021] Step S02: In the production control system, calculate the weight parameters and conductivity parameters of the FFC flexible flat cable according to the process parameters, wherein the weight parameters include weight per unit length and the conductivity parameters include resistance value; Specifically, after receiving process parameters, the production control system uses its built-in processing unit to model the physical structure of the cable. It obtains the total thickness information by superimposing the real-time acquired conductor thickness and insulation layer thickness, and then calculates the weight per unit length of FFC flexible flat cable using preset material density parameters. Further, for conductivity evaluation, the system calculates the actual effective cross-sectional area of ​​the conductor based on the acquired conductor thickness and the width and parallel spacing of the flat conductor. Understandably, the system further incorporates the resistivity characteristics of the current material, using a computational model described by textual logic to convert the cross-sectional area into a real-time resistance value. This allows the system to obtain the core conductivity parameters reflecting cable quality without stopping the production line.

[0022] Step S03: Based on the deviations of the weight parameters and conductivity parameters from the preset lightweight and high conductivity conditions, a control strategy for the production process is generated and executed in the production control system to optimize the lightweight and high conductivity performance of the FFC flexible flat cable.

[0023] Specifically, the production control system compares the calculated unit length weight and resistance value with the target threshold stored in the database in real time, automatically identifying the numerical deviation between the current output and the ideal state. When the weight parameter deviates from the preset range or the resistance value fluctuates abnormally, the system automatically triggers optimization logic to generate targeted equipment adjustment strategies. For example, it may fine-tune the tension by adjusting the speed of the drive motor, or intervene in the subsequent cable forming process in real time by adjusting the power output of the heating roller and the pressure setting of the hydraulic cylinder. Understandably, this deviation-based control strategy can directly send the generated instructions to the actuators, dynamically pulling the production state back to the optimal range, thereby ensuring that the cable has a significant lightweight advantage while maintaining excellent conductivity.

[0024] This embodiment achieves digital monitoring of the entire FFC flexible flat cable production process by constructing an integrated process parameter acquisition and performance mapping mechanism in the industrial control system. Compared with traditional manual sampling or single-parameter control, this invention can calculate the unit length weight and resistance value reflecting the core quality of the cable in real time. Through a quantified deviation feedback strategy, dynamic compensation is performed in real time during production, effectively solving the problem of conductivity fluctuations that easily occur when pursuing lightweighting in automotive cables. This closed-loop control mode can not only accurately lock the optimal balance point between lightweighting and high conductivity, significantly reducing the defect rate caused by fluctuations in material thickness or environmental factors, but also improve the automated adjustment capability of the production line to complex process requirements, providing a more consistent and compact electrical connection solution for new energy vehicle wiring systems.

[0025] In some embodiments, by deploying precision sensing units and control modules at key physical nodes of the production line, the source acquisition and closed-loop feedback of process parameters are realized. This enables precise capture of micron-level fluctuations during conductor arrangement, lamination, and insulation coating processes, ensuring that every set of core data affecting performance can be synchronized to the industrial control system in real time, thereby providing reliable data support for the high-precision processing of automotive flexible flat cables.

[0026] In the conductor alignment station, the thickness and parallel spacing of the flat conductors are recorded by sensors as the first set of process parameters; Specifically, in the upstream conductor laying area of ​​the production line, the industrial control system uses an online non-contact laser diameter gauge or a high-precision image vision sensor installed at the exit of the arranging die to scan each parallel flat conductor in real time. Furthermore, the sensor can accurately identify the cross-sectional edges of the conductors, record the conductor thickness, and simultaneously measure the parallel spacing between adjacent conductors. Understandably, this first set of process parameters, serving as the physical basis for subsequent calculations of the conductor cross-sectional area and resistance, is converted into digital signals in real time and uploaded to the industrial control system to monitor the physical consistency of the conductors during the arrangement process.

[0027] In the lamination station, lamination temperature, lamination pressure, and lamination speed are recorded by the control unit as a second set of process parameters. Specifically, when the conductor and insulating film enter the hot-pressing stage, thermistors and pressure sensors distributed inside the laminating rollers and on the press base begin to operate. Furthermore, the lamination control unit of the industrial control system reads the actual temperature of the heating roller surface in real time, and combines this with the pressure feedback value from the hydraulic or pneumatic transmission system, as well as the production line operating speed fed back by the drive motor encoder, to form a second set of process parameters. Understandably, these data reflect the rheological state of the hot melt adhesive material between the insulating layer and the conductor, and are key environmental indicators determining the final product's tightness and thickness stability.

[0028] In the testing station, the insulation layer thickness is monitored in real time and recorded as a third set of process parameters, which are then fed back to the production control system.

[0029] Specifically, after the ribbon cable is laminated and cooled for output, an online thickness gauge deployed at the end of the production line monitors the thickness of the insulating film layer on the surface of the finished FFC flexible ribbon cable. Further, the system uses ultrasonic or infrared penetration principles to peel off the pure insulating layer data above the conductor, recording it as the third set of process parameters. Understandably, this parameter not only reflects the original thickness of the raw material but also the final physical state of the material after compression during the lamination process. The system correlates this feedback data with the first two sets of parameters to form a complete production profile, which is then transmitted back to the central industrial control system, achieving a closed-loop parameter system throughout the entire process.

[0030] In some embodiments, such as Figure 2 As shown, by constructing a precise physical property mapping model in the industrial control system, the digital transformation from basic process parameters to core performance indicators is realized. This enables accurate prediction of the weight distribution and electrical performance of finished products under different cross-sectional areas and material properties, providing a scientific calculation basis for the refined management of achieving lightweight goals.

[0031] Step S31: Add the conductor thickness to the insulation layer thickness to obtain the total thickness, and calculate the weight per unit length as a weight parameter based on the density; Specifically, after acquiring the conductor thickness and the thickness of the laminated insulation layer, the industrial control system linearly sums the two through logical operations to determine the total physical thickness of the current flexible flat cable structure. Further, the system retrieves the conductor material density and insulation film material density preset in the database, and combines them with the standard width value of the flat cable to convert the volume information into mass information. Understandably, this real-time weight calculation based on dynamic thickness input can accurately reflect the mass fluctuation of each meter of flat cable on the production line, thereby generating a unit length weight parameter reflecting material consumption and weight reduction.

[0032] Step S32: Calculate the conductor cross-sectional area based on the conductor thickness and parallel spacing, and calculate the resistance value as a conductivity parameter based on the material resistivity.

[0033] Specifically, the industrial control system uses the conductor thickness data from the first set of process parameters, combined with the preset flat conductor width, to first determine the basic cross-section of a single conductor. Further, the system performs correlation analysis between the conductor thickness and the collected parallel spacing to assess the actual effective current-carrying space of the conductor under the insulation layer, thereby calculating the precise conductor cross-sectional area. Understandably, the system then, based on the pre-input resistivity characteristics of the conductor material, simulates the physical resistance of current flowing through this cross-sectional area, converting it into a real-time resistance value described in textual logic. In this way, the system can predict whether the conductivity of the finished cable meets the stringent requirements for high conductivity without performing contact measurements.

[0034] In some embodiments, by establishing a hierarchical early warning and dynamic compensation mechanism in the industrial control system, a second-level response from detecting deviations to executing corrections is achieved. This enables the automatic issuance of multi-dimensional equipment adjustment commands for production anomalies such as excessive material thickness or declining electrical performance. This eliminates defective products at the source while ensuring that lightweight indicators and high conductivity are synergistically met under closed-loop control.

[0035] If the weight parameter is higher than a preset weight threshold, an instruction is generated to reduce the conductor thickness or insulation layer thickness and correspondingly increase the lamination pressure. Specifically, when the industrial control system determines that the weight per unit length of the current FFC flexible flat cable exceeds the set weight reduction limit, the system immediately analyzes the physical properties causing the weight excess. Furthermore, if it is determined that the excess weight is due to material redundancy, the system sends instructions to the conductor stretching equipment or film feeding mechanism to slightly reduce the initial conductor thickness or select a thinner insulation material, reducing material input at the source. Understandably, to prevent the cable structure from becoming loose due to thickness reduction, the system simultaneously generates compensation instructions for the lamination station, increasing the lamination pressure by increasing the output value of the hydraulic cylinder or pneumatic device, making the thinned material more compact, thereby maintaining the cable's physical strength while meeting the weight reduction target.

[0036] If the conductivity parameter is higher than a preset resistance threshold, an instruction is generated to increase the conductor thickness or optimize the conductor material; Specifically, when the resistance value reported by the testing station exceeds the preset high conductivity threshold, it indicates a decrease in the current cable's transmission efficiency. Furthermore, the industrial control system prioritizes physical intervention strategies, fine-tuning the conductor's cross-sectional thickness by adjusting the conductor forming die or increasing the gap in the conductor rolling rollers to provide more current-carrying space and reduce resistance. Understandably, if the physical dimensional adjustments have reached the process limits, the system will trigger a material optimization warning, prompting the replacement with higher-quality copper or aluminum alloy materials with lower resistivity, or even adjusting the lamination temperature to improve the contact resistance between the conductor and the adhesive layer. This strategy ensures that conductivity remains within safe thresholds under any fluctuating production environment.

[0037] The generated control commands are sent to the corresponding workstations for execution, thereby achieving optimization in terms of lightweight design and high conductivity.

[0038] Specifically, the industrial control system converts the various logic instructions generated above into standard industrial control protocol signals, which are then distributed to the actuators at each workstation via a high-speed fieldbus. Further, the motor driver adjusts its speed according to the received instructions, the temperature control module adjusts the heating power, and the pressure servo system updates its pressure output curve in real time. Understandably, this issuance and execution of instructions is a continuous closed-loop process. The system constantly monitors whether the adjusted finished product performance returns to the preset lightweight and high conductivity range, thereby achieving stable operation of the production line at the optimal process point through continuous incremental iterations.

[0039] In some embodiments, by introducing a lateral consistency monitoring and parallel spacing compensation mechanism, the problem of conductor drift and disordered arrangement that are prone to occur in high-speed production of multi-core FFC flexible flat cables is effectively solved. It can accurately identify and eliminate the quality differences in the lateral distribution of the production line, and ensure the extreme uniformity of the overall weight distribution of the flat cable, thereby stabilizing the structural reliability of the lightweight design at the micro level.

[0040] Determine whether the weight parameters corresponding to multiple sets of parallel spacings are consistent; Specifically, when processing data, the industrial control system not only focuses on the thickness information at a single point, but also divides the transverse cross-section of the cable into multiple monitoring intervals, each corresponding to a different conductor parallel spacing region. Furthermore, the system uses a calculation module to measure the volume of the insulating material around each set of parallel spacings in real time, comparing the weight per unit length calculated within different intervals. Understandably, this comparison covers the complete cross-section from the left edge to the right edge. By analyzing the dispersion of each set of weight data, the system assesses the mass distribution of the cable in the width direction to determine if there is any localized material accumulation or loss.

[0041] If there is a discrepancy, the production deviation is determined to be uneven conductor arrangement, and an adjustment instruction is generated to the conductor arrangement equipment to improve the consistency of parallel spacing, thereby stabilizing the lightweight performance.

[0042] Specifically, when the system detects a significant difference in weight parameters corresponding to different parallel spacings, it determines that the conductors have shifted position at the arranging die or combing roller, resulting in localized material density imbalance. Furthermore, the industrial control system immediately calculates the orientation and value of the spacing deviation and sends a fine-tuning command to the conductor arranging equipment, driving a precision stepper motor or servo push rod to dynamically compensate for the lateral position of the arranging comb teeth. Understandably, this adjustment aims to forcibly restore the conductors to an equal spacing state, eliminating localized "heavy areas" or "weak areas" caused by uneven arrangement, thereby ensuring that the entire FFC flexible flat panel line meets the overall weight target while possessing highly consistent lightweight structural stability.

[0043] In some embodiments, by introducing multi-point lamination state comparison logic, dynamic matching of longitudinal speed and pressure field of production line is realized. It can accurately identify lamination deviation caused by roller wear, uneven heating or speed fluctuation, and use multi-variable collaborative algorithm to correct execution parameters in real time, thereby simultaneously locking the lightweight form and high conductivity of flexible flat cable under high-speed production conditions.

[0044] Determine whether the conductivity parameters corresponding to at least two lamination processes are consistent; Specifically, during continuous production, the industrial control system samples the lamination output at different timestamps and compares the real-time resistance values ​​corresponding to different production periods or different lamination roller groups. Furthermore, the system analyzes the conductivity parameters generated in the first lamination stage and the subsequent holding stage to check for differences in resistance values ​​exceeding normal fluctuation ranges. Understandably, this comparison not only monitors the magnitude of the values ​​but also focuses on the stability of the parameters. By comparing at least two sets of data laterally, the system can quantitatively evaluate the uniformity of the lamination process in terms of time or physical space.

[0045] If there is a discrepancy, the production deviation is determined to be uneven lamination. Specifically, when the system detects a significant mismatch between two or more sets of conductive parameters, the logic processing module automatically checks for conductor cross-sectional area deviations. If the original conductor dimensions are normal, the cause of the deviation is identified as uneven lamination. Further, the system determines that the deviation may stem from uneven lamination pressure distribution on the roller surface, resulting in varying degrees of pressure on local conductors, or from insufficient heat conduction due to excessively high lamination speed, affecting the contact resistance between the adhesive layer and the conductor. This deviation determination provides precise target guidance for subsequent parameter optimization, avoiding performance imbalances caused by blindly adjusting a single parameter.

[0046] The optimized values ​​of lamination pressure and lamination speed for each group are calculated in the production control system, and control commands are generated to apply the optimized lamination pressure and speed to the production process, so as to simultaneously improve lightweight and high conductivity.

[0047] Specifically, the industrial control system calculates the optimal coupling scheme of pressure and speed based on the identified degree of lamination unevenness using a preset process model. Furthermore, the system-generated control commands drive the pressure regulating valve to fine-tune the compaction of the lamination rollers, while simultaneously instructing the servo motor to synchronously correct the production line's traction speed, ensuring that the insulation layer and conductor achieve optimal tight coating under the set hot-pressing environment. Understandably, this collaborative optimization not only reduces contact resistance by eliminating gaps to improve conductivity but also prevents adhesive overflow or localized over-thickness by optimizing the lamination thickness, thereby precisely controlling the cable's volume and weight, achieving simultaneous iterative upgrades in lightweight design and high conductivity.

[0048] In some embodiments, by establishing differentiated process benchmarks for the physicochemical properties of different material systems, the industrial control system achieves precise compatibility with diverse material combinations. It can dynamically adjust the production threshold according to the differences in conductor conductivity and insulation rheological properties, ensuring that both copper and aluminum materials can achieve a balance between lightweight and high conductivity within their optimal process window.

[0049] Specifically, the conductor material is tin-plated flat copper wire or high-conductivity aluminum alloy wire, the insulating layer material is PET or PI film, the lamination process adopts hot rolling or hot pressing process, and the production control system adjusts the corresponding process parameter thresholds according to the material type.

[0050] During the production start-up phase, operators input the current raw material specifications into the interactive interface of the industrial control system. When tin-plated flat copper wire is selected as the conductor, the system automatically retrieves the preset model for high conductivity copper material; however, when switching to high conductivity aluminum alloy wire, considering the lower density and different resistivity of aluminum, the system automatically relaxes the weight threshold and tightens the resistance monitoring range.

[0051] For insulating layer materials, if PI film with strong thermal stability is selected, the system will automatically adjust the preset upper limit of the high-pressure station temperature; if cost-effective PET film is selected, the temperature will be lowered accordingly to prevent overheating and deformation. Understandably, for hot rolling processes, the system focuses on matching the roller speed and linear pressure, while for hot pressing processes, it emphasizes precise control of the holding time. This logic of dynamically adjusting process parameter thresholds based on material characteristics ensures that the production control strategy always aligns with the physical limits of the material, thereby achieving optimal performance under different material options.

[0052] In some embodiments, by establishing a verification mechanism of digital archives and physical measurements at the end of production, in-depth traceability of production process data and finished product quality performance is achieved, which can effectively verify the effectiveness of control strategies and provide accurate offline data support for subsequent process improvements, ensuring the performance consistency of automotive flexible flat cables throughout their entire life cycle.

[0053] In the production control system, the optimized process parameters, along with the corresponding weight and conductivity parameters, are recorded in the database. Specifically, after completing a round of production strategy optimization, the industrial control system automatically triggers a data persistence process, storing the optimized lamination temperature, pressure, speed, and real-time calculated conductor and insulation layer thicknesses into a local or cloud database. Furthermore, the system uses the corresponding unit length weight and resistance value within that time period as performance tags, associating them with the process parameters to form a complete production record index. Understandably, this historical data forms the basis of a digital twin of the production line, enabling managers to retrieve the control logic and output results of different production batches at any time.

[0054] The generated instructions control the detection device to perform resistance testing and weight measurement on the finished FFC flexible flat cable, and feed the test results back to the production control system to verify performance consistency.

[0055] Specifically, before the flexible flat cable completes slitting or winding, the industrial control system sends a trigger command to the end-of-line detection unit, controlling the automated testing fixture to perform contact resistance measurement on the finished product end and using a high-precision online weighing module to obtain the finished product weight. The detection device transmits the measured physical data back to the control system in real time. The system uses a comparison algorithm to verify the consistency between the measured value and the previous predicted value, determining whether the deviation is within the allowable tolerance range. Understandably, this actual measurement feedback is not only the final checkpoint for current product quality but also a closed-loop verification of the accuracy of the industrial control system's predictive model. Through continuous actual measurement and calibration, the reliability of the system's optimization strategy is further improved.

[0056] The present invention also provides another embodiment, such as Figure 3 As shown, this embodiment deeply couples production line hardware with digital algorithms to construct a modular industrial control system with self-sensing, self-computing, and self-decision-making capabilities. Through the decoupling and coordination of functional modules, this system 100 ensures that the manufacturing process of FFC flexible flat cables strictly adheres to preset lightweight and high conductivity logic. This system 100 includes: The acquisition module 101 is used to acquire process parameters in the production control system 100 during the production of the FFC flexible flat cable, wherein the process parameters include at least conductor thickness, insulation layer thickness, lamination temperature and lamination pressure. Specifically, the acquisition module 101 serves as the sensing interface of the production control system 100, receiving sensor data distributed across various workstations on the production line in real time via industrial Ethernet. Furthermore, this module 101 is responsible for synchronizing the collected physical quantities such as conductor thickness and insulation layer thickness, as well as environmental quantities such as temperature and pressure. Understandably, the acquisition module 101 provides the system 100 with a real-time, continuous data stream, ensuring that the input data for subsequent calculations is highly accurate and timely.

[0057] Calculation module 102 is used to calculate the weight parameters and conductivity parameters of the FFC flexible flat cable according to the process parameters in the production control system 100, wherein the weight parameters include weight per unit length and the conductivity parameters include resistance value; Specifically, the calculation module 102 incorporates a preset material property model and physical conversion logic, responsible for converting the raw process parameters transmitted by the acquisition module 101 into performance evaluation indicators. Furthermore, the module 102 utilizes built-in processing algorithms to automatically calculate the weight per unit length and the expected resistance value under the current process combination. In essence, the calculation module 102 abstracts complex production parameters into intuitive quality data, achieving real-time digital modeling of the production status.

[0058] The control module 103 is used to generate and execute a control strategy for the production process in the production control system 100 based on the deviation of the weight parameters and the conductivity parameters from the preset lightweight and high conductivity conditions, so as to optimize the lightweight and high conductivity performance of the FFC flexible flat cable.

[0059] Specifically, the control module 103 executes the decision-making logic of the system 100. By comparing the real-time parameters output by the calculation module 102 with preset conditions in the database, it automatically identifies performance deviations. Furthermore, based on the magnitude and nature of the deviation, the module 103 retrieves corresponding adjustment instructions from the strategy library and sends them to the execution mechanisms on the production line. Understandably, through this closed-loop "perception-computation-decision" chain, the control module 103 achieves intelligent intervention in the FFC flexible flat cable production process, ensuring synergistic optimization of the product in both lightweight and high conductivity dimensions.

[0060] In some embodiments, by introducing an end-to-end detection feedback link, data communication between the production site and the management level is realized, and a self-healing closed-loop control system is constructed. This system can automatically backtrack and correct the front-end process settings based on fluctuations in finished product quality, thereby ensuring the performance consistency of automotive flexible flat cable production over a long cycle under the overall factory control dimension.

[0061] The detection feedback module is used to monitor the process parameters and finished product performance in real time during the production process, and to feed back the monitoring data to the acquisition module 101 and the control module 103 to realize closed-loop control of the production process and overall plant control.

[0062] Specifically, the detection feedback module, acting as the monitoring hub of the production control system 100, is responsible for integrating all quality indicators from raw materials to finished products. Furthermore, this module not only monitors dynamic process parameters on the production line in real time but also receives measured resistance and weight data from the finished product testing device. Understandably, the detection feedback module compares these measured performance values ​​with the real-time process status provided by the acquisition module. If the measured value deviates from the prediction model, it immediately feeds back the deviation to the control module, triggering the system 100's self-calibration program.

[0063] Furthermore, at the overall factory control level, the detection feedback module uploads the production quality records of each batch to the central management platform via an industrial bus. Understandably, this closed-loop mechanism allows the production control system 100 to transcend the limitations of a single workstation and perform long-term optimization predictions of global variables such as conductor alignment speed and lamination thermal field distribution based on statistical trends from historical data. Through this closed-loop control across the entire process, system 100 can not only eliminate random deviations in single production runs but also effectively cope with systemic drift caused by equipment wear or changes in environmental temperature and humidity, ensuring the continued leading position of automotive FFC flexible flat cables in terms of lightweight design and high conductivity.

[0064] The above description is merely an exemplary embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural transformations made using the contents of the present invention specification and drawings under the technical concept of the present invention, or direct / indirect applications in other related technical fields, are included within the patent protection scope of the present invention.

Claims

1. A method for controlling the production process of lightweight, high-conductivity FFC flexible flat cable for automotive applications, characterized in that, The method includes the following steps: At least one set of process parameters is acquired in the production control system during the production of the FFC flexible flat cable, wherein the process parameters include at least conductor thickness, insulation layer thickness, lamination temperature and lamination pressure. In the production control system, the weight parameters and conductivity parameters of the FFC flexible flat cable are calculated according to the process parameters, wherein the weight parameters include weight per unit length and the conductivity parameters include resistance value. Based on the deviations of the weight parameters and conductivity parameters from the preset lightweight and high conductivity conditions, a control strategy for the production process is generated and executed in the production control system to optimize the lightweight and high conductivity performance of the FFC flexible flat cable. Wherein, the preset lightweight and high conductivity conditions are that the weight parameter is lower than a preset weight threshold and the conductivity parameter is lower than a preset resistance threshold, and the step of generating and executing a production process control strategy based on the deviation of the weight parameter and the conductivity parameter from the preset lightweight and high conductivity conditions includes: If the weight parameter is higher than a preset weight threshold, an instruction is generated to reduce the conductor thickness or insulation layer thickness and correspondingly increase the lamination pressure. If the conductivity parameter is higher than the preset resistance threshold, an instruction is generated to increase the conductor thickness; when the increase in conductor thickness reaches the process limit, an instruction is generated to adjust the lamination temperature to improve the contact resistance between the conductor and the adhesive layer. The generated control commands are sent to the corresponding workstations for execution, thereby achieving optimization in terms of lightweight design and high conductivity.

2. The method for controlling the production process of lightweight, high-conductivity FFC flexible flat cable for automobiles according to claim 1, characterized in that, The steps for obtaining process parameters during the production of the FFC flexible flat cable in the production control system include: In the conductor alignment station, the thickness and parallel spacing of the flat conductors are recorded by sensors as the first set of process parameters; In the lamination station, lamination temperature, lamination pressure, and lamination speed are recorded by the control unit as a second set of process parameters. In the testing station, the insulation layer thickness is monitored in real time and recorded as a third set of process parameters, which are then fed back to the production control system.

3. The method for controlling the production process of lightweight, high-conductivity FFC flexible flat cable for automobiles according to claim 2, characterized in that, The calculation of the weight and conductivity parameters of the FFC flexible flat cable based on the process parameters in the production control system includes: The total thickness is obtained by adding the conductor thickness and the insulation layer thickness, and the weight per unit length is calculated based on the density as a weight parameter. The conductor cross-sectional area is calculated based on the conductor thickness and parallel spacing, and the resistance value is calculated based on the material resistivity as a conductivity parameter.

4. The method for controlling the production process of lightweight, high-conductivity FFC flexible flat cable for automobiles according to claim 3, characterized in that, The process parameters also include process data corresponding to multiple sets of parallel spacings, and the deviations include inconsistencies in weight parameters corresponding to multiple sets of parallel spacings. The generation and execution of the production process control strategy includes: Determine whether the weight parameters corresponding to multiple sets of parallel spacings are consistent; if they are inconsistent, determine that the production deviation is due to uneven conductor arrangement, and generate an adjustment instruction to the conductor arrangement equipment to improve the consistency of parallel spacing, thereby stabilizing the lightweight performance.

5. The method for controlling the production process of lightweight, high-conductivity FFC flexible flat cable for automobiles according to claim 3, characterized in that, The process parameters include at least two sets of lamination pressure and lamination speed for the lamination process, the deviations include inconsistencies in the corresponding conductivity parameters of each set, and the control strategy for generating and executing the production process includes: Determine whether the conductivity parameters corresponding to at least two lamination processes are consistent; If there is a discrepancy, check for deviations in the conductor cross-sectional area. If the original dimensions of the conductor are normal, then the production deviation is determined to be uneven lamination. The optimized values ​​of lamination pressure and lamination speed for each group are calculated in the production control system, and control commands are generated to apply the optimized lamination pressure and speed to the production process, so as to simultaneously improve lightweight and high conductivity.

6. The method for controlling the production process of lightweight, high-conductivity FFC flexible flat cable for automobiles according to claim 2, characterized in that, The conductor material is tin-plated flat copper wire or high-conductivity aluminum alloy wire, the insulating layer material is PET or PI film, and the lamination process adopts hot rolling or hot pressing process. The production control system adjusts the corresponding process parameter thresholds according to the material type.

7. The method for controlling the production process of lightweight, high-conductivity FFC flexible flat cable for automobiles according to any one of claims 1 to 6, characterized in that, After optimizing the lightweight and high conductivity of the FFC flexible flat cable, it also includes: In the production control system, the optimized process parameters, along with the corresponding weight and conductivity parameters, are recorded in the database. The generated instructions control the detection device to perform resistance testing and weight measurement on the finished FFC flexible flat cable, and feed the test results back to the production control system to verify performance consistency.

8. A production process control system for lightweight, high-conductivity FFC flexible flat cable for automotive applications, characterized in that, include: The acquisition module is used to acquire process parameters in the production control system during the production of the FFC flexible flat cable, wherein the process parameters include at least conductor thickness, insulation layer thickness, lamination temperature and lamination pressure. The calculation module is used to calculate the weight parameters and conductivity parameters of the FFC flexible flat cable according to the process parameters in the production control system, wherein the weight parameters include weight per unit length and the conductivity parameters include resistance value; The control module is used to generate and execute a control strategy for the production process in the production control system based on the deviation of the weight parameters and the conductivity parameters from the preset lightweight and high conductivity conditions, so as to optimize the lightweight and high conductivity performance of the FFC flexible flat cable. The preset lightweight and high conductivity conditions are that the weight parameter is lower than a preset weight threshold and the conductivity parameter is lower than a preset resistance threshold. Specifically, the control module is used to: if the weight parameter is higher than the preset weight threshold, generate an instruction to reduce the conductor thickness or the insulation layer thickness and correspondingly increase the lamination pressure; if the conductivity parameter is higher than the preset resistance threshold, generate an instruction to increase the conductor thickness; when the increase in conductor thickness reaches the process limit, generate an instruction to adjust the lamination temperature to improve the contact resistance between the conductor and the adhesive layer; and send the generated control instruction to the corresponding workstation for execution.

9. The production process control system for lightweight, high-conductivity FFC flexible flat cable for automobiles according to claim 8, characterized in that, It also includes a detection feedback module, which is used to monitor process parameters and finished product performance in real time during the production process, and feed the monitoring data back to the acquisition module and control module to realize closed-loop control of the production process and overall plant control.

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