Film material conveying control method and control system based on vacuum suction roller
By introducing zoned control and negative pressure regulation on the vacuum adsorption roller, the problem of incomplete initial adhesion during film material transfer was solved, achieving stable film material adhesion and transfer, and improving processing accuracy and product quality.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- SHANGHAI YUZE M&E EQUIP CO LTD
- Filing Date
- 2026-03-19
- Publication Date
- 2026-06-02
Smart Images
Figure CN122126687A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of membrane material conveying control technology, specifically to a membrane material conveying control method and control system based on vacuum adsorption rollers. Background Technology
[0002] In the continuous processing of films such as optical films, protective films, release films, lithium battery separators, metal foil composite films, and adhesive films, traction rollers are typically used to stably transport the film materials to meet the requirements of conveying accuracy and tension stability in processes such as coating, lamination, slitting, and bonding. For films with functional coatings, adhesive layers, or easily damaged surfaces on one side, vacuum adsorption rollers are often used for single-sided contact traction to avoid damage, contamination, or adhesion. This involves one side of the film material contacting the vacuum adsorption roller, and using negative pressure adsorption to adhere the film material to the roller surface, thereby achieving traction transport.
[0003] However, in existing technologies, vacuum adsorption rollers typically employ constant negative pressure or a simple, uniform air extraction method for adsorption control. When the membrane material enters the inlet area of the vacuum adsorption roller, if no pressure roller or other pressure components are used to assist in the adhesion of the membrane material to the roller surface, an initial air gap can easily exist between the membrane material and the roller surface. Especially when the membrane material has a certain bending stiffness, curl memory, high operating speed, or changes in inlet tension, this initial air gap is difficult to expel in time, preventing the vacuum negative pressure from quickly establishing effective adsorption at the inlet stage, thus leading to incomplete adhesion of the membrane material during the initial conveying stage.
[0004] Incomplete initial adhesion can further cause localized slippage, tension fluctuations, conveyor jitter, and unstable conveyor trajectories in the inlet area, affecting the processing accuracy and product quality of subsequent processes. For adhesive-coated films or films with sensitive surface properties, simply increasing external pressure to improve the inlet adhesion may lead to new problems such as pressure damage to the adhesive surface, surface contamination, or disturbance of the functional layer.
[0005] Therefore, how to maintain single-sided contact and pressure-free introduction, and effectively regulate the vacuum adsorption roller itself to enable the film material to quickly establish a stable adhesion state when entering the vacuum adsorption roller, has become a technical problem that urgently needs to be solved in this field. Summary of the Invention
[0006] In view of the above-mentioned shortcomings mentioned in the background art, the purpose of this invention is to provide a film material conveying control method, system, computer-readable storage medium and computer program product based on vacuum adsorption roller.
[0007] A first aspect of the present invention provides a film material conveying control method based on a vacuum adsorption roller, the method comprising the following steps:
[0008] S1, obtain the initial adhesion state parameters when the membrane material enters the inlet area of the vacuum adsorption roller. The initial adhesion state parameters include the initial air gap characterization parameters that characterize the initial air gap size between the membrane material and the surface of the vacuum adsorption roller, the membrane material running speed, the inlet tension fluctuation parameters, and the membrane material deformation trend parameters.
[0009] S2, determine the adsorption control parameters of the inlet pre-attachment zone according to the initial attachment state parameters, and control the inlet pre-attachment zone to form a first negative pressure higher than that of the stable adsorption zone, so as to reduce the initial air gap between the film and the roller surface and establish attachment; wherein, the adsorption control parameters include the pre-attachment zone length and the pre-attachment zone negative pressure value;
[0010] S3, a progressive attachment zone is set after the inlet pre-attachment zone, and the negative pressure of the progressive attachment zone is gradually adjusted to transition the membrane material from the initial attachment state to the stable attachment state.
[0011] S4, after the progressive attachment zone, maintain the target negative pressure in the stable adsorption zone to achieve stable delivery, and dynamically adjust the adsorption control parameters of the inlet pre-attachment zone and / or the progressive attachment zone based on the membrane material's attachment response information; wherein, the attachment response information includes at least one of negative pressure establishment time, local slippage characteristics, tension fluctuation characteristics, vibration characteristics, or attachment delay characteristics.
[0012] A second aspect of the present invention provides a film material conveying control system based on a vacuum adsorption roller, the system comprising:
[0013] The parameter acquisition unit is used to acquire the initial adhesion state parameters when the membrane material enters the inlet area of the vacuum adsorption roller. The initial adhesion state parameters include the initial air gap characterization parameter, which characterizes the initial air gap size between the membrane material and the roller surface of the vacuum adsorption roller, the membrane material running speed, the inlet tension fluctuation parameter, and the membrane material deformation trend parameter.
[0014] A pre-attachment control unit is used to determine the adsorption control parameters of the inlet pre-attachment zone based on the initial attachment state parameters, and to control the inlet pre-attachment zone to form a first negative pressure higher than that of the stable adsorption zone, so as to reduce the initial air gap between the film and the roller surface and establish attachment; wherein, the adsorption control parameters include the pre-attachment zone length and the pre-attachment zone negative pressure value;
[0015] A progressive control unit is used to set a progressive attachment zone after the inlet pre-attachment zone and to progressively control the negative pressure of the progressive attachment zone so that the membrane material transitions from the initial attachment state to a stable attachment state.
[0016] A stable delivery and feedback adjustment unit is used to maintain the target negative pressure in the stable adsorption zone after the progressive attachment zone to achieve stable delivery, and to dynamically adjust the adsorption control parameters of the inlet pre-attachment zone and / or the progressive attachment zone based on the attachment response information of the membrane material; wherein, the attachment response information includes at least one of negative pressure establishment time, local slippage characteristics, tension fluctuation characteristics, vibration characteristics, or attachment delay characteristics.
[0017] A third aspect of the present invention provides a computer-readable storage medium storing a computer program that, when executed by a processor, implements the method described in any of the preceding claims.
[0018] A fourth aspect of the present invention provides a computer program product comprising instructions which, when executed, implement the method as described in any of the preceding claims.
[0019] Compared with existing technologies, this invention introduces a zoned control mechanism of an inlet pre-attachment zone and a progressive attachment zone during the vacuum adsorption roller conveying process. Combined with negative pressure regulation based on initial attachment state parameters and dynamic feedback adjustment of attachment response information, this enables the membrane material to quickly eliminate the initial air gap and achieve stable attachment under pressureless conditions. This effectively avoids slippage, tension fluctuations, and conveying jitter caused by incomplete initial attachment. At the same time, the smooth transition of the attachment process is achieved through negative pressure gradient regulation, reducing the risk of sudden stress changes and local deformation of the membrane material, improving the stability and control accuracy of the conveying process, and enhancing the system's adaptability to different types of membrane materials and changes in working conditions. Attached Figure Description
[0020] Figure 1 This is a schematic diagram of the overall process of a film material conveying control method based on a vacuum adsorption roller disclosed in an embodiment of the present invention;
[0021] Figure 2 This is a schematic diagram illustrating the layout of the inlet pre-attachment zone, the progressive attachment zone, and the stable adsorption zone of the vacuum adsorption roller disclosed in an embodiment of the present invention.
[0022] Figure 3 This is a schematic diagram of a film material conveying control system based on a vacuum adsorption roller disclosed in an embodiment of the present invention. Detailed Implementation
[0023] The following specific embodiments illustrate the implementation of this application. Those skilled in the art can easily understand other advantages and effects of this application from the content disclosed in this specification. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of the embodiments. Based on the embodiments in this application, all other embodiments obtained by those of ordinary skill in the art without creative effort should fall within the protection scope of this application. It should be understood that, without conflict, the technical features in the following embodiments can be combined with each other.
[0024] Please see Figure 1 , Figure 2 This embodiment discloses a film material conveying control method based on a vacuum adsorption roller. This method is used to regulate the adhesion establishment process and conveying stability of the film material at the inlet stage of the vacuum adsorption roller under pressureless or single-sided contact conditions. By identifying the initial adhesion state of the film material and controlling and gradually adjusting the negative pressure in different areas of the vacuum adsorption roller, a smooth transition of the film material from an initially unattached state to a stable attached state is achieved, thereby improving the stability and controllability of the film material conveying process. It is understood that this method can be applied to the conveying process of various film materials such as optical films, protective films, release films, lithium battery separators, metal foil composite films, and adhesive-backed films. It can be deployed in the control systems of coating equipment, laminating equipment, slitting equipment, or other film material processing production lines, or integrated into industrial controllers, embedded control units, or cloud control platforms to achieve collaborative control and optimized scheduling of the vacuum adsorption roller.
[0025] The implementation steps and their corresponding technical details are described in detail below.
[0026] S1, obtain the initial adhesion state parameters when the membrane material enters the inlet area of the vacuum adsorption roller. The initial adhesion state parameters include the initial air gap characterization parameters that characterize the initial air gap size between the membrane material and the surface of the vacuum adsorption roller, the membrane material running speed, the inlet tension fluctuation parameters, and the membrane material deformation trend parameters.
[0027] When the membrane material enters the inlet area of the vacuum adsorption roller, it is not initially in a fully bonded state with the roller surface due to the absence of a pressing roller or other external pressing components; rather, there is an initial air gap. The presence of this initial air gap directly affects whether the vacuum negative pressure can quickly establish effective adsorption. Therefore, in this step, the initial bonding state of the membrane material upon entering the inlet area is characterized to subsequently determine the control parameters for the inlet pre-bonding zone.
[0028] In practical implementation, a state detection unit can be arranged in front of or near the inlet of the vacuum adsorption roller to acquire the aforementioned initial attachment state parameters. The initial air gap characterization parameter characterizes the initial air gap size between the membrane material and the surface of the vacuum adsorption roller. This initial air gap characterization parameter can be a directly measured distance value or a characterization quantity indirectly calculated from other response quantities. For example, a laser displacement sensor, a capacitive displacement sensor, or a visual ranging unit can be used to directly measure the local distance between the free surface of the membrane material and the roller surface; alternatively, under inlet pre-evacuation conditions, the initial air gap size can be indirectly reflected by the negative pressure establishment delay time, instantaneous evacuation flow rate change, or pressure recovery rate. For instance, when two membrane materials enter the same vacuum adsorption roller at the same inlet velocity, if the time required for membrane material A to establish the inlet negative pressure to a preset threshold is significantly longer than that for membrane material B, then the initial air gap characterization parameter corresponding to membrane material A can be considered greater than that of membrane material B.
[0029] The membrane material running speed is used to characterize the linear velocity state of the membrane material when it enters the inlet region. The higher the running speed, the shorter the residence time of the membrane material in the inlet region, the smaller the time window for air to be expelled from the initial air gap, and correspondingly, the greater the difficulty of adhesion establishment in the inlet stage.
[0030] The inlet tension fluctuation parameter is used to characterize the tension stability of the membrane material before it enters the vacuum adsorption roller. This parameter can be expressed as tension standard deviation, peak-to-peak value, tension change rate per unit time, or tension variance within a sliding window. For example, if the membrane tension fluctuates significantly around a set value within 10 consecutive sampling periods, it indicates that the inlet section is significantly affected by the previous unwinding, guide roller sway, or unevenness of the material itself. In this case, the membrane material is more prone to local vibration or edge lifting at the inlet, which in turn affects subsequent adhesion establishment.
[0031] Membrane material deformation trend parameters are used to characterize the surface shape or deformation trend of the membrane material when it enters the inlet area. These parameters may include one or more of the following: curling trend, edge warping degree, local stiffness difference, lateral bending trend, or in-plane ripple trend. For example, for membrane materials with curling memory, if their natural bending direction is inconsistent with the curvature direction of the roller surface, the membrane material is more likely to form a non-uniform adhesion state in the inlet section, such as "the middle approaches first, then the two sides approach later" or "one side approaches first, then the other side approaches later".
[0032] It should be noted that the above parameters can be acquired separately or collaboratively by the same detection module. In some embodiments, to ensure the consistency of different parameters over time, displacement detection, velocity detection, and tension detection can be uniformly connected to the synchronous acquisition clock of the same controller. This ensures that the initial air gap characterization parameters, operating speed, inlet tension fluctuation parameters, and membrane deformation trend parameters obtained at the same sampling time correspond to the same inlet state. This avoids parameter mismatch problems caused by asynchronous acquisition. For example, if the velocity signal corresponds to the state before the membrane enters the inlet area, while the displacement signal corresponds to the state after the membrane has been partially attached, it can easily lead to distortion in the subsequent pre-attachment area parameter settings. Therefore, in this step, it is preferable to use a unified time base for multi-parameter synchronous acquisition to improve the targeting and accuracy of subsequent control.
[0033] S2, determine the adsorption control parameters of the inlet pre-attachment zone according to the initial attachment state parameters, and control the inlet pre-attachment zone to form a first negative pressure higher than that of the stable adsorption zone, so as to reduce the initial air gap between the film and the roller surface and establish attachment; wherein, the adsorption control parameters include the pre-attachment zone length and the pre-attachment zone negative pressure value;
[0034] After obtaining the initial adhesion parameters, this step does not employ uniform negative pressure adsorption across the entire roller. Instead, a pre-adhesion zone is first set up in the inlet area of the vacuum adsorption roller. By applying a first negative pressure higher than that in the stable adsorption zone to this area, the initial air gap is compressed and vented preferentially, ensuring that the membrane material has good adhesion establishment conditions as soon as it enters the vacuum adsorption roller. It can be understood that the inlet pre-adhesion zone is an adhesion establishment enhancement section constructed at the front end of the vacuum adsorption roller. This area is not for long-distance stable traction, but rather to address the adhesion establishment lag problem in the inlet stage.
[0035] As an example, the vacuum adsorption roller is provided with independent pre-attachment zone air extraction chamber, progressive attachment zone air extraction chamber and stable adsorption zone air extraction chamber along the film conveying direction, so as to form the first negative pressure, the progressive negative pressure and the target negative pressure respectively.
[0036] Please see Figure 2Inside the roller, multiple independent suction chambers can be divided along the circumferential path of the film material coating and along the film material conveying direction. Each suction chamber is connected to a corresponding negative pressure regulating branch or valve control branch. This allows for zonal control of the inlet pre-coating zone, the subsequent progressive coating zone, and the stable adsorption zone. In specific implementation, the suction chambers in the pre-coating zone can be located within the foremost wrap angle range after the film material enters the roller surface, for example, within the initial angle range corresponding to the initial contact of the film material with the roller surface; the suction chambers in the progressive coating zone are located after the pre-coating zone; and the suction chambers in the stable adsorption zone are located in the main traction wrap angle area. It should be understood that the above independence does not require complete physical separation to the point of being unconnectable, but rather refers to the ability to independently adjust the negative pressure of the corresponding sections to meet the requirements of this invention for differentiated negative pressure settings in each zone.
[0037] Furthermore, in this step, it is necessary to determine the adsorption control parameters of the inlet pre-attachment zone based on the initial attachment state parameters. These adsorption control parameters include the pre-attachment zone length and the pre-attachment zone negative pressure value. The pre-attachment zone length is used to determine the range of duration of the enhanced adsorption effect at the inlet along the membrane material transport direction; the pre-attachment zone negative pressure value is used to determine the intensity of the enhanced adsorption at the inlet.
[0038] The length of the pre-attachment zone can be determined based on the initial air gap characterization parameters and the membrane material's operating speed. For example, when the initial air gap is large and the operating speed is high, the length of the pre-attachment zone can be appropriately increased to maintain a high adsorption intensity within a longer inlet path, ensuring sufficient time for attachment establishment. Conversely, when the membrane material's operating speed is low, the initial air gap is small, and deformation trend parameters indicate a relatively flat membrane surface, the length of the pre-attachment zone can be appropriately reduced to avoid excessive adsorption and unnecessary energy consumption increases.
[0039] As an example, the difference between the first negative pressure and the target negative pressure is determined based on the difficulty of initial membrane attachment, which is positively correlated with at least one of the initial air gap characterization parameters, membrane running speed, and membrane deformation trend parameters.
[0040] In other words, the higher the initial adhesion establishment difficulty of the membrane material, the greater the degree of negative pressure reinforcement required in the inlet pre-attachment zone, and correspondingly, the greater the difference between the first negative pressure and the target negative pressure. For example, for a high-speed protective membrane with a relatively thin thickness but obvious lateral edge curling, its initial air gap characterization parameter is large, its operating speed is high, and the membrane material deformation trend parameter indicates obvious edge curling. Then, the initial adhesion establishment difficulty of this membrane material can be determined to be higher than that of another release membrane with a flat surface and low-speed operation. Therefore, the difference between the first negative pressure and the target negative pressure of the former should be set to be larger.
[0041] In a further embodiment, the difference between the first negative pressure and the target negative pressure is determined based on the difficulty of initial membrane adhesion establishment, including:
[0042] Based on the initial air gap characterization parameters, the membrane material running speed, and the membrane material deformation trend parameters, a first difficulty component characterizing the basic resistance of membrane material adhesion establishment is determined. Based on the inlet tension fluctuation parameters and the membrane material deformation trend parameters, a second difficulty component characterizing the dynamic instability of membrane material adhesion establishment is determined. The initial adhesion establishment difficulty level of the membrane material is obtained according to the coupling relationship between the first difficulty component and the second difficulty component.
[0043] Specifically, the first difficulty component reflects the basic resistance faced by the membrane material in establishing adhesion under static or quasi-static conditions. For example, a large initial air gap, high running speed, or significant curling or stiffness of the membrane material itself will make it difficult for the membrane material to quickly adhere to the roller surface at the inlet section.
[0044] The second difficulty component mainly reflects the additional adhesion difficulties caused by instability in inlet tension, local oscillation, or deformation during the dynamic entry of the membrane material. For example, although the average tension value of some membrane materials is not high when entering the inlet section, the tension fluctuates frequently, causing the edge of the membrane material to continuously rise and fall within a small time scale. At this time, even if the basic resistance is not large, adhesion establishment will be difficult due to dynamic instability.
[0045] By coupling the first difficulty component with the second difficulty component, a more realistic initial membrane attachment difficulty level can be obtained. This coupling relationship can be achieved through weighted summation, segmented grading, or rule table mapping. For example, when both the first and second difficulty components are at a high level, it can be directly determined as the highest difficulty level; when the first difficulty component is moderate and the second difficulty component is low, it can be determined as a medium difficulty level.
[0046] The basic negative pressure difference is determined based on the difficulty level of the initial membrane adhesion. Then, the basic negative pressure difference is nonlinearly corrected by combining the synergistic amplification relationship between the initial air gap characterization parameters and the inlet tension fluctuation parameters to obtain the difference between the first negative pressure and the target negative pressure.
[0047] Specifically, after obtaining the initial adhesion establishment difficulty level, the basic negative pressure difference can be determined first based on the difficulty level. Then, a nonlinear correction can be performed by combining the synergistic amplification relationship between the initial air gap characterization parameters and the inlet tension fluctuation parameters. The synergistic amplification relationship means that under certain operating conditions, a large initial air gap and large tension fluctuations do not act independently, but rather superimpose and jointly amplify the difficulty of inlet adhesion. For example, if there is already a large initial air gap between the membrane material and the roller surface, and the preceding unwinding causes rapid fluctuations in the inlet tension, the membrane material will repeatedly approach and leave the roller surface in the inlet section, thus frequently interrupting the effective venting process. In this case, simply increasing the first negative pressure according to a linear relationship may be insufficient. Therefore, the basic negative pressure difference can be appropriately expanded through nonlinear correction to give the pre-adhesion zone a stronger adhesion establishment capability. For example, this correction can be achieved through a preset nonlinear mapping function, a lookup table method, or an empirical model. For instance, when the initial air gap characterization parameter exceeds the first threshold and the inlet tension fluctuation parameter exceeds the second threshold, an additional correction amount can be added to the basic negative pressure difference to ensure the consistency and sufficiency of adsorption establishment in the inlet section.
[0048] The following example demonstrates how to obtain the above difference by performing nonlinear corrections using an empirical model:
[0049] First, establish the difficulty level based on the initial application of the membrane material. Determine the base negative pressure difference value .in, This is a difficulty level variable, which can be level 1, 2, 3, 4, or 5. A higher level indicates greater difficulty in establishing the adhesion at the entry stage. Correspondingly, an empirical correlation between the difficulty level and the baseline negative pressure difference can be obtained through pre-calibration, for example:
[0050]
[0051] in, This is the basic negative pressure differential value, in kPa. This is the baseline negative pressure difference value corresponding to the lowest difficulty level, in kPa. This is the gain coefficient for each level, expressed in kPa per level.
[0052] Based on this, and further based on the initial air gap characterization parameters With inlet tension fluctuation parameters The synergistic effect on the base negative pressure difference Corrections are made. To ensure the comparability of each parameter in the empirical model, it is preferable to first normalize the above parameters. Let the initial air gap characterization parameters be... The unit is mm, and the inlet tension fluctuation parameter is... The unit is N, and each is taken from its empirical reference value. and ,in, The unit is mm. If the unit is N, then:
[0053]
[0054]
[0055] in, and These are used to characterize the degree of deviation of the current initial air gap level and the current tension fluctuation level from the empirical reference state, respectively.
[0056] Furthermore, the synergistic amplification relationship between the initial air gap and the inlet tension fluctuation can be expressed as an empirical correction factor. ,For example:
[0057]
[0058] in, For empirical correction factors; , , and These are all empirical coefficients, obtained by fitting a large amount of experimental data under different membrane materials, speeds, and inlet conditions. Where, Used to characterize the direct impact of the initial air gap on the correction of the negative pressure difference. Used to characterize the direct impact of inlet tension fluctuations on the correction of negative pressure differential. Used to characterize the synergistic amplification effect between the two. This is used to characterize the nonlinear enhancement effect of an initially large air gap on the correction result.
[0059] Taking into account the empirical correction factor As the operating conditions increase, the correction should not be infinitely amplified. To keep the correction results within a reasonable range, a saturation-type empirical correction model can be further employed. For example, the final difference between the first negative pressure and the target negative pressure... It can be represented as:
[0060]
[0061] in, This is the final difference between the first negative pressure and the target negative pressure, expressed in kPa. To correct the amplitude coefficient; This is the saturation adjustment coefficient, and .when When the value is slightly greater than 1, the correction result gradually increases with the increase of the co-amplification relationship; while when As it continues to increase, due to the presence of [missing information] in the denominator... The correction range will gradually flatten out, thus avoiding an excessive increase in the difference between the first negative pressure and the target negative pressure.
[0062] After obtaining the final difference Then, the first negative pressure of the inlet pre-attachment area can be further determined. If the absolute value of the negative pressure is used to represent the magnitude in this embodiment, then:
[0063]
[0064] in, This represents the magnitude of the first negative pressure, expressed in kPa. The magnitude of the target negative pressure, expressed in kPa; The difference between the two is expressed in kPa. .
[0065] Suppose that a certain type of membrane material has been determined to have the following empirical parameters after testing and calibration: , The current level of difficulty in establishing initial membrane adhesion. The base negative pressure difference is:
[0066]
[0067] Furthermore, let the current initial air gap characterization parameters be... Reference value ,but:
[0068]
[0069] Let the current inlet tension fluctuation parameters be... Reference value ,but:
[0070]
[0071] Let's set an empirical coefficient. , , , Then we have:
[0072]
[0073] Reset , The final difference is:
[0074]
[0075] If the target negative pressure of the stable adsorption region is... The magnitude of the first negative pressure in the inlet pre-attached area is:
[0076]
[0077] Therefore, in this example, the basic negative pressure difference is... After considering the synergistic amplification effect of the initial air gap and inlet tension fluctuations, the final difference obtained after correction by the empirical model is approximately This allows the inlet pre-attachment zone to provide an adsorption strength more suitable for the current operating conditions, thereby improving the membrane's adhesion establishment capability at the inlet stage.
[0078] It should be noted that the empirical coefficients and reference values in the above empirical model can be obtained through pre-testing and calibration based on different membrane material types, equipment structures, and operating speed ranges. For example, multiple typical operating conditions can be selected, and the initial air gap characterization parameters, inlet tension fluctuation parameters, adhesion establishment results, and the corresponding difference between the first negative pressure and the target negative pressure can be recorded. Then, the results can be determined through least squares fitting, piecewise regression fitting, or table lookup interpolation. , , , , and The value of is chosen such that the empirical model maintains good engineering feasibility while also reflecting the synergistic amplification law between the initial air gap and the inlet tension fluctuation.
[0079] S3, a progressive attachment zone is set after the inlet pre-attachment zone, and the negative pressure of the progressive attachment zone is gradually adjusted to transition the membrane material from the initial attachment state to the stable attachment state.
[0080] After step S2, the membrane material has achieved initial air gap reduction and preliminary adhesion within the inlet pre-attachment zone. However, at this point, the membrane material has just experienced strong inlet adsorption. If the target negative pressure of the stable adsorption zone is switched immediately after the pre-attachment zone ends, it is prone to local rebound, slight edge detachment, tension redistribution, or abrupt changes in membrane surface shape due to sudden changes in adsorption intensity. Therefore, this step sets a progressive attachment zone after the inlet pre-attachment zone. By gradually controlling the negative pressure within this zone, the membrane material smoothly transitions from the inlet-strength adhesion state to the stable attachment state. It can be understood that the progressive attachment zone is a buffer zone between the pre-attachment zone and the stable adsorption zone, ensuring that the membrane material gradually transitions to a stable state after adhesion is established, rather than abruptly switching to the stable state.
[0081] As an example, the gradual regulation includes at least one of the following methods:
[0082] The negative pressure is continuously reduced along the membrane material conveying direction according to a preset gradient; the progressive attachment area is divided into multiple sub-segments and the negative pressure is reduced segment by segment; the negative pressure reduction rate is dynamically changed according to the attachment response information.
[0083] In the first method, the negative pressure in the progressive attachment zone can be continuously reduced along the membrane material transport direction, for example, gradually transitioning from a higher negative pressure near the pre-attachment zone to a target negative pressure near the stable adsorption zone. This allows the adsorption force on the membrane material to change slowly, reducing disturbances caused by sudden changes in adsorption intensity.
[0084] In the second method, the progressive attachment zone can be divided into multiple sub-segments, such as a first sub-segment, a second sub-segment, and a third sub-segment. Each sub-segment corresponds to a different negative pressure value, and these values are set to decrease progressively along the conveying direction. This method is relatively simple to implement and can be easily achieved through multiple independent suction chambers or multiple valve-controlled branches.
[0085] In the third approach, the negative pressure reduction rate can be dynamically adjusted based on the real-time adhesion response of the membrane material. For example, if local slippage or vibration is detected in the membrane material within the progressive adhesion zone, the negative pressure reduction rate can be temporarily slowed down to allow the membrane material to maintain a longer transition distance at a higher adsorption level. Conversely, when the membrane material adhesion is relatively stable, the negative pressure reduction can be appropriately accelerated to reduce system energy consumption and improve control response efficiency.
[0086] It should be noted that both continuous reduction of negative pressure and segmented reduction of negative pressure can achieve the technical effect of gradual control in this invention, and there is no conflict between the two. In some embodiments, to balance control accuracy and implementation cost, a segmented approach with fine-tuning within each segment can be adopted. That is, the progressive attachment area is first divided into several sub-segments, and then small-range continuous adjustments are made within each sub-segment. This facilitates zoned control through independent air extraction chambers and achieves a smoother negative pressure transition effect within each sub-segment. For example, the progressive attachment area can be divided into three sub-segments. The negative pressure of the first sub-segment is slightly lower than the first negative pressure, the second sub-segment further reduces it, and the third sub-segment approaches the target negative pressure. When slight vibration of the membrane material is detected in the second sub-segment, the rate of decrease in negative pressure can be temporarily slowed down within the second sub-segment, thereby improving the consistency and stability of the transition process.
[0087] S4, after the progressive attachment zone, maintain the target negative pressure in the stable adsorption zone to achieve stable delivery, and dynamically adjust the adsorption control parameters of the inlet pre-attachment zone and / or the progressive attachment zone based on the membrane material's attachment response information; wherein, the attachment response information includes at least one of negative pressure establishment time, local slippage characteristics, tension fluctuation characteristics, vibration characteristics, or attachment delay characteristics.
[0088] After the membrane material passes through the inlet pre-attachment zone and the progressive attachment zone, a relatively stable adhesion relationship has been established between it and the vacuum adsorption roller. At this point, the target negative pressure is maintained in the stable adsorption zone to ensure the stability of the membrane material during subsequent traction and conveying. It should be noted that the target negative pressure usually does not need to be maintained at a high level in the pre-attachment zone, but is preferably set to a negative pressure level that meets the requirements of stable traction while also considering energy consumption and membrane material protection.
[0089] Meanwhile, after the membrane material enters the stable adsorption zone, the adsorption control parameters of the inlet pre-attachment zone and / or progressive attachment zone are dynamically adjusted based on the membrane material's attachment response information to form a closed-loop optimization mechanism. The attachment response information includes at least one of the following: negative pressure build-up time, local slippage characteristics, tension fluctuation characteristics, vibration characteristics, or attachment delay characteristics.
[0090] Among them, the negative pressure establishment time can be used to reflect the time required for the membrane material to complete effective adhesion in the inlet section; local slip characteristics can be obtained by surface speed difference, image displacement tracking, or comparison of roller speed and membrane speed; tension fluctuation characteristics can be reflected by the short-term fluctuation output by the downstream tension sensor; vibration characteristics can be obtained by acceleration sensor, displacement sensor, or visual inspection unit; and adhesion delay characteristics can be characterized by the time difference or position difference between the membrane material entering the inlet area and forming a stable adhesion.
[0091] When the above-mentioned adhesion response information indicates insufficient adhesion establishment in the inlet section or poor stability in the transition section, the adsorption control parameters of the inlet pre-attachment zone and / or the progressive attachment zone can be dynamically adjusted. For example, when the negative pressure establishment time is too long and the adhesion delay characteristic is obvious, the negative pressure value of the pre-attachment zone can be appropriately increased or the length of the pre-attachment zone can be extended; when the local slippage characteristic mainly appears in the later part of the progressive attachment zone, the negative pressure gradient range of the progressive attachment zone can be adjusted or the negative pressure gradient deceleration rate can be slowed down; when the tension fluctuation characteristics and vibration characteristics both indicate that the membrane material has basically stabilized in the pre-attachment zone, but slight disturbances occur in the progressive transition stage, the pre-attachment zone parameters can be kept unchanged, and only the segmented negative pressure values of the progressive attachment zone can be corrected. Furthermore, within the same production batch, different rolls of membrane material may have consistent process parameters but slightly different surface shapes. In this case, by statistically analyzing the adhesion response information of several rolls of membrane material, batch-level adaptive corrections can be made to the pre-attachment zone length and the progressive attachment zone reduction strategy, thereby improving the control consistency throughout the entire batch production process.
[0092] It is understandable that the dynamic adjustment in this step can be either online adjustment during a single roll entry or iterative optimization based on historical data during the operation of multiple rolls of film. For example, if the control system detects that a certain type of optical film exhibits a prolonged negative pressure build-up time in the pre-attachment zone multiple times under the same operating speed and target tension, it can automatically increase the difference between the first negative pressure and the target negative pressure in the corresponding process template for that type of film in subsequent operations, or increase the length of the pre-attachment zone; if another type of release film shows no significant vibration in the progressive attachment zone, the length of the progressive attachment zone can be appropriately shortened or the negative pressure deceleration rate can be increased to improve system efficiency. Through the above methods, this invention can not only improve the quality of inlet attachment establishment in a single operation, but also gradually improve the control adaptability and stability under different film materials and different operating conditions during continuous operation.
[0093] In summary, this embodiment first obtains the initial adhesion state parameters when the membrane material enters the inlet area of the vacuum adsorption roller. Then, based on the initial adhesion state parameters, it constructs an inlet pre-attachment zone, a progressive attachment zone, and a stable adsorption zone on the vacuum adsorption roller. It then implements a first negative pressure control higher than that of the stable adsorption zone, a gradual negative pressure regulation, and a target negative pressure maintenance control, respectively. This allows the membrane material to first complete initial air gap compression and adhesion establishment under pressureless conditions, then smoothly transition from enhanced adhesion to stable adhesion, and finally achieve reliable transport within the stable adsorption zone. Simultaneously, by dynamically adjusting the adsorption control parameters of the pre-attachment zone and / or the progressive attachment zone in conjunction with the adhesion response information, the consistency, stability, and adaptability of the inlet adhesion establishment process under different membrane materials and working conditions can be further improved.
[0094] Please see Figure 3 This invention also provides a film material conveying control system 200 based on a vacuum adsorption roller, the system comprising:
[0095] The parameter acquisition unit 10 is used to acquire the initial attachment state parameters when the membrane material enters the inlet area of the vacuum adsorption roller. The initial attachment state parameters include the initial air gap characterization parameter, which characterizes the initial air gap size between the membrane material and the surface of the vacuum adsorption roller, the membrane material running speed, the inlet tension fluctuation parameter, and the membrane material deformation trend parameter.
[0096] The pre-attachment control unit 20 is used to determine the adsorption control parameters of the inlet pre-attachment zone according to the initial attachment state parameters, and control the inlet pre-attachment zone to form a first negative pressure higher than that of the stable adsorption zone, so as to reduce the initial air gap between the film and the roller surface and establish attachment; wherein, the adsorption control parameters include the pre-attachment zone length and the pre-attachment zone negative pressure value;
[0097] The progressive control unit 30 is used to set a progressive attachment zone after the inlet pre-attachment zone and to progressively control the negative pressure of the progressive attachment zone so that the membrane material transitions from the initial attachment state to a stable attachment state.
[0098] The stable delivery and feedback adjustment unit 40 is used to maintain the target negative pressure in the stable adsorption zone after the progressive attachment zone to achieve stable delivery, and to dynamically adjust the adsorption control parameters of the inlet pre-attachment zone and / or the progressive attachment zone based on the attachment response information of the membrane material; wherein, the attachment response information includes at least one of negative pressure establishment time, local slippage characteristics, tension fluctuation characteristics, vibration characteristics, or attachment delay characteristics.
[0099] As an example, the vacuum adsorption roller is provided with independent pre-attachment zone air extraction chamber, progressive attachment zone air extraction chamber and stable adsorption zone air extraction chamber along the film conveying direction, so as to form the first negative pressure, the progressive negative pressure and the target negative pressure respectively.
[0100] As an example, the difference between the first negative pressure and the target negative pressure is determined based on the difficulty of initial membrane attachment, which is positively correlated with at least one of the initial air gap characterization parameters, membrane running speed, and membrane deformation trend parameters.
[0101] As an example, the difference between the first negative pressure and the target negative pressure is determined based on the difficulty of initial membrane adhesion establishment, including:
[0102] Based on the initial air gap characterization parameters, the membrane material running speed, and the membrane material deformation trend parameters, a first difficulty component characterizing the basic resistance of membrane material adhesion establishment is determined. Based on the inlet tension fluctuation parameters and the membrane material deformation trend parameters, a second difficulty component characterizing the dynamic instability of membrane material adhesion establishment is determined. The initial adhesion establishment difficulty level of the membrane material is obtained according to the coupling relationship between the first difficulty component and the second difficulty component.
[0103] The basic negative pressure difference is determined based on the difficulty level of the initial membrane adhesion. Then, the basic negative pressure difference is nonlinearly corrected by combining the synergistic amplification relationship between the initial air gap characterization parameters and the inlet tension fluctuation parameters to obtain the difference between the first negative pressure and the target negative pressure.
[0104] As an example, the gradual regulation includes at least one of the following methods:
[0105] The negative pressure is continuously reduced along the membrane material conveying direction according to a preset gradient; the progressive attachment area is divided into multiple sub-segments and the negative pressure is reduced segment by segment; the negative pressure reduction rate is dynamically changed according to the attachment response information.
[0106] This invention also provides a computer-readable storage medium storing a computer program that, when executed by a processor, implements the method described in any of the preceding embodiments.
[0107] This invention also provides a computer program product, which includes instructions that, when executed, implement the method described in any of the preceding embodiments.
[0108] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.
Claims
1. A method for controlling film material conveying based on a vacuum adsorption roller, characterized in that, The method includes the following steps: S1, obtain the initial adhesion state parameters when the membrane material enters the inlet area of the vacuum adsorption roller. The initial adhesion state parameters include the initial air gap characterization parameters that characterize the initial air gap size between the membrane material and the surface of the vacuum adsorption roller, the membrane material running speed, the inlet tension fluctuation parameters, and the membrane material deformation trend parameters. S2, determine the adsorption control parameters of the inlet pre-attachment zone according to the initial attachment state parameters, and control the inlet pre-attachment zone to form a first negative pressure higher than that of the stable adsorption zone, so as to reduce the initial air gap between the film and the roller surface and establish attachment; wherein, the adsorption control parameters include the pre-attachment zone length and the pre-attachment zone negative pressure value; S3, a progressive attachment zone is set after the inlet pre-attachment zone, and the negative pressure of the progressive attachment zone is gradually adjusted to transition the membrane material from the initial attachment state to the stable attachment state. S4, after the progressive attachment zone, maintain the target negative pressure in the stable adsorption zone to achieve stable delivery, and dynamically adjust the adsorption control parameters of the inlet pre-attachment zone and / or the progressive attachment zone based on the membrane material's attachment response information; wherein, the attachment response information includes at least one of negative pressure establishment time, local slippage characteristics, tension fluctuation characteristics, vibration characteristics, or attachment delay characteristics.
2. The film material conveying control method based on a vacuum adsorption roller according to claim 1, characterized in that: The vacuum adsorption roller is provided with independent pre-attachment zone air extraction chamber, progressive attachment zone air extraction chamber and stable adsorption zone air extraction chamber along the film material conveying direction, so as to form the first negative pressure, the progressive negative pressure and the target negative pressure respectively.
3. The film material conveying control method based on a vacuum adsorption roller according to claim 1, characterized in that: The difference between the first negative pressure and the target negative pressure is determined based on the difficulty of initial membrane adhesion establishment. The difficulty of initial membrane adhesion establishment is positively correlated with at least one of the initial air gap characterization parameters, membrane running speed, and membrane deformation trend parameters.
4. The film material conveying control method based on a vacuum adsorption roller according to claim 3, characterized in that: The difference between the first negative pressure and the target negative pressure is determined based on the difficulty of initial membrane adhesion establishment, including: Based on the initial air gap characterization parameters, the membrane material running speed, and the membrane material deformation trend parameters, a first difficulty component characterizing the basic resistance of membrane material adhesion establishment is determined. Based on the inlet tension fluctuation parameters and the membrane material deformation trend parameters, a second difficulty component characterizing the dynamic instability of membrane material adhesion establishment is determined. The initial adhesion establishment difficulty level of the membrane material is obtained according to the coupling relationship between the first difficulty component and the second difficulty component. The basic negative pressure difference is determined based on the difficulty level of the initial membrane adhesion. Then, the basic negative pressure difference is nonlinearly corrected by combining the synergistic amplification relationship between the initial air gap characterization parameters and the inlet tension fluctuation parameters to obtain the difference between the first negative pressure and the target negative pressure.
5. The film material conveying control method based on a vacuum adsorption roller according to claim 1, characterized in that: The gradual regulation includes at least one of the following methods: The negative pressure is continuously reduced along the membrane material conveying direction according to a preset gradient; the progressive attachment area is divided into multiple sub-segments and the negative pressure is reduced segment by segment; the negative pressure reduction rate is dynamically changed according to the attachment response information.
6. A film material conveying control system based on a vacuum adsorption roller, characterized in that, The system includes: The parameter acquisition unit is used to acquire the initial adhesion state parameters when the membrane material enters the inlet area of the vacuum adsorption roller. The initial adhesion state parameters include the initial air gap characterization parameter, which characterizes the initial air gap size between the membrane material and the roller surface of the vacuum adsorption roller, the membrane material running speed, the inlet tension fluctuation parameter, and the membrane material deformation trend parameter. A pre-attachment control unit is used to determine the adsorption control parameters of the inlet pre-attachment zone based on the initial attachment state parameters, and to control the inlet pre-attachment zone to form a first negative pressure higher than that of the stable adsorption zone, so as to reduce the initial air gap between the film and the roller surface and establish attachment; wherein, the adsorption control parameters include the pre-attachment zone length and the pre-attachment zone negative pressure value; A progressive control unit is used to set a progressive attachment zone after the inlet pre-attachment zone and to progressively control the negative pressure of the progressive attachment zone so that the membrane material transitions from the initial attachment state to a stable attachment state. A stable delivery and feedback adjustment unit is used to maintain the target negative pressure in the stable adsorption zone after the progressive attachment zone to achieve stable delivery, and to dynamically adjust the adsorption control parameters of the inlet pre-attachment zone and / or the progressive attachment zone based on the attachment response information of the membrane material; wherein, the attachment response information includes at least one of negative pressure establishment time, local slippage characteristics, tension fluctuation characteristics, vibration characteristics, or attachment delay characteristics.
7. A film material conveying control system based on a vacuum adsorption roller according to claim 6, characterized in that: The vacuum adsorption roller is provided with independent pre-attachment zone air extraction chamber, progressive attachment zone air extraction chamber and stable adsorption zone air extraction chamber along the film material conveying direction, so as to form the first negative pressure, the progressive negative pressure and the target negative pressure respectively.
8. A film material conveying control system based on a vacuum adsorption roller according to claim 6, characterized in that: The difference between the first negative pressure and the target negative pressure is determined based on the difficulty of initial membrane adhesion establishment. The difficulty of initial membrane adhesion establishment is positively correlated with at least one of the initial air gap characterization parameters, membrane running speed, and membrane deformation trend parameters.
9. A computer-readable storage medium storing a computer program, characterized in that, When the computer program is executed by a processor, it implements the method as described in any one of claims 1 to 5.
10. A computer program product, characterized in that, The computer program product includes instructions that, when executed, implement the method as described in any one of claims 1 to 5.