A tension and alignment cooperative control method and device for an oversized bag making machine

Abstract

This invention provides a method and apparatus for controlling tension and alignment coordination in an ultra-large bag-making machine. The method includes: real-time acquisition of tension measurement values ​​and alignment deviation measurement values ​​in each tension control section; generating tension control commands and correction control commands based on the tension measurement values ​​and alignment deviation measurement values, respectively; calculating the effective length change of the film path on the conveying path corresponding to the correction control command to generate a feedforward compensation amount, thereby suppressing the coupling disturbance of the correction action on tension and alignment; performing anomaly detection based on the tension measurement values, the alignment deviation measurement values, and the drive state signal reflecting the load of the drive system to obtain anomaly state information and determine a risk score; and triggering corresponding preset graded fault-tolerant actions according to the risk score. This effectively suppresses tension fluctuations, alignment drift, and correction coupling disturbances on key processes, enhancing the continuous production capacity and robustness of the equipment.

Description

Technical Field

[0001] This invention relates to the field of packaging bag making equipment and automation control technology, and in particular to a method and device for controlling tension and alignment coordination in an ultra-large bag making machine. Background Technology

[0002] In the field of flexible packaging bag manufacturing, oversized packaging bags typically require multiple processes to be completed continuously on the same film conveyor path, including unwinding, traction positioning, color mark detection and alignment, edge trimming and shaping, longitudinal sealing, transverse sealing, and cutting. To reduce floor space, minimize manual handling, and improve production cycle time and consistency, bag manufacturing solutions integrating multiple processes into the same equipment have emerged in the industry. For example, existing publicly available solutions propose integrating modules such as raw material feeding, traction positioning, punching / processing, sealing, tension control, detection, and cutting / unloading on a single production line to achieve continuous production.

[0003] However, the above-mentioned integrated solution still faces constraints in cutting accuracy, printing alignment, and dimensional stability when dealing with ultra-large sizes.

[0004] Specifically, in actual high-speed bag making operations, film is a typical continuous strip material, and its tension exhibits multi-segment, multi-actuator coupling characteristics: factors such as changes in unwinding diameter, traction speed fluctuations, roller inertia and frictional slippage, and material elasticity and thickness non-uniformity cause tension to be transmitted between different spans, leading to time-varying coupling. Especially in ultra-large-size bag making scenarios, due to the wider film width, longer film path, and greater inertia of the roller system and roll material, the above coupling effects are more easily amplified, making tension fluctuations difficult to suppress, which in turn causes registration drift, wrinkles, and accumulation of dimensional errors. Research has been conducted on coupling modeling, decoupling control, and disturbance rejection control for multi-span tension systems. For example, studies have been conducted on improving tension control accuracy and disturbance rejection through multi-span tension coupling relationship modeling and analysis, and the use of self-tuning decoupling / ADRC methods. There are also reports on using advanced control strategies such as nonlinear MPC to suppress tension disturbances in roll-to-roll systems. However, most existing technologies are designed for scenarios with limited width or film path length. For the engineering challenges unique to ultra-large bag making machines, such as "accumulation of errors along the long film path" and "strong coupling between multiple actuators," these studies have not yet provided a complete, integrated solution for actual production processes.

[0005] On the other hand, misalignment and printing misalignment are also key sources of quality risk in the process of making oversized bags. Traditionally, bag-making equipment uses photoelectric / CCD detection in conjunction with EPC / CPC correction mechanisms to achieve lateral alignment of the tape. However, this method faces more complex challenges in oversized applications. Printing misalignment (color mark / overprinting) is not only affected by lateral misalignment, but also by tension fluctuations, speed fluctuations, and slippage errors. Fluctuations in tension levels significantly affect the lateral dynamics and control of the tape, especially when tension is insufficient or disturbances are large, making lateral errors more difficult to suppress. On the other hand, the lateral movement or swaying motion of the correction actuator changes the total effective length of the film path and its contact state with the roller system, thereby inducing sudden tension changes and speed perturbations, further leading to color mark phase drift and overprinting deviation, forming a coupled loop of mutual excitation between "correction—tension—alignment". Although there have been studies on lateral control dynamics modeling and control, existing bag-making equipment mostly separates the design of correction control and tension control, lacking a quantitative compensation mechanism for the changes in film path length caused by correction and its impact on pattern alignment, making it difficult to ensure alignment stability in ultra-large size scenarios.

[0006] Furthermore, extra-large bag making machines place higher demands on the consistency of cutting length and the stability of forming dimensions. Due to the long film path, high speed, and the susceptibility of material to micro-slippage, relying solely on traction encoders or single-point color mark triggers for cutting control can easily lead to the accumulation of length errors, resulting in deviations in bag length, sealing position, and forming dimensions. The aforementioned pattern alignment deviations further exacerbate the problem, affecting the consistency between the cutting position and the forming reference, leading to an increased scrap rate. Existing technical solutions, such as tension adjustment based on displacement sensors and cylinder / PLC-controlled pressure bars, or calibration and correction structures for folded films, as well as some automatic correction and film supply control patents, mostly focus on solving problems in a single area or adopt relatively static and localized approaches. For example, mechanical counterweight constant tension adjustment suffers from problems of dispersion and insufficient precision. Therefore, when faced with the complex working conditions of ultra-large bag making machines, these existing technical solutions are unable to systematically and holistically solve the interconnected and jointly interacting engineering challenges of "multi-region tension coupling", "tension disturbance induced by correction action", "stability assurance of printing alignment" and "elimination of cumulative cutting length error".

[0007] In summary, while existing multi-process integrated solutions have theoretically demonstrated their advantages in continuous production in the field of ultra-large flexible packaging bag manufacturing, they still have significant limitations in practical applications. These limitations include addressing the tension coupling effect caused by long film paths, uncontrollable disturbances introduced by the web-correction process itself, precise alignment of printed patterns, stable maintenance of cutting length accuracy, and consistency of formed dimensions. Therefore, there is an urgent need to develop a novel, comprehensive solution for ultra-large bag-making machines that integrates multi-segment tension coupling control, suppression of tension disturbances induced by the web-correction process, stable printing alignment, and elimination of accumulated cutting length errors. Such a solution would help overcome the bottlenecks in processing accuracy and stability of existing bag-making equipment, thereby fundamentally improving the production quality and efficiency of ultra-large packaging bags. Summary of the Invention

[0008] This invention provides a method and device for controlling tension and alignment coordination in an ultra-large bag making machine, aiming to solve problems such as multi-segment tension fluctuation and image alignment / deviation correction coupling, overprinting / color mark alignment drift, accumulation of cutting length error, and insufficient handling of abnormal working conditions in the high-speed continuous production process of ultra-large bag making machines.

[0009] In a first aspect, the present invention provides a method for controlling the tension and alignment coordination of an ultra-large bag-making machine, comprising: The tension measurement values ​​of each tension control section are collected in real time, as well as the alignment deviation measurement values ​​between the actual position of the printed mark on the film material and the preset reference position; the tension control section is obtained by dividing the film material conveying path of the ultra-large size bag making machine production line; Based on the tension measurement value and the alignment deviation measurement value, tension control command and correction control command are generated respectively; Calculate the change in effective membrane length on the delivery path corresponding to the correction control command, in order to generate feedforward compensation. The feedforward compensation is superimposed on the tension control command or speed control command to suppress the coupling disturbance of the correction action on tension and alignment. Based on the tension measurement value, the alignment deviation measurement value, and the drive status signal reflecting the load of the drive system, anomaly detection is performed to obtain anomaly status information in order to determine a risk score; Based on the risk score, the corresponding preset fault-tolerant action is triggered.

[0010] Optionally, after triggering the corresponding preset fault-tolerant action based on the risk score, the method further includes: Determine whether the tension measurement value and / or the alignment deviation measurement value meet the preset safety conditions, and dynamically permit the execution of the horizontal sealing and cutting processes when they are met.

[0011] Optionally, determining whether the tension measurement value and / or the alignment deviation measurement value meet preset safety conditions, and dynamically permitting the execution of the horizontal sealing and cutting processes when they are met, includes: Define a process allow window, the opening conditions of which are related to the fluctuation range of the tension measurement value, the magnitude of the alignment deviation measurement value and whether its rate of change is lower than the corresponding threshold; The execution of the horizontal sealing and cutting processes is dynamically permitted only when the opening conditions are met.

[0012] Optionally, tension control commands and alignment deviation control commands are generated based on the tension measurement value and the alignment deviation measurement value, respectively, including: Calculate the tension error between the measured tension value and the set tension value; Based on the aforementioned tension error, the preliminary tension control amount for each section is calculated using a controller that is independently set for each section. The actuator allocation matrix maps each initial tension control quantity into tension control commands for the unwinding brake, traction servo drive, and tension compensation mechanism of the ultra-large bag making machine production line.

[0013] Optionally, tension control commands and alignment deviation control commands are generated based on the tension measurement value and the alignment deviation measurement value, respectively, including: Calculate the alignment error between the measured alignment deviation value and the alignment reference value; Based on the alignment error, a correction feedback command is calculated by the correction controller; The correction feedback command is subjected to amplitude and slope limiting processing, and the output is the correction control command.

[0014] Optionally, based on the tension measurement value, the alignment deviation measurement value, and the drive state signal reflecting the load of the drive system, anomaly detection is performed to obtain anomaly state information to determine a risk score, including: Construct a risk feature vector that includes at least one of the following features: tension error of each section, alignment error, frequency and amplitude of correction action per unit time, and load rate of drive motor; The risk feature vector is input into the risk assessment function to calculate the risk score.

[0015] Optionally, the effective length change of the membrane path on the delivery path corresponding to the correction control command is calculated to generate a feedforward compensation amount, including: Calculate the difference between the corrective control commands in adjacent control cycles; The difference is input into a pre-calibrated geometric relationship model to calculate the change in the effective length of the membrane path; The effective length change of the membrane path is converted into an equivalent speed compensation or position compensation according to the control cycle; The speed compensation amount is superimposed on the traction speed command, or the position compensation amount is superimposed on the position command of the tension compensation mechanism.

[0016] Optionally, based on the risk score, a corresponding preset fault-tolerant action is triggered, including: If the risk score exceeds the first threshold but is lower than the second threshold, the first level of fault tolerance action is executed. The first level of fault tolerance action includes reducing the gain of feedforward compensation or tightening the rate of change limit of correction instructions. If the risk score exceeds the second threshold but is lower than the third threshold, a second-level fault-tolerant action is executed. The second-level fault-tolerant action includes reducing the production line speed and suspending the horizontal sealing and cutting processes that are sensitive to tension and alignment fluctuations. If the risk score exceeds the third threshold, the third level of fault tolerance action is executed. The third level of fault tolerance action includes controlling the correction actuator to return to the zero position, switching the tension setting value to the safe range, and starting the low-speed alignment calibration process.

[0017] Secondly, the present invention provides a control device for tension and alignment coordination in an ultra-large bag making machine, comprising: The acquisition module is used to acquire the tension measurement values ​​of each tension control section in real time, as well as the alignment deviation measurement values ​​between the actual position of the printed mark on the film and the preset reference position; the tension control section is obtained by dividing the film conveying path of the ultra-large size bag making machine production line; The instruction generation module is used to generate tension control instructions and alignment deviation control instructions based on the tension measurement value and the alignment deviation measurement value, respectively. The compensation amount generation module is used to calculate the effective length change of the membrane path on the delivery path corresponding to the correction control command, so as to generate the feedforward compensation amount; The suppression module is used to superimpose the feedforward compensation amount into the tension control command or speed control command to suppress the coupling disturbance of the correction action on tension and alignment. The risk scoring determination module is used to perform anomaly detection based on the tension measurement value, the alignment deviation measurement value, and the drive state signal reflecting the load of the drive system to obtain anomaly state information, so as to determine the risk score; The triggering module is used to trigger the corresponding preset graded fault-tolerant action based on the risk score.

[0018] Thirdly, the present invention provides an electronic device including a processor and a memory, the memory storing computer-readable instructions that, when executed by the processor, perform the steps of the method provided in the first aspect above.

[0019] Fourthly, the present invention provides a storage medium having a computer program stored thereon, which, when executed by a processor, performs the steps of the method provided in the first aspect above.

[0020] Fifthly, the present invention provides a computer program product comprising a computer program that, when executed by a processor, performs the steps of the method provided in the first aspect above.

[0021] As can be seen from the above technical solutions, the present invention has the following advantages: This invention provides a method and apparatus for controlling tension and alignment coordination in an ultra-large size bag making machine. The method includes: real-time acquisition of tension measurement values ​​in each tension control section, and alignment deviation measurement values ​​between the actual position of the printed mark on the film material and the preset reference position; the tension control sections are obtained by dividing the film material conveying path of the ultra-large size bag making machine production line; tension control commands and correction control commands are generated based on the tension measurement values ​​and the alignment deviation measurement values, respectively; the effective length change of the film path on the conveying path corresponding to the correction control command is calculated to generate a feedforward compensation amount; the feedforward compensation amount is superimposed on the tension control command or speed control command to suppress the coupling disturbance of the correction action on tension and alignment; based on the tension measurement values, the alignment deviation measurement values, and the drive state signal reflecting the load of the drive system, anomaly detection is performed to obtain anomaly state information to determine a risk score; and based on the risk score, a corresponding preset graded fault-tolerant action is triggered. It can effectively suppress the adverse effects of tension fluctuations, alignment drift, and correction coupling disturbances on key processes such as alignment, horizontal sealing, and cutting, and improve the accuracy of cutting length and consistency of forming dimensions, reduce wrinkles and scrap rates, thereby enhancing the continuous production capacity and robustness of the equipment. Attached Figure Description

[0022] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0023] Figure 1 This is a flowchart illustrating the first embodiment of the tension and alignment coordination control method for an ultra-large bag making machine according to the present invention. Figure 2 This is a flowchart illustrating the second embodiment of the tension and alignment coordination control method for an ultra-large bag making machine according to the present invention. Figure 3 This is a schematic diagram of the structure of the coordination system in Embodiment 2 of the control method for tension and alignment coordination of an ultra-large size bag making machine according to the present invention; Figure 4 This is a structural block diagram of an embodiment of a tension and alignment coordination control device for an ultra-large bag making machine according to the present invention. Detailed Implementation

[0024] This invention provides a method and device for controlling tension and alignment coordination in an ultra-large bag making machine, aiming to solve problems such as multi-segment tension fluctuation and image alignment / deviation correction coupling, overprinting / color mark alignment drift, accumulation of cutting length error, and insufficient handling of abnormal working conditions in the high-speed continuous production process of ultra-large bag making machines.

[0025] To make the objectives, features, and advantages of this invention more apparent and understandable, the technical solutions of the embodiments of this invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the embodiments described below are only some embodiments of this invention, and not all embodiments. Based on the embodiments of this invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this invention.

[0026] Example 1 Please see Figure 1 , Figure 1 This is a flowchart illustrating the steps of a method for controlling tension and alignment coordination in an ultra-large bag-making machine according to the present invention. The method includes: Step S101: Real-time acquisition of tension measurement values ​​for each tension control section, as well as alignment deviation measurement values ​​between the actual position of the printed mark on the film material and the preset reference position; the tension control section is obtained by dividing the film material conveying path of the ultra-large size bag making machine production line; In this embodiment, the film material conveying path is divided into at least three tension control sections, such as an unwinding area, a processing area, and a forming and cutting area. Tension sensors are arranged in each section to acquire tension measurements in real time. Color marks or vision sensors are arranged at the alignment points to detect the actual position of the printed marks and compare them with a preset benchmark to obtain alignment deviation measurements, such as color mark phase difference or lateral deviation.

[0027] Step S102: Based on the tension measurement value and the alignment deviation measurement value, generate tension control command and correction control command respectively; In this embodiment, the error between the measured tension value and the set value of each section is calculated. An independent controller, such as a PID controller, is used to calculate the initial control quantity for each section. This quantity is then mapped via an actuator allocation matrix to the unwinding brake, traction servo, and tension compensation mechanism as the final tension control command. Simultaneously, the alignment deviation measurement value is calculated, and a correction feedback command is generated by the correction controller. After being processed by amplitude and slope limiting, the correction control command, such as the guide roller lateral movement, is output.

[0028] Step S103: Calculate the effective length change of the membrane path on the delivery path corresponding to the correction control command, so as to generate the feedforward compensation amount; In this embodiment, based on the difference in correction control commands between adjacent control cycles and combined with a pre-calibrated geometric relationship model, such as linear mapping coefficients, the change in the effective length of the membrane path caused by the correction action is calculated. This change is then converted into an equivalent speed compensation amount or a position compensation amount for the tension compensation mechanism according to the control cycle.

[0029] Step S104: The feedforward compensation amount is superimposed on the tension control command or speed control command to suppress the coupling disturbance of the correction action on tension and alignment. In the embodiments of this application, the calculated speed feedforward compensation amount is superimposed on the speed command of the traction servo in real time, or the position compensation amount is superimposed on the compensation mechanism command, so as to actively offset the tension change and alignment drift caused by the change of membrane length within the same cycle of the correction action, thereby achieving collaborative decoupling control.

[0030] Step S105: Based on the tension measurement value, the alignment deviation measurement value, and the drive state signal reflecting the load of the drive system, perform anomaly detection to obtain anomaly state information in order to determine the risk score; In this embodiment, a risk feature vector is constructed in real time, including features such as tension error in each section, alignment error, frequency and amplitude of correction actions per unit time, and drive motor load rate. This vector is then input into a preset risk assessment function to calculate a quantified risk score; a higher score indicates a greater risk of system anomaly.

[0031] Step S106: Based on the risk score, trigger the corresponding preset graded fault-tolerant action.

[0032] In this embodiment, a graded response is triggered based on the threshold range of the risk score: if the score exceeds the first-level threshold, an early warning action is executed, such as reducing the feedforward gain or tightening the correction change rate; if it exceeds the second-level threshold, an intervention action is executed, such as slowing down the operation or pausing key processes such as horizontal sealing / cutting; if it exceeds the highest-level threshold, a severe anomaly handling process is executed, such as zeroing the correction, switching to the safety tension setting, or initiating low-speed alignment calibration and repositioning.

[0033] This invention provides a method for coordinated tension and alignment control in an ultra-large bag-making machine. This method involves real-time acquisition of tension measurements in each tension control section, as well as alignment deviation measurements between the actual position of the printed mark on the film and a preset reference position. The tension control sections are obtained by dividing the film conveying path of the ultra-large bag-making machine production line. Tension control commands and correction control commands are generated based on the tension measurements and alignment deviation measurements, respectively. The effective length change of the film path corresponding to the correction control command is calculated to generate a feedforward compensation amount. This feedforward compensation amount is superimposed on the tension control command or speed control command to suppress the coupling disturbance of the correction action on tension and alignment. Based on the tension measurements, the alignment deviation measurements, and the drive state signal reflecting the drive system load, anomaly detection is performed to obtain anomaly state information to determine a risk score. Based on the risk score, a corresponding preset graded fault-tolerant action is triggered. It can effectively suppress the adverse effects of tension fluctuations, alignment drift, and correction coupling disturbances on key processes such as alignment, horizontal sealing, and cutting, and improve the accuracy of cutting length and consistency of forming dimensions, reduce wrinkles and scrap rates, thereby enhancing the continuous production capacity and robustness of the equipment.

[0034] Example 2 Please see Figure 2 , Figure 2 This is a flowchart illustrating a second embodiment of the tension and alignment coordination control method for an ultra-large bag making machine according to the present invention. The steps include: Step S201: Real-time acquisition of tension measurement values ​​for each tension control section, as well as alignment deviation measurement values ​​between the actual position of the printed mark on the film material and the preset reference position; the tension control section is obtained by dividing the film material conveying path of the ultra-large size bag making machine production line; This invention is applied to Figure 3 In the collaborative system shown, Figure 3 This is a schematic diagram of the collaborative system of a second embodiment of the tension and alignment coordination control method for an ultra-large bag making machine according to the present invention. The system includes at least a multi-segment tension detection unit 1, a multi-segment tension execution unit 2, a print alignment / deviation detection unit 3, a deviation correction execution mechanism 4, a data acquisition and communication unit 5, and a controller 6. The controller 6 is used to receive real-time signals such as multi-segment tension, print alignment deviation / deviation, and drive status, and outputs control quantities to the unwinding brake, traction servo, compensation mechanism, and deviation correction execution mechanism, thereby realizing closed-loop adjustment and coordinated control of tension and alignment.

[0035] In this embodiment, the controller 6 divides the film material conveying path into at least three tension control sections, such as the unwinding section T1, the alignment processing section T2, and the forming and cutting entry section T3 as shown in the figure. If necessary, it can be extended to a post-forming cutting synchronous section T4. Tension signals are collected in real time at each section's tension detection point by the multi-segment tension detection unit 1 and converted into measured values. Tension sensors, such as tension sensing rollers or S-shaped load cells, are arranged in each section by the printing alignment / deviation detection unit 3 to collect tension voltage or current signals in real time, which are then converted into measured tension values ​​using calibration coefficients. At alignment detection points, such as color mark detection positions, color mark sensors or industrial cameras are arranged to detect the actual position of printed marks on the film material, such as color marks or patterns, in real time and compare them with preset reference positions to obtain alignment deviation measurements, which characterize the color mark phase deviation or lateral deviation. Simultaneously, drive status signals are collected: linear velocity, acceleration, estimated drive current and torque, and the output of the correction actuator 4. The data acquisition and communication unit 5 synchronizes the signals of each sensor with a unified clock and performs filtering and outlier removal.

[0036] In addition, to facilitate the subsequent fusion and decoupling control of the timing characteristics of the controller, after acquiring each measurement value, the state vector and the control input vector are first defined, where the state vector is: ; in, For state vectors, For the linear velocity of the membrane material, Linear acceleration, For driving current, For torque. When an explicit description of the correction-tension coupling is required, the correction output can be incorporated into the state variables, for example, by expanding it to... .

[0037] The control input vector is: ; in, To control the input vector, To control the input vector, For traction side speed / torque control, To compensate for the amount controlled by the agency, This refers to the control quantity of the correction mechanism, namely the lateral movement or swing angle of the guide roller.

[0038] Step S202: Based on the tension measurement value and the alignment deviation measurement value, generate tension control command and correction control command respectively; Specifically, this includes: calculating the tension error between the measured tension value and the set tension value; calculating the preliminary tension control amount for each section based on the tension error using controllers independently configured for each section; mapping each preliminary tension control amount to the tension control commands for the unwinding brake, traction servo drive, and tension compensation mechanism of the extra-large bag making machine production line using an actuator allocation matrix; and... Calculate the alignment error between the measured alignment deviation value and the alignment reference value; based on the alignment error, calculate the correction feedback command through the correction controller; perform amplitude and slope limiting processing on the correction feedback command, and output it as the correction control command.

[0039] In this embodiment, the specific scheme for generating tension control commands is as follows: calculate the tension error of each section, expressed by the formula: ; in, For tension error, for The tension measurement value at that moment, for The tension setting value (tension reference value) at any given time.

[0040] At the discrete time of the fast loop, we have: ; in, For fast loop time The tension measurement value, For fast loop time The tension setting value (tension reference value), where, , This is the sampling period for the tension fast loop.

[0041] Each section is independently configured with a PID controller (which can also be replaced by ADRC or MPC, etc.). Based on the tension error, a preliminary tension control quantity in discrete form is calculated, i.e.: ; in, This is the initial tension control amount. For the first Tension control ratio of the control section. For the first Tension control integral of the control section, For the first The tension control differential coefficient of the control section, 0~ Any moment in time.

[0042] The control quantities of each control section are combined into a vector. Subsequently, through the actuator allocation matrix, the initial tension control quantity is mapped to the final tension control command for the unwinding brake, traction servo drive, and tension compensation mechanism (such as the gyratory roller), i.e.: ; in, Determined by the equipment configuration and membrane path topology, it reflects the engineering division of labor: "the unwinding end mainly acts on the front tension, the traction end mainly acts on the middle and rear tension, and the compensation mechanism absorbs high-frequency disturbances." It can be obtained through equipment structural parameter derivation, system identification, or calibration tests. For actuator control vectors, such as: ; in, This is the initial tension control amount for the unwinding section. This is the initial tension control amount for the traction section. This is to compensate for the initial tension control amount in the channel.

[0043] To ensure system safety and actuator feasibility, it is preferable to apply amplitude limiting constraints to the output of each actuator: ; Furthermore, slope constraints can be applied to suppress shocks and secondary disturbances: ; in and These represent the lower and upper limits of the allowable output for each actuator. This is the threshold for the maximum output change in a single cycle.

[0044] The specific scheme for generating the correction control command is as follows: calculate the alignment error, expressed by the formula: ; in, For alignment error, As a measurement of alignment deviation, it can characterize the phase deviation of color marks, overprinting deviation, or the offset between the pattern baseline and the detection baseline; when the equipment only has edge / lateral position detection functions, it can also be equivalent to the lateral deviation. The reference value is 0, which is preferred.

[0045] At the discrete time of the slow loop, we have: ; in, For the discrete time of the slow loop The alignment deviation measurement value, when When characterized by color mark phase deviation, It can be calculated from the difference between the color mark detection signal and the reference phase. When characterized by equivalent lateral deviation, The horizontal offset can be obtained by converting the visual / color mark positioning results. For the discrete time of the slow loop, , For the update cycle.

[0046] The correction feedback command is calculated by a correction controller (such as a PID controller). This command is then limited in amplitude and slope, and the output is the correction control command, such as the guide roller's lateral displacement or swing angle. Taking a PID controller as an example, its discrete control law is: ; in, For corrective feedback instructions, For the slow-cycle ratio, For slow-loop integrals, For the slow-cycle differential coefficient.

[0047] To avoid abrupt changes in membrane path length and tension disturbances induced by the correction action, it is preferable to apply amplitude and slope limits to the correction feedback command: ; ; in, The minimum allowable output value for the correction mechanism. The maximum allowable output value for the correction mechanism. This represents the maximum output change in a single cycle.

[0048] Step S203: Calculate the difference in the correction control commands within adjacent control cycles; In this embodiment of the application, the current cycle correction control command and the previous cycle command are recorded within the alignment slow loop update cycle (e.g., 0.2s).

[0049] Step S204: Input the difference into the pre-calibrated geometric relationship model and calculate the change in the effective length of the membrane path; In this embodiment, the action of the correction actuator 4 causes a change in the membrane path geometry, which in turn induces a sudden change in tension and leads to color mark phase / overprint drift. To suppress this coupling disturbance, this embodiment calculates or estimates the change in membrane path geometry online when the correction action is triggered or the output changes, and generates a feedforward compensation amount for the tension channel.

[0050] Let the equivalent output of the correction actuator be (This can be the lateral displacement of the guide roller or the equivalent angle of the swing frame), then the change in the effective length of the membrane path can be analytically derived from the structural parameters or obtained through a calibration function, that is: ; In discrete implementation, we have: ; The incremental form is preferred to characterize the change in equivalent membrane path length caused by changes in the correction action, i.e.: ; in, For calibration functions, This represents the change in the effective length of the membrane path. This represents the change in the effective length of the membrane path under discrete conditions.

[0051] Step S205: Convert the effective length change of the membrane path into an equivalent speed compensation amount or position compensation amount according to the control cycle; In this embodiment of the application, velocity feedforward compensation can be used, that is: ; in, This is the velocity compensation amount, used to counteract the disturbance link of "sudden change in membrane path length - velocity mismatch - sudden change in tension". This is the feedforward gain coefficient.

[0052] Step S206: The speed compensation amount is superimposed on the traction speed command, or the position compensation amount is superimposed on the position command of the tension compensation mechanism; In this embodiment, the speed compensation amount is superimposed on the traction servo speed reference command, or the position compensation amount is superimposed on the compensation mechanism position command, to achieve real-time compensation for changes in membrane path length.

[0053] The calculated feedforward compensation is injected into the control channel in real time. If it is speed feedforward, the traction speed command is corrected. If it is position feedforward, the compensation mechanism command is corrected, thereby actively counteracting the membrane path length change caused by the correction action and suppressing the resulting tension surge.

[0054] Step S207: The feedforward compensation amount is superimposed on the tension control command or speed control command to suppress the coupling disturbance of the correction action on tension and alignment. In the embodiments of this application, the feedforward compensation is injected into the tension or velocity channel within the same control cycle in which the correction action occurs, to offset the tension abrupt change and color mark drift caused by the change in membrane path length, thereby achieving cooperative decoupling.

[0055] To address the tendency of tension and alignment deviations to become unstable under high-speed operating conditions, this invention adds a predictive feedforward module to the controller 6. In addition to feedback closed-loop and geometrically based correction feedforward compensation, this module provides a forward-looking short-term predictive compensation mechanism, aiming to suppress the tendency of tension and alignment errors to increase in advance, thereby further improving the system's stability under high-speed operation.

[0056] In its implementation, the prediction feedforward function begins with the construction of temporal feature vectors, and controller 6 performs prediction at each time step. The key states of the acquisition system are collected and organized into time-series feature vectors. : Furthermore, controller 6 will recently... The vectors at each time step are combined to form a time window. : This is used as input to the predictive model to capture the dynamic evolution trend of the system state.

[0057] The core of the predictive model is denoted as The parameterized function of the model takes the aforementioned time series window as input and has two output forms: one is a direct prediction of the future. Tension and alignment state values ​​after time: Another, and more preferred, form is the direct output compensation. ;in, To predict the compensation amount for the traction speed channel, This is the predicted compensation amount superimposed on the correction channel.

[0058] Subsequently, the predicted compensation amount needs to be integrated with the existing feedback control amount and geometric feedforward compensation amount to generate the final control command. Taking the traction speed channel as an example, its comprehensive command consists of three superimposed parts: the reference speed command, the geometric feedforward compensation amount calculated from the change in the correction geometry length, and the predicted feedforward compensation amount, namely: ; in, To correct the traction speed command, As the reference speed command, This is the geometric feedforward compensation amount. To predict the feedforward compensation amount.

[0059] The instructions for the correction channel are similarly merged into: .

[0060] To ensure actuator safety and avoid introducing secondary disturbances in the prediction stage, the original prediction output must be strictly limited in amplitude and slope before fusion, i.e.: ; ; in, Represents the amplitude limiting function. Represents the slope function. and These are the maximum compensation amplitude and the maximum rate of change threshold, respectively; the same treatment can be applied to the correction channel.

[0061] Finally, to ensure the robustness and practicality of the entire predictive feedforward module, the system sets explicit backoff conditions and a safety mode. When any of the following conditions are met, the controller disables predictive feedforward and only uses feedback closed-loop and geometric feedforward compensation: , or The rollback control command is: , ,in, For the threshold, This represents the confidence level. Anomaly logs are also recorded for subsequent analysis and model optimization.

[0062] Step S208: Construct a risk feature vector containing at least one of the following features: tension error of each section, alignment error, frequency and amplitude of correction action per unit time, and load rate of drive motor. In this embodiment, to reduce the impact of abnormal operating conditions on finished product quality and equipment safety, the controller 6 constructs a comprehensive risk feature vector in real time: ; in, This is the set of tension errors for each section, and ; For the tension set of each section; This refers to the number of corrective actions or the cumulative amount of corrective displacement per unit time. For drive current or equivalent load signal; The peak tension transition within a preset time window after the correction is triggered is used to characterize the abnormal coupling between the correction and tension.

[0063] Step S209: Input the risk feature vector into the risk assessment function to calculate the risk score. In this embodiment, a weighted scoring function is used to calculate the risk score, with a higher score indicating a higher system risk. The risk score is provided by an anomaly detection function. ; in, A risk score is assigned, with higher scores indicating a higher risk of anomalies. This is an anomaly detection function, which can be one or a combination of rule-based threshold discrimination, statistical anomaly detection, or learning-based classification / regression models.

[0064] Step S210: Based on the risk score, trigger the corresponding preset graded fault tolerance action; In this embodiment, if the risk score exceeds a first threshold but is lower than a second threshold, a first-level fault-tolerant action is executed. The first-level fault-tolerant action includes reducing the gain of the feedforward compensation or tightening the rate of change limit of the correction command. If the risk score exceeds the second threshold but is lower than a third threshold, a second-level fault-tolerant action is executed. The second-level fault-tolerant action includes reducing the production line operating speed and suspending the horizontal sealing and cutting processes that are sensitive to tension and alignment fluctuations. If the risk score exceeds the third threshold, a third-level fault-tolerant action is executed. The third-level fault-tolerant action includes controlling the correction actuator to return to the zero position, switching the tension setpoint to a safe range, and starting a low-speed alignment calibration process.

[0065] In the specific implementation, a tiered response is executed based on the threshold range of the risk score. If the definition is at a normal level, no response is required; if If it is defined as being at the warning level, a mild intervention is triggered, such as adjusting the predicted feedforward gain or tightening the correction output limit slope; if If it is defined as being at the normal intervention level, then speed reduction and critical process window protection will be implemented; if If so, it is defined as a severe level, requiring the suspension of critical processes and initiation of a relocation and recovery procedure. .

[0066] In some embodiments, when a minor intervention is triggered, controller 6 performs deceleration and window protection: ; And enable allowable window constraints for key processes such as punching, horizontal sealing, and cutting: when or When this occurs, the triggering of this process is paused (only the conveyor belt and closed loop remain stable).

[0067] When the condition is critical, controller 6 enters the repositioning process, including: zeroing the deviation, switching the tension reference value to the safety reference, and alignment calibration and recovery judgment. Specifically, it can be performed in the following steps: (1) Zeroing the deviation, that is: (2) Tension safety reference switching, i.e.: (3) Alignment calibration, in At that time, perform low-level alignment calibration and correction closed loop; (4) if the recovery window conditions are met, enter the recovery phase. This serves as a safety tension reference (preferably lower than the normal production reference) to reduce the risk of membrane stretching and breakage.

[0068] Once the system meets the recovery window conditions and stably and continuously reaches the duration threshold, controller 6 automatically resumes the production cycle. The formula is as follows: If , Duration ,and When, execute ,as well as .in, This is the alignment error tolerance threshold. This is the tension error tolerance threshold. The duration threshold, To correct the frequency of actions, This is the upper limit threshold for the correction frequency. The target tension value to be maintained in the tension control section. For normal production tension reference, This is a normal production speed instruction.

[0069] Subsequently, fault-tolerant events are logged for traceability and parameter retuning.

[0070] Step S211: Determine whether the tension measurement value and / or the alignment deviation measurement value meet the preset safety conditions, and dynamically permit the execution of the horizontal sealing and cutting process when they are met.

[0071] In this embodiment of the application, a process permission window is defined. The opening conditions of the process permission window are related to the fluctuation range of the tension measurement value, the magnitude of the alignment deviation measurement value and its rate of change and whether they are lower than the corresponding thresholds. The execution of the horizontal sealing and cutting processes is dynamically permitted only when the opening conditions are met.

[0072] To reduce the probability of defects occurring under unstable conditions, this invention defines a set of allowed process windows within the controller 6 for gating and scheduling of alignment-sensitive processes such as pattern alignment triggering, horizontal sealing forming, and cutting. The set of allowed process windows is defined as follows: ; ; ; in, This is the reference value for tension in the tension control section. The threshold for the rate of change of tension. Take as needed (Only when edge / deviation detection is available) This is the set of windows allowed for the process.

[0073] when At this time, key processes such as pattern alignment triggering, horizontal sealing forming, and cutting are allowed to be executed; when At this time, the controller prohibits the triggering of the above-mentioned alignment-sensitive processes and prioritizes the execution of multi-segment tension stabilization and alignment stabilization control, including: fast-loop tension adjustment, slow-loop alignment correction, and geometric feedforward compensation for tension disturbances caused by alignment correction. Furthermore, the controller can incorporate risk scoring. Triggering tiered fault-tolerance strategies such as slowdown, pause, or relocation; waiting for the system to meet the requirements. After the window conditions are met, the above key process actions are automatically restored, thereby reducing the probability of defects such as poor horizontal sealing, misregistration and cutting size deviation, and improving the forming consistency and production stability under the condition of continuous bag making of ultra-large size.

[0074] This invention provides a method for coordinated tension and alignment control in an ultra-large bag-making machine. This method involves real-time acquisition of tension measurements in each tension control section, as well as alignment deviation measurements between the actual position of the printed mark on the film and a preset reference position. The tension control sections are obtained by dividing the film conveying path of the ultra-large bag-making machine production line. Tension control commands and correction control commands are generated based on the tension measurements and alignment deviation measurements, respectively. The effective length change of the film path corresponding to the correction control command is calculated to generate a feedforward compensation amount. This feedforward compensation amount is superimposed on the tension control command or speed control command to suppress the coupling disturbance of the correction action on tension and alignment. Based on the tension measurements, the alignment deviation measurements, and the drive state signal reflecting the drive system load, anomaly detection is performed to obtain anomaly state information to determine a risk score. Based on the risk score, a corresponding preset graded fault-tolerant action is triggered. It can effectively suppress the adverse effects of tension fluctuations, alignment drift, and correction coupling disturbances on key processes such as alignment, horizontal sealing, and cutting, and improve the accuracy of cutting length and consistency of forming dimensions, reduce wrinkles and scrap rates, thereby enhancing the continuous production capacity and robustness of the equipment.

[0075] Example 3 This embodiment provides a control method for tension and alignment coordination in an ultra-large bag making machine. It is based on a closed-loop control system that coordinates tension control, image alignment detection, and correction execution. The complete process covers system construction and segmentation, parameter calibration and benchmark setting, multi-source signal acquisition and preprocessing, state quantity construction, control loop establishment and parameter tuning, feedforward compensation for tension disturbance caused by correction, online anomaly detection and fault-tolerant scheduling, and finally, effect verification and index statistics based on measured data.

[0076] The control system mainly comprises six core units: a multi-segment tension detection unit, a multi-segment tension execution unit, a print alignment detection unit, a correction mechanism, a data acquisition and communication unit, and a controller. The tension detection unit preferably employs tension sensing rollers or S-shaped load cells, arranged at different spans to obtain tension feedback for each segment. Its control accuracy is comparable to publicly available high-precision roll-to-roll (R2R) systems, with a tension tracking error on the order of ±0.79% to ±1.58%. The tension execution unit includes at least an unwinding shaft, a brake (or unwinding servo), a traction main servo, and a guide roller assembly, and may include compensation mechanisms such as waving rollers and floating rollers for film material conveying and tension adjustment. The print alignment detection unit preferably employs color mark sensors or industrial cameras, with a detection accuracy on the order of 0.01 mm. The correction actuator is an EPC / CPC mechanism, employing a displacement guide roller or deflector frame structure. Its closed-loop dynamic performance has been publicly verified; with a step input of approximately 10.795mm, the rise time can be reduced to 60-80ms, and the settling time is less than 100ms. The data acquisition and communication unit is responsible for the synchronous acquisition and alignment of all signals. The controller is preferably a combination of a PLC or industrial PC and a motion control card, responsible for executing all control algorithms and scheduling strategies. In this embodiment, the tension fast loop sampling period is set to... (Corresponding sampling frequency 200Hz), the alignment slow loop update period is set to... (Corresponding update frequency 5Hz), linear velocity set to .

[0077] The membrane material conveying path is divided into three tension control sections: S1 (unwinding section), S2 (alignment processing section), and S3 (forming / sealing / cutting entrance section). The tension sensors in each section must be calibrated by applying standard forces (such as 0N and 200N) and reading the sensor's initial count values, calculating the zero-point offset and sensitivity coefficient. Each tension testing point was calibrated by loading standard weights / standard tension gauges, and the following results were obtained: ,in, This represents the actual tension value of the tension section. This represents the zero-point offset (or intercept) of the tension zone sensor. For example, for zone S2, if the count is 1000 counts at 0 N and 5000 counts at 200 N, then: ; ; Therefore, the online tension is calculated as follows: ,in, This is the original count value of the tension section sensor. Similarly, we obtain... and The calibration parameters are then written into the parameter library.

[0078] Simultaneously, the geometric relationship between the corrective action and the change in the effective length of the membrane path needs to be calibrated. By applying a known corrective displacement step at a low speed (e.g., 10 m / min) and observing the response of the tension or compensation roller, a linear estimation model can be fitted. ; in, This represents the change in the effective length of the membrane path. To correct the displacement, For swing angle, This is the correction displacement coefficient. This is the swing angle coefficient.

[0079] Running at low speed (e.g., v=10 m / min), apply two sets of corrective displacement steps and record the changes in compensation roller displacement / equivalent length (or use "tension mutation minimization" to back-calculate the equivalent): when When =+5mm, ≈0.60mm, When =+10mm, ≈1.22mm.

[0080] Fitting a linear model , Therefore, online estimation: .

[0081] The real-time acquired signals include tension, linear velocity, traction servo current, alignment error, and correction displacement for each section. Preprocessing is required after acquisition: first, the tension and alignment error signals are subjected to moving average filtering (e.g., a window length of 10 points, corresponding to 50ms) to suppress noise and obtain the corresponding smoothed values; that is: ; ; in, The filtered tension, This is the proportionality coefficient. This represents the alignment error after filtering.

[0082] Secondly, all multi-source signals are time-stamped and aligned using the motion control clock as a reference. Finally, abnormal jump values ​​that clearly exceed the physical range are subjected to amplitude limiting and interpolation to ensure data reliability.

[0083] The controller constructs the state variables required for control based on the preprocessed signals.

[0084] Tension error is calculated from the difference between the measured tension value and the set value for each section: ; in, Set the tension value for each section.

[0085] In one example, let the tension setpoint be: , , After filtering, we can obtain: , , The error can be obtained as follows: , , and relative error: .

[0086] The alignment error is: ; in, This refers to the current position or phase of the color mark detection. Used as the target alignment reference.

[0087] For example, if a deviation of +0.18 mm is detected, then =0.18mm. Simultaneously, the correction action amount was recorded for subsequent feedforward compensation. The correction action amount and the estimated value of the coupled disturbance were: ; For example, if the correction displacement increment is... =+6, then the corresponding estimate of the membrane path length change is: .

[0088] The control model includes a tension fast loop and an alignment slow loop. The tension fast loop uses a discrete PID controller designed independently for each segment. ; in, These respectively act on the unwinding brake, traction servo, or compensating roll channel. It may include roll diameter variation compensation, speed feedforward, etc. The goal of this control structure is to enable the tension error to converge quickly. Publicly available research provides a performance benchmark for similar systems: in a two-actuator roll-to-roll (R2R) system, the tension tracking error can reach the order of ±0.79% to ±1.58% (linear velocity 0.1 to 0.3 m / s).

[0089] In discrete implementations, the controller uses a fixed sampling period. For example, the PID parameters are set to... , , Assume that for segment S2, the tension error at the previous moment... Error at the current time e =+6N, and the discrete cumulative value of the error integral ,but: ; Substitution , , We can obtain: .

[0090] Calculated As a dimensionless control quantity, it needs to be converted into the actual torque increment or speed correction command of the traction servo through specific mapping coefficients of the servo driver and mechanical mechanism.

[0091] The stability of printing alignment (color mark / overprinting) is maintained through a slow loop with a low update frequency. This loop takes the alignment deviation as input and outputs commands to control the correction actuator. A PI control law can meet general accuracy requirements, and its continuous form is as follows: ; in, This is a correction control command.

[0092] The correction actuator (such as EPC / CPC) adjusts the lateral position or swing angle of the guide roller according to the correction control command, driving the alignment error to converge. The basis for the performance of this ring is the high precision of the alignment detection unit. Publicly available research on color mark detection has shown that its detection accuracy can reach the order of 0.01 mm.

[0093] In practical implementation, for example, setting the PI parameter , If the current alignment error after filtering... =0.18 mm, cumulative value of the error integral term ,but: ; income It can be directly used as a correction displacement command (unit: mm), or it can be proportionally converted according to the transmission ratio of the specific correction mechanism and sent to the driver, thereby achieving precise and stable correction of the lateral position of the membrane material.

[0094] To mitigate the problem of changes in membrane geometry caused by the movement of the correction actuator, which in turn leads to changes in the effective length of the membrane and induces sudden tension changes and overprint drift, this embodiment introduces a feedforward compensation strategy of "correction-tension" collaborative decoupling based on the alignment slow-loop correction control. The basic idea is to estimate the change in the equivalent length of the membrane online based on the correction action amount, and then convert this change into a compensation amount for the tension channel through feedforward mapping. This compensation is then superimposed and injected into the control channel of the traction servo or compensation mechanism to achieve early cancellation of correction coupling disturbances.

[0095] First, based on the calibrated geometric relationships: Real-time estimation of length change, or using a linear approximation model: ,in, and These are the mapping coefficients obtained from offline calibration. , Subsequently, the change is converted into a feedforward compensation amount for the traction speed channel: , Feedforward gain (e.g., 0.8). Inject the feedforward compensation amount into the traction speed command (or equivalently into the compensation roller position / speed command): If the system uses a compensation roller position channel to achieve equivalent compensation, the equivalent membrane path length change can be further converted into a compensation roller displacement / velocity compensation amount and superimposed into the corresponding execution channel. This achieves suppression of the coupled link of "correction action → membrane path length change → tension mutation / alignment drift," forming a coordinated decoupling control. To counteract the equivalent membrane path length change caused by correction, velocity feedforward compensation is used. , For example, the calculation is as follows Finally, this compensation amount is added to the traction speed reference command: This allows the correction action to actively counteract the disturbance it causes within the same cycle, achieving coordinated decoupling of the correction and tension.

[0096] The dynamic performance of the correction mechanism can be referenced from the publicly available web guide closed-loop step response test: under a step input of approximately 10.795 mm, the closed-loop rise time can reach 60–80 ms, and the settling time is less than 100 ms, to support the decoupling feedforward requirements of this embodiment in the fast response scenario of correction.

[0097] During continuous operation of the bag-making machine, the controller executes the following steps in a loop: (1) Acquire and preprocess each signal; (2) Calculate the tension error, alignment error, and ΔL; (3) Perform tension fast-loop PID calculation to obtain the control quantity for each section; (4) Perform alignment slow loop PID calculation to drive the correction mechanism; (5) Generate the feedforward decoupling compensation amount and inject it into the tension channel; (6) Perform anomaly detection and risk classification, and trigger fault tolerance strategies when the threshold is exceeded; (7) Record logs and resume production as needed.

[0098] Anomaly detection is based on set thresholds, such as a tension error threshold of 3% of the set value (4.2N for S2), an alignment error threshold of 0.2mm, and a correction frequency threshold of 20 times / minute. The risk score can be calculated by combining various indicators; an example formula is as follows: .

[0099] In one example, the example is: N, N, then N; mm, mm, servo current ratio , Substituting, we get: .

[0100] Based on the scoring results, a graded response is given: If If the threshold is exceeded, the "pause horizontal blocking / cutting + repositioning" process will be triggered.

[0101] To illustrate the control accuracy and dynamic performance of this embodiment, a verification method combining "publicly disclosed benchmarking indicators + on-site measured data" is preferred. The publicly disclosed benchmarking indicators define the achievable levels of similar continuous strip (R2R) systems in terms of tension control, registration detection, and dynamic correction. On-site measurements verify the stable control effect of this invention under ultra-wide, multi-process continuous bag making conditions.

[0102] Regarding tension control accuracy, experimental verification of the publicly disclosed two-actuator R2R system shows that the magnitude of the tension tracking error that can be achieved at online speed can be used as a benchmark for the tension closed-loop accuracy of this embodiment.

[0103] Regarding alignment detection capability, publicly available research reports have presented results on registration / color mark error detection at a magnitude that can serve as a benchmark for the alignment error detection capability of this embodiment.

[0104] Regarding the dynamic performance of the correction, the published step test provides a description of the rise time as approximately and the settling time as less than the order of magnitude, which can be used as a benchmark for the closed-loop dynamic response of the correction in this embodiment.

[0105] In the field verification of this embodiment, to ensure the consistency and repeatability of the comparison, the following indicators were recorded and output according to a unified statistical standard: tension error of each section (e.g., represented by mean μ and 3σ), alignment error (RMS / peak value), frequency and output amplitude of correction actions, tension mutation amount triggered by correction, cutting length error, scrap rate, and number of fault-tolerant triggers (speed reduction / pause / repositioning). The above field measurement results are given in Tables 1, 2, and 3 respectively: Table 1. Field measurement results of multi-segment tension fast-loop control

[0106] Table 2 Inhibition effect

[0107] Table 3. Field measurement results of cutting / forming quality and fault tolerance scheduling

[0108] Wherein, C1 represents low-speed steady state, C2 represents medium-speed steady state, C3 represents high-speed steady state, C4 represents roll diameter variation, C5 represents frequent correction, and tension error is calculated according to... Calculate and statistically analyze within the operating condition window. The alignment error is given in terms of RMS and peak value. Count the number of corrective actions per unit time; The tension peak transition within a preset time window after the correction action is triggered; the consistency between the cutting length error and the forming size is obtained by online length measurement / offline sampling inspection statistics; the number of fault-tolerant triggers is statistically analyzed for deceleration, suspension of key processes and repositioning.

[0109] This demonstrates that under ultra-wide continuous bag making conditions, the present invention can effectively suppress the adverse effects of tension fluctuations, alignment drift, and correction coupling disturbances on key processes (alignment, horizontal sealing, and cutting), improve cutting length accuracy and forming size consistency, reduce wrinkles and scrap rates, thereby enhancing the continuous production capacity and robustness of the equipment.

[0110] Example 4 Please see Figure 4 , Figure 4 This is a structural block diagram of an embodiment of a tension and alignment coordination control device for an ultra-large bag making machine according to the present invention. The device includes: The acquisition module 301 is used to acquire the tension measurement values ​​of each tension control section in real time, as well as the alignment deviation measurement values ​​between the actual position of the printed mark on the film material and the preset reference position; the tension control section is obtained by dividing the film material conveying path of the ultra-large size bag making machine production line; The instruction generation module 302 is used to generate tension control instructions and alignment control instructions based on the tension measurement value and the alignment deviation measurement value, respectively. The compensation amount generation module 303 is used to calculate the effective length change of the membrane path on the delivery path corresponding to the correction control command, so as to generate the feedforward compensation amount; The suppression module 304 is used to superimpose the feedforward compensation amount into the tension control command or speed control command to suppress the coupling disturbance of the correction action on tension and alignment. The risk scoring determination module 305 is used to perform anomaly detection based on the tension measurement value, the alignment deviation measurement value, and the drive state signal reflecting the load of the drive system to obtain anomaly state information, so as to determine the risk score; Trigger module 306 is used to trigger a corresponding preset graded fault-tolerant action based on the risk score.

[0111] In an optional embodiment, it further includes: The judgment module is used to determine whether the tension measurement value and / or the alignment deviation measurement value meet the preset safety conditions, and dynamically permits the execution of the horizontal sealing and cutting processes when they are met.

[0112] In an optional embodiment, the determining module includes: The window setting submodule is used to define the process allow window. The opening conditions of the process allow window are related to the fluctuation range of the tension measurement value, the magnitude of the alignment deviation measurement value and whether its rate of change is lower than the corresponding threshold. The dynamic licensing submodule is only used to dynamically license the execution of the horizontal sealing and cutting processes when the opening conditions are met.

[0113] In an optional embodiment, the instruction generation module 302 includes: The tension error calculation submodule is used to calculate the tension error between the measured tension value and the set tension value. The preliminary tension control quantity determination calculation submodule is used to calculate the preliminary tension control quantity of each section based on the tension error and through controllers that are independently set for each section. The tension control quantity determination calculation submodule is used to map each preliminary tension control quantity to the tension control command for the unwinding brake, traction servo drive and tension compensation mechanism of the ultra-large size bag making machine production line through the actuator allocation matrix.

[0114] In an optional embodiment, the instruction generation module 302 includes: The alignment error calculation submodule is used to calculate the alignment error between the alignment deviation measurement value and the alignment reference value; The correction feedback command determination submodule is used to calculate the correction feedback command through the correction controller based on the alignment error. The correction control command determination submodule is used to perform amplitude and slope limiting processing on the correction feedback command and output the correction control command.

[0115] In an optional embodiment, the risk scoring determination module 305 includes: The risk feature vector construction submodule is used to construct a risk feature vector containing at least one of the following features: tension error of each section, alignment error, frequency and amplitude of correction action per unit time, and load rate of drive motor. The risk score calculation submodule is used to input the risk feature vector into the risk assessment function and calculate the risk score.

[0116] In an optional embodiment, the compensation amount generation module 303 includes: The instruction difference calculation submodule is used to calculate the difference between the correction control instructions in adjacent control cycles; The length change calculation submodule is used to input the difference into a pre-calibrated geometric relationship model and calculate the effective length change of the membrane path. The conversion submodule is used to convert the effective length change of the membrane path into an equivalent speed compensation amount or position compensation amount according to the control cycle. The superposition submodule is used to superimpose the speed compensation amount onto the traction speed command, or to superimpose the position compensation amount onto the position command of the tension compensation mechanism.

[0117] In an optional embodiment, the trigger module 306 includes: The first execution submodule is used to execute a first-level fault-tolerant action if the risk score value exceeds a first threshold but is lower than a second threshold. The first-level fault-tolerant action includes reducing the gain of the feedforward compensation or tightening the rate of change limit of the correction instruction. The second execution submodule is used to execute a second-level fault-tolerant action if the risk score exceeds the second threshold but is lower than the third threshold. The second-level fault-tolerant action includes reducing the production line speed and suspending the horizontal sealing and cutting processes that are sensitive to tension and alignment fluctuations. The third execution submodule is used to execute a third-level fault-tolerant action if the risk score exceeds the third threshold. The third-level fault-tolerant action includes controlling the correction actuator to return to the zero position, switching the tension setting value to the safe range, and starting a low-speed alignment calibration process.

[0118] Example 5 This invention also provides an electronic device, including a memory and a processor. The memory stores a computer program, which, when executed by the processor, causes the processor to perform the steps of a tension and alignment coordination control method for an ultra-large bag making machine according to any embodiment.

[0119] Example 6 This invention also provides a computer storage medium storing a computer program, which, when executed by the processor, implements the steps of a tension and alignment coordination control method for an ultra-large bag making machine according to any embodiment.

[0120] Example 7 This invention also provides a computer program product storing a computer program, which, when executed by the processor, implements the steps of a tension and alignment coordination control method for an ultra-large bag making machine according to any embodiment.

[0121] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the specific working processes of the systems, devices, and units described above can be referred to the corresponding processes in the foregoing method embodiments, and will not be repeated here.

[0122] In the several embodiments provided in this application, it should be understood that the methods, apparatuses, electronic devices, and storage media disclosed in this invention can be implemented in other ways. For example, the apparatus embodiments described above are merely illustrative. For instance, the division of units is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the displayed or discussed mutual couplings, direct couplings, or communication connections may be through some interfaces; indirect couplings or communication connections between devices or units may be electrical, mechanical, or other forms.

[0123] The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0124] Furthermore, the functional units in the various embodiments of the present invention can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The integrated unit can be implemented in hardware or as a software functional unit.

[0125] If the integrated unit is implemented as a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the present invention, in essence, or the part that contributes to the prior art, or all or part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a readable storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of the present invention. The aforementioned readable storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0126] The above-described embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for controlling tension and alignment coordination in an ultra-large bag-making machine, characterized in that, include: The tension measurement values ​​of each tension control section are collected in real time, as well as the alignment deviation between the actual position of the printed mark on the membrane material and the preset reference position. The tension control zone is obtained by dividing the film material conveying path of the ultra-large size bag making machine production line; Based on the tension measurement value and the alignment deviation measurement value, tension control command and correction control command are generated respectively; Calculate the change in effective membrane length on the delivery path corresponding to the correction control command, in order to generate feedforward compensation. The feedforward compensation is superimposed on the tension control command or speed control command to suppress the coupling disturbance of the correction action on tension and alignment. Based on the tension measurement value, the alignment deviation measurement value, and the drive status signal reflecting the load of the drive system, anomaly detection is performed to obtain anomaly status information in order to determine a risk score; Based on the risk score, the corresponding preset fault-tolerant action is triggered.

2. The method for controlling tension and alignment coordination in an ultra-large bag-making machine according to claim 1, characterized in that, Based on the risk score, after triggering the corresponding preset fault-tolerant action, the process further includes: Determine whether the tension measurement value and / or the alignment deviation measurement value meet the preset safety conditions, and dynamically permit the execution of the horizontal sealing and cutting processes when they are met.

3. The method for controlling tension and alignment coordination in an ultra-large bag-making machine according to claim 2, characterized in that, Determining whether the tension measurement value and / or the alignment deviation measurement value meet preset safety conditions, and dynamically permitting the execution of the horizontal sealing and cutting processes when they are met, includes: Define a process allow window, the opening conditions of which are related to the fluctuation range of the tension measurement value, the magnitude of the alignment deviation measurement value and whether its rate of change is lower than the corresponding threshold; The execution of the horizontal sealing and cutting processes is dynamically permitted only when the opening conditions are met.

4. The method for controlling tension and alignment coordination in an ultra-large bag-making machine according to claim 1, characterized in that, Based on the tension measurement value and the alignment deviation measurement value, tension control commands and correction control commands are generated respectively, including: Calculate the tension error between the measured tension value and the set tension value; Based on the aforementioned tension error, the preliminary tension control amount for each section is calculated using a controller that is independently set for each section. The actuator allocation matrix maps each initial tension control quantity to the tension control commands for the unwinding brake, traction servo drive, and tension compensation mechanism of the extra-large bag making machine production line.

5. The method for controlling tension and alignment coordination in an ultra-large bag-making machine according to claim 4, characterized in that, Based on the tension measurement value and the alignment deviation measurement value, tension control commands and correction control commands are generated respectively, including: Calculate the alignment error between the measured alignment deviation value and the alignment reference value; Based on the alignment error, a correction feedback command is calculated by the correction controller; The correction feedback command is subjected to amplitude and slope limiting processing, and the output is the correction control command.

6. The method for controlling tension and alignment coordination in an ultra-large bag-making machine according to claim 1, characterized in that, Based on the tension measurement value, the alignment deviation measurement value, and the drive state signal reflecting the load of the drive system, anomaly detection is performed to obtain anomaly state information, thereby determining a risk score, including: Construct a risk feature vector that includes at least one of the following features: tension error of each section, alignment error, frequency and amplitude of correction action per unit time, and load rate of drive motor; The risk feature vector is input into the risk assessment function to calculate the risk score.

7. The method for controlling tension and alignment coordination in an ultra-large bag-making machine according to claim 1, characterized in that, Calculating the change in the effective length of the membrane path on the delivery path corresponding to the correction control command, in order to generate the feedforward compensation amount, includes: Calculate the difference between the corrective control commands in adjacent control cycles; The difference is input into a pre-calibrated geometric relationship model to calculate the change in the effective length of the membrane path; The effective length change of the membrane path is converted into an equivalent speed compensation or position compensation according to the control cycle; The speed compensation amount is superimposed on the traction speed command, or the position compensation amount is superimposed on the position command of the tension compensation mechanism.

8. The method for controlling tension and alignment coordination in an ultra-large bag-making machine according to claim 3, characterized in that, Based on the risk score, the corresponding preset fault-tolerant actions are triggered, including: If the risk score exceeds the first threshold but is lower than the second threshold, the first level of fault tolerance action is executed. The first level of fault tolerance action includes reducing the gain of feedforward compensation or tightening the rate of change limit of correction instructions. If the risk score exceeds the second threshold but is lower than the third threshold, a second-level fault-tolerant action is executed. The second-level fault-tolerant action includes reducing the production line speed and suspending the horizontal sealing and cutting processes that are sensitive to tension and alignment fluctuations. If the risk score exceeds the third threshold, the third level of fault tolerance action is executed. The third level of fault tolerance action includes controlling the correction actuator to return to the zero position, switching the tension setting value to the safe range, and starting the low-speed alignment calibration process.

9. A control device for tension and alignment coordination in an ultra-large bag making machine, characterized in that, include: The acquisition module is used to acquire the tension measurement values ​​of each tension control section in real time, as well as the alignment deviation measurement values ​​between the actual position of the printed mark on the membrane material and the preset reference position. The tension control zone is obtained by dividing the film material conveying path of the ultra-large size bag making machine production line; The instruction generation module is used to generate tension control instructions and alignment deviation control instructions based on the tension measurement value and the alignment deviation measurement value, respectively. The compensation amount generation module is used to calculate the effective length change of the membrane path on the delivery path corresponding to the correction control command, so as to generate the feedforward compensation amount; The suppression module is used to superimpose the feedforward compensation amount into the tension control command or speed control command to suppress the coupling disturbance of the correction action on tension and alignment. The risk scoring determination module is used to perform anomaly detection based on the tension measurement value, the alignment deviation measurement value, and the drive state signal reflecting the load of the drive system to obtain anomaly state information, so as to determine the risk score; The triggering module is used to trigger the corresponding preset graded fault-tolerant action based on the risk score.

10. An electronic device, characterized in that, It includes a processor and a memory, the memory storing computer-readable instructions that, when executed by the processor, perform the method as described in any one of claims 1-8.

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