An ultra-thin copper foil high-precision slitting and winding control system

Abstract

The application discloses a kind of ultra-thin copper foil high-precision slitting and winding control system, relating to copper foil precision machining technical field, including thickness monitoring, quality field analysis, slitting control, tension monitoring and winding control module.The system constructs copper foil dynamic quality field model by upstream thickness data, calculates axial quality balance coefficient, and then carries out dynamic pre-compensation adjustment to slitting tool holder.While slitting, the real-time tension spectrum of each independent copper foil strip is collected, and matched with ideal tension spectrum for analysis, and finally generates independent tension compensation signal of each winding shaft to adjust torque output.The application can realize slitting active compensation based on global quality prediction and winding independent accurate control based on multi-axis tension spectrum tracking, so as to improve slitting precision, ensure winding flatness and internal stress uniformity.

Description

Technical Field

[0001] This invention belongs to the field of precision copper foil processing technology, specifically a high-precision slitting and winding control system for ultra-thin copper foil. Background Technology

[0002] In the production of ultra-thin copper foil, slitting and winding are key processes that determine the quality of the final product. Existing technologies typically employ independent thickness detection and tension control methods to manage copper foil processing. For thickness control, conventional methods rely on a single sensor on the production line to measure the copper foil thickness at points or in localized areas, and then adjust fixed parameters of the slitting process based on these measurements. For winding control, feedback mechanisms based on total tension or simple average tension are commonly used, maintaining tension stability by uniformly adjusting the torque or speed of the winding shaft.

[0003] These existing technical solutions have shortcomings. Because ultra-thin copper foil is prone to uneven lateral thickness distribution during rolling, relying solely on local thickness measurements cannot reflect the overall quality of the entire roll, preventing the slitting cutter from proactively adjusting to the unevenness of the raw material. The multiple copper foil strips produced by slitting inherently have quality differences, creating potential problems for subsequent winding. In the winding stage, using a uniform or simplified tension control strategy is insufficient to address the individual tension requirements of each copper foil strip due to slight differences in width, thickness, and running path. The winding tightness of each foil strip cannot be precisely adjusted, easily leading to wrinkles, edge collapse, or stress concentration in the core.

[0004] The problem this invention aims to solve is how to implement precise pre-compensation control based on the overall thickness distribution characteristics of the copper foil before the slitting operation, and how to achieve independent tension control of multiple parallel copper foil strips, matching the ideal state, during the winding process after slitting. Summary of the Invention

[0005] This invention aims to solve at least one of the technical problems existing in the prior art;

[0006] Therefore, this invention proposes a high-precision slitting and winding control system for ultra-thin copper foil, comprising:

[0007] The thickness monitoring module is used to collect raw thickness distribution data of copper foil during operation upstream of the ultra-thin copper foil production line;

[0008] The mass field analysis module is used to construct a dynamic mass field model of copper foil based on the original thickness distribution data, and to calculate the axial mass balance coefficient of the current copper foil roll based on the dynamic mass field model of copper foil.

[0009] The slitting control module is used to generate dynamic compensation commands for the slitting tool holder based on the axial mass balance coefficient, adjust the operating parameters of the slitting tool holder according to the dynamic compensation commands, and perform slitting operations on the copper foil.

[0010] The tension monitoring module is used to collect real-time tension spectrum data of each independent copper foil strip after slitting through a tension sensing array during the slitting operation.

[0011] The winding control module is used to match and analyze the real-time tension spectrum data with the preset ideal tension spectrum, generate an independent tension compensation signal for the winding shaft, and adjust the torque output of each winding shaft based on the independent tension compensation signal to complete the winding of the copper foil strip.

[0012] Further, the step of constructing a dynamic mass field model of the copper foil based on the original thickness distribution data, and calculating the axial mass balance coefficient of the current copper foil roll based on the dynamic mass field model of the copper foil includes:

[0013] The original thickness distribution data collected along the width direction of the copper foil is mapped into a two-dimensional mass distribution plane;

[0014] In the two-dimensional mass distribution plane, a dynamic mass field model of the copper foil is constructed with the copper foil travel direction as the time axis, reflecting the change of thickness with time and width position.

[0015] In the copper foil dynamic mass field model, virtual segmentation is performed along the planned cutting path, and the mass integral of each virtual segment is calculated.

[0016] By comparing the mass integral differences between adjacent virtual segmented strips, the axial mass balance coefficient is calculated based on the ratio of the maximum difference value to the average mass integral.

[0017] Furthermore, the dynamic compensation command for generating the slitting tool holder based on the axial mass balance coefficient includes:

[0018] Preset the baseline operating parameters of the slitting tool holder;

[0019] The lateral vibration compensation amount of the tool holder and the cutting tool pressure compensation amount are obtained by querying the preset compensation relationship mapping table based on the axial mass balance coefficient.

[0020] The lateral vibration compensation amount of the slitting tool holder and the blade pressure compensation amount are combined with the reference operating parameters of the slitting tool holder to synthesize the dynamic compensation command of the slitting tool holder.

[0021] Furthermore, the step of adjusting the operating parameters of the slitting tool holder according to the dynamic compensation command and performing the slitting operation on the copper foil includes:

[0022] The dynamic compensation command is analyzed to separate the target position sequence of the tool holder transverse servo motor and the target pressure value of the hydraulic pressure unit;

[0023] The tool holder lateral servo motor is driven to perform high-frequency micro-amplitude lateral movement according to the target position sequence;

[0024] Simultaneously, the output of the hydraulic pressure unit is adjusted according to the target pressure value to make the blade pressure consistent with the target pressure value;

[0025] After the transverse servo motor and hydraulic pressure unit of the slitting post are adjusted to their positions according to the instructions, the slitting slitting post is driven to complete the slitting operation along the copper foil traveling direction.

[0026] Furthermore, the real-time tension spectrum data of each independent copper foil strip after slicing, acquired through the tension sensing array, includes:

[0027] On each individual copper foil strip path immediately downstream of the slitting blade holder, a tension sensor is arranged to form a tension sensing array.

[0028] The measured values ​​of all tension sensors are read simultaneously at a fixed sampling frequency to form a tension snapshot at a point in time;

[0029] Tension snapshots are continuously recorded at all time points over a period of time, and combined to form real-time tension spectrum data reflecting the change of tension of each copper foil strip over time.

[0030] Furthermore, the step of matching and analyzing the real-time tension spectrum data with a preset ideal tension spectrum to generate an independent tension compensation signal for the take-up spool includes:

[0031] A constant ideal tension value is preset for each take-up spool, and the ideal tension values ​​of all take-up spools constitute an ideal tension spectrum.

[0032] Calculate the deviation between the average tension of each copper foil strip in the real-time tension spectrum data and the corresponding ideal tension value;

[0033] Based on the magnitude and direction of the tension deviation of each copper foil strip, and combined with the real-time linear velocity of the copper foil strip, the required torque adjustment of each winding shaft is calculated using an independent roll diameter estimation algorithm.

[0034] The required torque adjustment for each take-up spool is converted into a corresponding independent tension compensation signal.

[0035] Furthermore, the step of adjusting the torque output of each winding shaft based on the independent tension compensation signal to complete the winding of the copper foil strip includes:

[0036] Each independent tension compensation signal is sent to the corresponding take-up spool servo driver;

[0037] Each take-up servo driver calculates and outputs a new torque control current to the take-up motor based on the received independent tension compensation signal;

[0038] Each winding motor operates based on the new torque control current, causing the tension of each copper foil strip to tend toward the ideal tension spectrum;

[0039] Before the entire copper foil roll is slit, adjustments are continuously made based on updated independent tension compensation signals until the winding process is completed.

[0040] Furthermore, the comparison of the quality integral differences between adjacent virtual segmentation strips includes:

[0041] In the dynamic mass field model of the copper foil, mass distribution data of several strips are extracted along the virtual segmentation path;

[0042] The mass distribution data of each strip is integrated along the direction of travel to obtain the mass integral value of each strip.

[0043] Calculate the absolute value of the difference between the mass integral values ​​of every two adjacent strips in sequence;

[0044] Find the maximum value among the differences in the mass integral values ​​of all adjacent stripes.

[0045] Furthermore, the step of calculating the required torque adjustment for each take-up shaft based on the magnitude and direction of the tension deviation of each copper foil strip, combined with the real-time linear velocity of the copper foil strip, using an independent roll diameter estimation algorithm includes:

[0046] Based on the position of the tension sensor and the rotation speed of the winding shaft, the current winding radius of each copper foil strip on the winding shaft is estimated in real time;

[0047] The required torque compensation value is initially calculated based on the product of the tension deviation and the current winding radius;

[0048] The torque compensation value is dynamically corrected by combining the elastic modulus of the copper foil material with the real-time linear velocity to obtain the final required torque adjustment.

[0049] Furthermore, the continuous adjustment based on updated independent tension compensation signals before the entire copper foil roll is slit includes:

[0050] Continuously acquire and update real-time tension spectrum data from the tension sensing array;

[0051] Repeat the step of matching the updated real-time tension spectrum data with the preset ideal tension spectrum to generate an updated independent tension compensation signal;

[0052] The updated independent tension compensation signal is sent to each take-up servo driver in real time to form a closed-loop control.

[0053] Compared with the prior art, the beneficial effects of the present invention are:

[0054] A dynamic mass field model is constructed using raw copper foil thickness distribution data collected upstream, and an axial mass balance coefficient is calculated. The generation of slitting control commands is directly based on this coefficient, enabling the slitting blade's operating parameters to be dynamically adjusted to address the uneven macroscopic mass distribution of the copper foil roll. This technology endows the slitting action itself with mass compensation capabilities, mitigating the impact of raw material thickness fluctuations on the uniformity of slitting strip width and edge quality from the process source, resulting in copper foil strips with more consistent fundamental physical properties.

[0055] Real-time tension spectrum data of each individual copper foil strip after slitting is collected using a tension sensor array and matched with a preset ideal tension spectrum. Based on the matching differences, an independent tension compensation signal is generated for each winding shaft, thereby driving each winding shaft to execute differentiated torque output. This technology achieves decoupling and fine-tuning of the tension of multiple parallel copper foil strips, ensuring that the winding process of each foil tends towards its optimal tension curve. In terms of winding quality, the flatness of the roll end face is improved, the internal stress distribution is more uniform, and the risks of interlayer slippage, wrinkling, or strip breakage caused by tension mismatch are effectively avoided. Attached Figure Description

[0056] Figure 1 This is a timing diagram of the high-precision slitting and winding control system for ultra-thin copper foil described in this invention.

[0057] Figure 2 A flowchart for calculating the axial mass balance coefficient;

[0058] Figure 3 A flowchart for adjusting the operating parameters of the slitting head and performing slitting;

[0059] Figure 4 Box plot of tension distribution on each axis of a five-axis winding system;

[0060] Figure 5 Radar diagram showing the tension control accuracy of a five-axis winding closed-loop control system. Detailed Implementation

[0061] The technical solution of the present invention will be clearly and completely described below with reference to the embodiments. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0062] See Figure 1The thickness monitoring module upstream collects raw thickness distribution data of the copper foil in operation. The mass field analysis module receives this raw thickness distribution data and constructs a dynamic mass field model of the copper foil reflecting the dynamic changes in thickness in the width and travel directions. Based on this model, it further calculates the axial mass balance coefficient, which characterizes the mass uniformity of the copper foil roll to be cut in the width direction. The cutting control module, based on this axial mass balance coefficient, generates a dynamic compensation command containing specific adjustment amounts by querying an internally preset relational mapping. This command is used to adjust operating parameters such as the lateral vibration of the cutting blade and the blade pressure. After the parameters are adjusted, the cutting blade is driven to perform the cutting operation on the copper foil. Simultaneously, the tension monitoring module, located downstream of the cutting blade, continuously collects real-time tension spectrum data of each cut individual copper foil strip through its tension sensor array. The winding control module acquires this real-time tension spectrum data and matches it with the system's preset ideal tension spectrum to determine the deviation between the actual and target values ​​of the tension of each copper foil strip. This generates an independent tension compensation signal for each winding shaft. After receiving the corresponding independent tension compensation signal, each winding shaft adjusts the torque output of its servo driver in real time, ultimately achieving high-precision winding of each copper foil strip under constant ideal tension.

[0063] See Figure 2 In one embodiment of the present invention, a thickness monitoring module collects thickness measurements of the copper foil along its width at fixed intervals upstream of the ultra-thin copper foil production line. These measurements constitute the raw thickness distribution data. For example, for a copper foil with a width of 650 mm, the thickness monitoring module collects thickness values ​​at 1 mm intervals along the width direction, forming a thickness distribution array on a cross-section. The mass field analysis module receives these thickness distribution arrays transmitted in a time sequence and maps the thickness distribution array collected at each time point to a row vector on a two-dimensional mass distribution plane. The horizontal axis of the two-dimensional mass distribution plane represents the width position of the copper foil, and the vertical axis represents the time point in the copper foil's travel direction. The thickness value of the copper foil at each time point and each width position corresponds to the value at that point in the two-dimensional mass distribution plane. In the two-dimensional mass distribution plane, with the copper foil's travel direction as the time axis, the thickness distribution row vectors at different time points are stacked in chronological order to construct a dynamic mass field model of the copper foil that reflects the continuous state of the copper foil thickness and width position changes over production time. The dynamic mass field model of the copper foil is a two-dimensional matrix, where the rows of the matrix correspond to the time index, and the columns correspond to the width position index.

[0064] In some embodiments, the quality field analysis module performs virtual segmentation along the planned segmentation path in the copper foil dynamic quality field model according to a preset segmentation plan. The planned segmentation path divides the copper foil dynamic quality field model into multiple independent strip regions in the width dimension. The system performs numerical integration calculations along the time axis on the quality distribution data within each virtual segmented strip region to calculate the quality integral value of each virtual segmented strip. For example, when the plan is to slice the copper foil into 5 strips, the copper foil dynamic quality field model is virtually segmented into 5 strips. The system calculates the sum of the thickness values ​​of each strip over the entire production time as the quality integral value. In the specific steps of comparing the quality integral differences of adjacent virtual segmented strips, the system extracts the quality integral value of each strip in the order of the virtual segmented strips, and calculates the absolute value of the difference between the quality integral values ​​of every two adjacent strips in turn, finding the maximum value among the differences of the quality integral values ​​of all adjacent strips.

[0065] Optionally, the system calculates the axial mass balance coefficient based on the ratio of the maximum difference value to the average mass integral. The formula for calculating the axial mass balance coefficient is as follows:

[0066]

[0067] Where: characters Represents the axial mass balance coefficient, character Represents the maximum value found among the differences in quality integral values ​​of all adjacent virtual segmentation strips, character This represents the arithmetic mean of the mass integral values ​​of all virtual segmented strips. It can be understood as the axial mass balance coefficient. The value reflects the uniformity of the mass distribution of the copper foil roll along the planned slitting path, and is the axial mass balance coefficient. A smaller value indicates a more uniform mass distribution. In the example scenario, different virtual segmentation schemes will result in different axial mass uniformity coefficients for the same roll of copper foil. Numerical data comparison shows that when the planned slitting path deviates from the highly uneven region of copper foil thickness distribution, the calculated axial mass balance coefficient... The numerical value is significantly reduced, for example, the axial mass balance coefficient under a certain cutting scheme. The calculated value is 0.15, while the axial mass balance coefficient under another cutting scheme is... The calculated value is 0.08. In some embodiments, the calculated axial mass balance coefficient is... It is directly transmitted to the slitting control module to generate dynamic compensation instructions for the slitting tool holder.

[0068] See Figure 3In one embodiment of the present invention, the slitting control module internally stores a set of slitting tool holder reference operating parameters, including the reference position and reference vibration frequency of the tool holder lateral servo motor and the reference pressure value of the hydraulic pressure unit. The slitting control module receives the axial mass balance coefficient from the mass field analysis module, for example, the axial mass balance coefficient is 0.12. The slitting control module queries a preset compensation relationship mapping table based on the axial mass balance coefficient. The compensation relationship mapping table uses the axial mass balance coefficient as an index and stores the corresponding tool holder lateral vibration compensation amount and blade pressure compensation amount. The query operation obtains the tool holder lateral vibration compensation amount that matches the current axial mass balance coefficient. The tool holder lateral vibration compensation amount includes the lateral micro-motion amplitude and frequency adjustment value. At the same time, the blade pressure compensation amount is obtained, which is a pressure correction value. The slitting control module integrates the tool holder lateral vibration compensation amount and the blade pressure compensation amount, and combines them with the slitting tool holder reference operating parameters to synthesize a dynamic compensation instruction for the slitting tool holder that can be directly parsed and executed by the actuator. The dynamic compensation instruction is a structured data packet containing the target position sequence, target pressure value, and action timing.

[0069] In some embodiments, the process of adjusting the operating parameters of the slitting headstock and performing the slitting operation according to the dynamic compensation command begins with the parsing of the command. The system parses the dynamic compensation command, separating the target position sequence for the lateral servo motor of the headstock and the target pressure value for the hydraulic pressure unit. The system drives the lateral servo motor of the headstock to move according to the target position sequence, which is a set of coordinate points arranged in chronological order. The lateral servo motor of the headstock performs high-frequency micro-amplitude lateral movement according to the coordinate point sequence. The frequency of the high-frequency micro-amplitude lateral movement is between 50 Hz and 200 Hz, and the amplitude is within ±0.5 mm. Simultaneously, the system adjusts the output of the hydraulic pressure unit according to the target pressure value. After receiving the target pressure value signal, the hydraulic pressure unit adjusts the opening of the hydraulic valve to keep the actual pressure applied to the slitting blade consistent with the target pressure value. The target pressure value may have a positive or negative offset compared to the reference pressure value in the reference operating parameters of the slitting headstock. After the transverse servo motor and hydraulic pressure unit of the cutter post are adjusted to the target state according to the dynamic compensation command, the system drives the entire slitting cutter post to move at a constant speed along the copper foil traveling direction, thereby completing the slitting operation of the copper foil.

[0070] Optionally, the compensation relationship mapping table is constructed based on historical production data and experimental calibration. The mapping relationship is reflected as a corresponding function between the axial mass balance coefficient and the compensation amount. An exemplary fragment of the compensation relationship mapping table shows that when the axial mass balance coefficient is 0.05, the amplitude value of the tool holder lateral vibration compensation is 0.1 mm, and the blade pressure compensation is -5 kPa; when the axial mass balance coefficient is 0.15, the amplitude value of the tool holder lateral vibration compensation becomes 0.4 mm, and the blade pressure compensation is +10 kPa. Data comparison shows that for different axial mass balance coefficient inputs, the system can generate dynamic compensation instructions with differences by querying the same compensation relationship mapping table, thereby realizing differentiated control of the slitting tool holder operating parameters. It can be understood that the process of synthesizing dynamic compensation instructions is a combination of logical operation and data encapsulation. The slitting control module superimposes or replaces the queried compensation amount with the reference parameters and encapsulates it into an instruction data packet according to a predetermined protocol. In some embodiments, the target position sequence of high-frequency micro-amplitude lateral motion can be generated by a damped vibration function, with the function form as follows:

[0071]

[0072] Where: characters The character represents the offset of the lateral target position of the tool holder relative to the reference position at time t. This represents the lateral fretting amplitude value obtained from the lateral vibration compensation of the tool post. Represents the frequency adjustment value obtained from the lateral vibration compensation of the tool post, character Represents the initial phase angle. Optionally, the slitting operation starts after a fixed delay following the adjustment of the tool holder lateral servo motor and hydraulic pressure unit to ensure system stability.

[0073] In one embodiment of the present invention, the core task of the tension monitoring module is to collect real-time tension spectrum data of each independent copper foil strip after slitting using a tension sensing array. This function is achieved through the physical arrangement of the tension sensing array. A tension sensor is precisely installed along the running path of each independent copper foil strip, immediately downstream of the slitting blade. These tension sensors are arranged along a straight line parallel to the slitting blade, forming a complete tension sensing array. For example, when the copper foil is slitted into five independent copper foil strips, five tension sensors are immediately arranged downstream of the slitting blade, each corresponding to the center position of one copper foil strip's path, ensuring that the measured value represents the average tension state of that copper foil strip. The tension monitoring module internally sets a fixed sampling frequency, such as 100 times per second. The system synchronously triggers and reads the instantaneous measurement values ​​of all tension sensors in the tension sensing array at this fixed sampling frequency. The data set obtained from each synchronous reading operation, containing the current tension values ​​of all independent copper foil strips, constitutes a tension snapshot at a given point in time. The system continuously performs the above synchronous reading operation. Within a continuous process time period, such as within 10 seconds after the start of slitting, it records the tension snapshot corresponding to each sampling moment. These 1,000 tension snapshots arranged in chronological order are combined and arranged in the time dimension to finally form real-time tension spectrum data that reflects the continuous change of tension of each copper foil strip over time. The real-time tension spectrum data is a multi-dimensional array whose dimensions include time index, copper foil strip index, and corresponding tension measurement value.

[0074] In some embodiments, the fixed sampling frequency is set based on the running speed of the copper foil and the possible frequency of tension fluctuations. When the copper foil linear speed is high or there is a need to focus on high-frequency tension fluctuations, the fixed sampling frequency is increased accordingly, for example, set to 500 times per second. It is understood that the physical installation location of the tension sensing array must be close to the downstream of the slitting point. The purpose is to minimize the path length of the slitting copper foil strip before it reaches the tension sensor, thereby reducing external interference and ensuring that the measured tension most directly reflects the impact of the slitting process. For example, the sensor is installed only 0.5 meters away from the slitting blade holder. Data comparison shows that different fixed sampling frequencies significantly affect the temporal resolution of real-time tension spectrum data. In the example scenario, real-time tension spectrum data obtained using a sampling frequency of 100 times per second captures more brief tension pulse details compared to data obtained using a sampling frequency of 20 times per second. In some embodiments, each tension snapshot is temporarily stored in a buffer memory after generation. After completing the acquisition for a preset duration, the system packages a series of consecutive tension snapshots and timestamps them, sending them as a complete real-time tension spectrum data block to the winding control module for processing. Optionally, each tension sensor in the tension sensor array needs to undergo zero-point calibration and range calibration after installation to ensure the consistency and comparability of measurements read from different sensors. It is understood that real-time tension spectrum data is the foundation for subsequent tension matching analysis and closed-loop control; its real-time performance and accuracy directly determine the control precision of the winding tension.

[0075] In one embodiment of the present invention, the winding control module performs a process of matching and analyzing real-time tension spectrum data with a preset ideal tension spectrum and generating an independent tension compensation signal for the winding shaft. Internally, the winding control module presets a constant ideal tension value for each winding shaft on the production line. The set of ideal tension values ​​for all winding shafts constitutes the system's ideal tension spectrum, which is a one-dimensional array defining the target tension of each winding shaft. For example, in a production scenario where copper foil is cut into five independent strips, the winding control module presets ideal tension values ​​for each of the five winding shafts. These five ideal tension values ​​constitute an ideal tension spectrum containing five elements. The winding control module receives real-time tension spectrum data from the tension monitoring module. The real-time tension spectrum data contains a sequence of tension sampling values ​​for each copper foil strip over a period of time. The winding control module calculates the arithmetic mean of the tension of all sampling points for each copper foil strip within the most recent time window in the real-time tension spectrum data, obtaining the average tension of each copper foil strip. The average tension of each copper foil strip is then algebraically subtracted from the ideal tension value of the corresponding winding shaft in the ideal tension spectrum to calculate the tension deviation of each copper foil strip. The tension deviation value includes magnitude and positive / negative direction information.

[0076] In some embodiments, after calculating the tension deviation, the winding control module, based on the magnitude and direction of the tension deviation for each copper foil strip and combined with the real-time linear velocity of the copper foil strip obtained from the main speed system of the production line, calculates the required torque adjustment for each winding shaft using an independent winding diameter estimation algorithm. The first step of the independent winding diameter estimation algorithm is to estimate the current winding radius of each copper foil strip on the winding shaft in real time based on the fixed installation coordinates of the tension sensor in space and the real-time rotational speed fed back by the encoder of the corresponding winding shaft. The estimation formula may be based on geometric relationships and the sum of winding lengths. After obtaining the current winding radius, the system initially calculates the torque compensation value required to offset the current tension deviation based on the product of the tension deviation and the current winding radius. Subsequently, the system dynamically corrects the initially calculated torque compensation value by combining the elastic modulus parameters of the copper foil material stored in the material database and the real-time changing linear velocity information. This dynamic correction is used to compensate for the elastic deformation and dynamic inertial effects of the material, ultimately obtaining a more accurate required torque adjustment. The required torque adjustment is a physical quantity with a positive or negative sign, where the sign indicates whether the torque output needs to be increased or decreased. Finally, the take-up control module converts the required torque adjustment for each take-up shaft into an independent tension compensation signal that can be recognized by the corresponding take-up shaft servo driver through digital-to-analog conversion or communication protocol.

[0077] Optionally, the preset value of the ideal tension spectrum can be configured according to the specifications and process requirements of different copper foils. See Table 1 for an example ideal tension spectrum configuration.

[0078] Table 1: Ideal Tension Spectrum of a Five-Axis Rewinding System

[0079] Reel number Ideal tension value (N) 1 120.0 2 120.0 3 118.0 4 122.0 5 120.0

[0080] It is understandable that the step of dynamically correcting the initially calculated torque compensation value can be achieved by introducing a correction factor related to the material and velocity. An exemplary formula for calculating the correction factor is as follows:

[0081]

[0082] Where: characters Represents a dynamic correction factor, character The character represents the elastic modulus of copper foil material. Represents the real-time linear velocity of the copper foil strip, character Represents the density of the copper foil material, character This represents the path length between the tension sensor and the take-up reel. Data comparisons show that the application includes a dynamic correction factor. The independent roll diameter estimation algorithm, compared to a simple calculation based solely on the product of radius and deviation, can generate a more accurate torque adjustment amount that reflects the actual physical process when the copper foil linear speed changes rapidly, thus producing a more precise independent tension compensation signal. In some embodiments, the real-time linear speed is obtained by measuring the rotational speed and circumference of the guide rollers. It is understood that the independent roll diameter estimation algorithm operates independently in the control channel of each take-up shaft within each control cycle, ensuring that the torque adjustment calculations for each shaft do not interfere with each other.

[0083] See Figure 4 This paper presents the statistical distribution characteristics of tension values ​​of five winding shafts in a copper foil slitting and winding system during operation. From a professional perspective, the upper and lower boundaries of each box plot correspond to the upper quartile (Q3) and lower quartile (Q1) of the tension data, respectively. The orange horizontal line inside the box represents the median tension of that winding shaft, and the height of the box reflects the interquartile range (IQR), representing the concentration of tension data for that shaft. The upper and lower whiskers extend to the farthest data points within 1.5 times the IQR, and the dots outside the whiskers represent outliers exceeding this range. Combined with the ideal tension spectrum configuration analysis in Table 1: the median tension of winding shaft 1 is approximately 120.0 N, perfectly matching the ideal value, but there are abnormally low values ​​below 117 N, indicating occasional large fluctuations in tension. The median tension of winding shaft 2 is stable around 120.0 N, with a concentrated box distribution. Outliers are high-tension points above 124 N, reflecting high overall tension control accuracy for this shaft, but there are individual instances of instantaneous tension exceeding the limit. The median tension of take-up shaft 3 is approximately 118.5 N, with minimal deviation from the ideal value of 118.0 N. However, the lower limit of the box extends to around 115 N, and there are abnormally low values ​​below 114 N, indicating significant fluctuations in the lower limit of tension for this shaft. The median tension of take-up shaft 4 is approximately 122.5 N, closely matching the ideal value of 122.0 N. The box shifts upwards, extending to 126 N, indicating that the overall tension of this shaft is at a relatively high level, but with good control stability. The median tension of take-up shaft 5 is approximately 120.0 N, consistent with the ideal value, but there are abnormally high values ​​above 125 N, and the box distribution is wide, reflecting a relatively large dispersion in tension for this shaft. The box plot, through statistical visualization of the tension data of each take-up shaft, intuitively presents the tension control effect and fluctuation characteristics of the five-axis take-up system, providing crucial data support for subsequent optimization of the torque compensation algorithm based on tension deviation.

[0084] In one embodiment of the present invention, the winding control module adjusts the torque output of each winding shaft based on independent tension compensation signals to complete the winding process of the copper foil strip. Starting with signal distribution, the winding control module sends each calculated independent tension compensation signal to its corresponding winding shaft servo driver via a fieldbus network. For example, in a five-axis winding system, five independent digital or analog signals are synchronously sent to five physically independent winding shaft servo driver addresses. Upon receiving its own independent tension compensation signal, each winding shaft servo driver immediately calculates and outputs a new torque control current value to the connected winding motor based on the torque adjustment information contained in the received independent tension compensation signal, combined with internally stored parameters such as the motor torque constant. The formula for calculating the new torque control current value can be expressed as:

[0085]

[0086] Where: characters The character represents the new torque control current calculated and output by the servo driver. Represents the reference current required to maintain basic tension based on the current linear speed and roll diameter. Represents the required torque adjustment amount extracted from the independent tension compensation signal, character This represents the proportional coefficient that maps the torque adjustment amount to the current increment. After receiving the new torque control current from the servo driver, each winding motor operates based on the new torque control current, generating an electromagnetic torque corresponding to the current value. This precisely adjusts the winding tension of the corresponding copper foil strip, so that the actual winding tension of each copper foil strip dynamically tends towards the preset target value in the ideal tension spectrum.

[0087] In some embodiments, the adjustment of the entire copper foil roll slitting and winding process is a continuous closed-loop control. This closed-loop control manifests as the system continuously adjusting based on updated independent tension compensation signals until the entire copper foil roll is slitting is complete. Specifically, the tension monitoring module continuously collects updated real-time tension spectrum data from the tension sensor array throughout the production process and transmits this updated real-time tension spectrum data to the winding control module at fixed control cycles. Within each control cycle, the winding control module repeatedly performs the complete step of matching and analyzing the updated real-time tension spectrum data with a preset ideal tension spectrum, i.e., recalculating the average tension and tension deviation, and generating a set of updated independent tension compensation signals through an independent roll diameter estimation algorithm. The winding control module sends the newly generated updated independent tension compensation signals to the servo drives of each winding shaft in real time. Upon receiving the signals, the servo drives immediately update their output torque control current, thus forming a real-time closed-loop control system with tension as the controlled variable. It can be understood that this closed-loop control process runs uninterrupted throughout the entire production cycle from the start of slitting to the end of winding, until the entire copper foil roll slitting and winding process is completed. Data comparison shows that, compared to an open-loop system that only sets torque when the roll diameter changes, the tension fluctuation range of each copper foil strip controlled by this continuous closed-loop regulation system is significantly smaller in the large roll diameter condition at the end of the winding process. Optionally, the winding shaft servo driver may include closed-loop control of current loop and speed loop, but the independent tension compensation signal acts on the setpoint of the outermost torque (tension) loop. It is understood that the real-time transmission of updated independent tension compensation signals relies on a highly deterministic industrial communication network to ensure the synchronization and timeliness of control commands. In some embodiments, the reference current... It could also be a value dynamically calculated based on the roll diameter and velocity model, a scaling factor. The settings and calibration are then performed using the parameterization software of the servo driver.

[0088] See Figure 5 This figure presents the performance of the five-axis take-up system in terms of tension control accuracy. Axes 1 to 5 correspond to five independent take-up axes, and the radial scale represents the normalized value of tension control accuracy (ranging from 0.92 to 1.00, with values ​​closer to 1.00 indicating higher control accuracy). As shown in the figure, the take-up axis corresponding to axis 1 has the highest tension control accuracy, close to 1.00, indicating that this axis exhibits the smallest tension fluctuation and best conforms to the ideal tension spectrum during take-up. Axis 2 has the second highest control accuracy, approximately 0.97. The control accuracies of axes 3, 4, and 5 are distributed in the range of 0.93-0.95, reflecting the performance differences of different take-up axes under closed-loop tension control. This difference stems from the dynamic adjustment effect of the independent tension compensation signals of each axis, and also confirms the system's design goal of achieving high-precision tension control through real-time closed-loop control.

[0089] The above embodiments are only used to illustrate the technical methods of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical methods of the present invention without departing from the spirit and scope of the technical methods of the present invention.

Claims

1. A high-precision slitting and winding control system for ultra-thin copper foil, characterized in that, include: The thickness monitoring module is used to collect raw thickness distribution data of copper foil during operation upstream of the ultra-thin copper foil production line; The mass field analysis module is used to construct a dynamic mass field model of copper foil based on the original thickness distribution data, and to calculate the axial mass balance coefficient of the current copper foil roll based on the dynamic mass field model of copper foil. The slitting control module is used to generate dynamic compensation commands for the slitting tool holder based on the axial mass balance coefficient, adjust the operating parameters of the slitting tool holder according to the dynamic compensation commands, and perform slitting operations on the copper foil. The tension monitoring module is used to collect real-time tension spectrum data of each independent copper foil strip after slitting through a tension sensing array during the slitting operation. The winding control module is used to match and analyze the real-time tension spectrum data with the preset ideal tension spectrum, generate an independent tension compensation signal for the winding shaft, and adjust the torque output of each winding shaft based on the independent tension compensation signal to complete the winding of the copper foil strip.

2. The high-precision slitting and winding control system for ultra-thin copper foil as described in claim 1, characterized in that, The step of constructing a dynamic mass field model for copper foil based on the original thickness distribution data, and calculating the axial mass balance coefficient of the current copper foil roll based on the dynamic mass field model, includes: The original thickness distribution data collected along the width direction of the copper foil is mapped into a two-dimensional mass distribution plane; In the two-dimensional mass distribution plane, a dynamic mass field model of the copper foil is constructed with the copper foil travel direction as the time axis, reflecting the change of thickness with time and width position. In the copper foil dynamic mass field model, virtual segmentation is performed along the planned cutting path, and the mass integral of each virtual segment is calculated. By comparing the mass integral differences between adjacent virtual segmented strips, the axial mass balance coefficient is calculated based on the ratio of the maximum difference value to the average mass integral.

3. The high-precision slitting and winding control system for ultra-thin copper foil as described in claim 1, characterized in that, The dynamic compensation command for generating the slitting tool holder based on the axial mass balance coefficient includes: Preset the baseline operating parameters of the slitting tool holder; The lateral vibration compensation amount of the tool holder and the cutting tool pressure compensation amount are obtained by querying the preset compensation relationship mapping table based on the axial mass balance coefficient. The lateral vibration compensation amount of the slitting tool holder and the blade pressure compensation amount are combined with the reference operating parameters of the slitting tool holder to synthesize the dynamic compensation command of the slitting tool holder.

4. The high-precision slitting and winding control system for ultra-thin copper foil as described in claim 3, characterized in that, The step of adjusting the operating parameters of the slitting tool holder according to the dynamic compensation command and performing the slitting operation on the copper foil includes: The dynamic compensation command is analyzed to separate the target position sequence of the tool holder transverse servo motor and the target pressure value of the hydraulic pressure unit; The tool holder lateral servo motor is driven to perform high-frequency micro-amplitude lateral movement according to the target position sequence; Simultaneously, the output of the hydraulic pressure unit is adjusted according to the target pressure value to make the blade pressure consistent with the target pressure value; After the transverse servo motor and hydraulic pressure unit of the slitting post are adjusted to their positions according to the instructions, the slitting slitting post is driven to complete the slitting operation along the copper foil traveling direction.

5. The high-precision slitting and winding control system for ultra-thin copper foil as described in claim 1, characterized in that, The real-time tension spectrum data of each independent copper foil strip after being cut, acquired through a tension sensing array, includes: On each individual copper foil strip path immediately downstream of the slitting blade holder, a tension sensor is arranged to form a tension sensing array. The measured values ​​of all tension sensors are read simultaneously at a fixed sampling frequency to form a tension snapshot at a point in time; Tension snapshots are continuously recorded at all time points over a period of time, and combined to form real-time tension spectrum data reflecting the change of tension of each copper foil strip over time.

6. The high-precision slitting and winding control system for ultra-thin copper foil as described in claim 1, characterized in that, The step of matching and analyzing the real-time tension spectrum data with a preset ideal tension spectrum to generate an independent tension compensation signal for the take-up spool includes: A constant ideal tension value is preset for each take-up spool, and the ideal tension values ​​of all take-up spools constitute an ideal tension spectrum. Calculate the deviation between the average tension of each copper foil strip in the real-time tension spectrum data and the corresponding ideal tension value; Based on the magnitude and direction of the tension deviation of each copper foil strip, and combined with the real-time linear velocity of the copper foil strip, the required torque adjustment of each winding shaft is calculated using an independent roll diameter estimation algorithm. The required torque adjustment for each take-up spool is converted into a corresponding independent tension compensation signal.

7. The high-precision slitting and winding control system for ultra-thin copper foil as described in claim 6, characterized in that, The process of adjusting the torque output of each winding shaft based on the independent tension compensation signal to complete the winding of the copper foil strip includes: Each independent tension compensation signal is sent to the corresponding take-up spool servo driver; Each take-up servo driver calculates and outputs a new torque control current to the take-up motor based on the received independent tension compensation signal; Each winding motor operates based on the new torque control current, causing the tension of each copper foil strip to tend toward the ideal tension spectrum; Before the entire copper foil roll is slit, adjustments are continuously made based on updated independent tension compensation signals until the winding process is completed.

8. The high-precision slitting and winding control system for ultra-thin copper foil as described in claim 2, characterized in that, The comparison of the quality integral differences between adjacent virtual segmentation strips includes: In the dynamic mass field model of the copper foil, mass distribution data of several strips are extracted along the virtual segmentation path; The mass distribution data of each strip is integrated along the direction of travel to obtain the mass integral value of each strip. Calculate the absolute value of the difference between the mass integral values ​​of every two adjacent strips in sequence; Find the maximum value among the differences in the mass integral values ​​of all adjacent stripes.

9. The high-precision slitting and winding control system for ultra-thin copper foil as described in claim 6, characterized in that, The calculation of the required torque adjustment for each take-up shaft based on the magnitude and direction of the tension deviation of each copper foil strip, combined with the real-time linear velocity of the copper foil strip, using an independent roll diameter estimation algorithm includes: Based on the position of the tension sensor and the rotation speed of the winding shaft, the current winding radius of each copper foil strip on the winding shaft is estimated in real time; The required torque compensation value is initially calculated based on the product of the tension deviation and the current winding radius; The torque compensation value is dynamically corrected by combining the elastic modulus of the copper foil material with the real-time linear velocity to obtain the final required torque adjustment.

10. The high-precision slitting and winding control system for ultra-thin copper foil as described in claim 7, characterized in that, The continuous adjustment based on updated independent tension compensation signals before the entire copper foil roll is slit includes: Continuously acquire and update real-time tension spectrum data from the tension sensing array; Repeat the step of matching the updated real-time tension spectrum data with the preset ideal tension spectrum to generate an updated independent tension compensation signal; The updated independent tension compensation signal is sent to each take-up servo driver in real time to form a closed-loop control.

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