An automatic film pasting machine for aluminum profile protection film

Abstract

The application discloses an automatic protective film pasting machine for aluminum profiles, which comprises a pasting machine frame, a feeding mechanism, a discharging mechanism, an industrial camera, a PLC control cabinet, a film roll switching bin, a protective film cutting device and a pressing assembly. The industrial camera collects profile data of the aluminum profile and transmits the profile data to the PLC control cabinet. The PLC control cabinet controls the film roll switching bin to unwind, controls the protective film cutting device to cut online, and controls the pressing assembly to press the protective film onto the surface of the aluminum profile. The pressing assembly comprises a flexible horizontal pressing roller movable along a horizontal direction and a flexible vertical pressing roller movable along a vertical direction. The automatic pasting machine realizes full-automatic closed-loop control from feeding, detection, cutting, pressing to discharging, is good in adaptability to aluminum profiles with special-shaped cross sections, is high in pasting efficiency and stable in quality, and can effectively reduce film material waste.

Description

Technical Field

[0001] This invention relates to the field of aluminum profile surface treatment technology, and in particular to an automatic protective film applicator for aluminum profiles. Background Technology

[0002] After processing, aluminum profiles typically require a protective film to prevent scratches and contamination during transportation, storage, and subsequent processing. Traditionally, the application of protective films to aluminum profiles has relied primarily on manual labor. However, manual application has several drawbacks: low efficiency, averaging only about 3 meters per minute; significant material waste due to the difficulty in precisely controlling film tension and adhesion position, resulting in a loss rate of 15% to 20%; and inconsistent adhesion quality, easily leading to defects such as bubbles, wrinkles, and misalignment, failing to meet the stringent appearance quality requirements of modern manufacturing.

[0003] To address these issues, some semi-automated film application equipment has emerged in the industry. However, existing semi-automated equipment generally suffers from the following drawbacks: poor adaptability to irregularly shaped aluminum profiles, making contour-following application impossible; low positioning accuracy, making it difficult to ensure the alignment accuracy between the protective film and the profile edge; and, these devices typically lack online cutting capabilities, requiring pre-cut protective film before application, further increasing process complexity and material waste. Therefore, developing a fully automated machine capable of precise, efficient, and high-quality film application has become a pressing technical challenge in this field. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide an automatic film applicator for aluminum profiles, so as to achieve accurate, efficient and high-quality automatic application of protective film for aluminum profiles.

[0005] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is: an automatic film applicator for aluminum profiles, comprising: Film applicator frame (20); The feeding mechanism located at one end of the film application frame (20) is used to convey aluminum profiles (90); The discharge mechanism located at the other end of the film-applying frame (20) is used to output the film-applied aluminum profiles; An industrial camera (31) positioned above the film application frame (20) is used to collect contour data of the aluminum profile (90); A film roll switching chamber (60) is used to supply protective film and can unwind it at a predetermined speed; A pressing assembly for pressing the cut protective film onto the surface of an aluminum profile (90); The pressing assembly includes at least one set of flexible horizontal pressing rollers (40) and at least one set of flexible vertical pressing rollers (51). The flexible horizontal pressing rollers (40) are movably mounted on the horizontal pressing roller guide (41) in the horizontal direction, and the flexible vertical pressing rollers (51) are movably mounted on the vertical pressing roller guide (54) in the vertical direction. The PLC control cabinet (21) is electrically connected to the industrial camera (31), the film roll switching chamber (60), the flexible horizontal pressing roller (40) and the flexible vertical pressing roller (51), respectively. The protective film cutter (71) is electrically connected to the PLC control cabinet (21) and is used to cut the protective film according to the instructions of the PLC control cabinet (21).

[0006] Furthermore, the flexible horizontal pressing roller (40) is slidably mounted on the horizontal pressing roller guide rail (41) via the horizontal pressing roller slider (42) and is connected to the horizontal pressing roller adjusting rod (43). The horizontal pressing roller adjusting rod (43) adjusts the horizontal pressing distance of the flexible horizontal pressing roller (40) by turning the screw thread.

[0007] Furthermore, the flexible horizontal pressing rollers (40) are arranged in pairs, and at least four pairs are provided.

[0008] Furthermore, the flexible vertical pressing roller (51) is slidably mounted on the vertical pressing roller bracket (50) via the vertical pressing roller slider (55) and is connected to the vertical pressing roller adjusting rod (52). The vertical pressing roller adjusting rod (52) adjusts the vertical pressing distance of the flexible vertical pressing roller (51) by turning the screw thread. The vertical pressing roller bracket (50) is also provided with a synchronous shaft (53) for synchronously adjusting the vertical pressing roller sliders (55) on both sides. The synchronous shaft (53) realizes the synchronous lifting and lowering of the vertical pressing roller sliders (55) on both sides through shaft and gear meshing.

[0009] Furthermore, the flexible vertical pressing rollers (51) are arranged in pairs, and at least two pairs are provided.

[0010] Furthermore, the membrane roll switching chamber (60) is provided with multiple membrane roll mounting shafts and a switching drive device for switching working membrane rolls.

[0011] Furthermore, the protective film cutter (71) is mounted on the protective film cutting bracket (70) and can reciprocate along the protective film cutting guide rail (72).

[0012] Furthermore, the industrial camera (31) is fixedly mounted above the film applicator frame (20) via an industrial camera bracket (30), with its data acquisition end facing the aluminum profile (90) fed by the feeding mechanism.

[0013] Furthermore, the feeding mechanism includes a feeding guide bracket (10) and multiple feeding rollers (11) disposed on the feeding guide bracket (10).

[0014] Furthermore, the discharge mechanism includes a discharge guide rail bracket (80) and multiple discharge rollers (81) disposed on the discharge guide rail bracket (80).

[0015] The beneficial effects of this invention are as follows: Real-time acquisition of aluminum profile contour data via an industrial camera is transmitted to a PLC control cabinet. The PLC intelligently calculates and controls the protective film cutter to achieve precise online cutting. Simultaneously, the film roll switching chamber is controlled to unwind as needed. The cut protective film is then subjected to bidirectional contour pressing using flexible horizontal pressing rollers that can move horizontally and flexible vertical pressing rollers that can move vertically. This achieves fully automated closed-loop control from feeding, inspection, cutting, pressing to unloading. This technical solution significantly improves the adaptability of film application to irregularly shaped aluminum profiles, effectively avoiding bubbles, wrinkles, and misalignment, improving bonding quality, and greatly increasing film application efficiency while reducing film waste. It solves the problems of low efficiency, unstable quality, and poor adaptability to irregularly shaped profiles in existing equipment. Attached Figure Description

[0016] 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 the structures shown in these drawings without creative effort.

[0017] Figure 1 This is an isometric schematic diagram of the overall structure of the automatic aluminum profile protective film applicator according to an embodiment of the present invention.

[0018] Figure 2 This is a partial enlarged schematic diagram of the automatic film applicator for aluminum profile protective film according to an embodiment of the present invention.

[0019] Among them, 10. Feeding guide rail bracket; 11. Feeding roller; 20. Film applicator frame; 21. PLC control cabinet; 22. Human-machine interface screen; 30. Industrial camera bracket; 31. Industrial camera; 40. Flexible horizontal pressing roller; 41. Horizontal pressing roller guide rail; 42. Horizontal pressing roller slider; 43. Horizontal pressing roller adjusting rod; 50. Vertical pressing roller bracket; 51. Flexible vertical pressing roller; 52. Vertical pressing roller adjusting rod; 53. Synchronous shaft; 54. Vertical pressing roller guide rail; 55. Vertical pressing roller slider; 60. Film roll switching chamber; 70. Protective film cutting bracket; 71. Protective film cutter; 72. Protective film cutting guide rail; 80. Discharge guide rail bracket; 81. Discharge roller; 90. Aluminum profile. Detailed Implementation

[0020] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0021] It should be noted that the descriptions involving "first," "second," etc., in this invention are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of that feature. Furthermore, the technical solutions of the various embodiments can be combined with each other, but only on the basis of being achievable by those skilled in the art. When the combination of technical solutions is contradictory or impossible to implement, such a combination of technical solutions should be considered non-existent and not within the scope of protection claimed by this invention.

[0022] like Figures 1-2 As shown, an embodiment of the present invention is: an automatic protective film applicator for aluminum profiles, comprising: 20mm film applicator frame; The feeding mechanism, located at one end of the film-applying frame 20, is used to convey the aluminum profile 90; The discharge mechanism located at the other end of the film-applying frame 20 is used to output the film-applied aluminum profiles; An industrial camera 31, positioned above the film application frame 20, is used to collect contour data of the aluminum profile 90. The film roll switching chamber 60 is used to supply protective film and can unwind it at a predetermined speed. A pressing assembly is used to press the cut protective film onto the surface of an aluminum profile at 90°. The pressing assembly includes at least one set of flexible horizontal pressing rollers 40 and at least one set of flexible vertical pressing rollers 51. The flexible horizontal pressing rollers 40 are movably mounted on the horizontal pressing roller guide rail 41 in the horizontal direction, and the flexible vertical pressing rollers 51 are movably mounted on the vertical pressing roller guide rail 54 in the vertical direction. PLC control cabinet 21, which is electrically connected to the industrial camera 31, the film roll switching chamber 60, the flexible horizontal pressing roller 40 and the flexible vertical pressing roller 51 respectively. The protective film cutter 71 is electrically connected to the PLC control cabinet (21) and is used to cut the protective film according to the instructions of the PLC control cabinet 21.

[0023] In this embodiment, the aluminum profile 90 to be coated is fed into the conveyor line of the coating machine frame 20 at a uniform speed by the feeding mechanism. The industrial camera 31 collects the contour data of the aluminum profile 90 in real time and transmits it to the PLC control cabinet 21. The PLC control cabinet 21 is equipped with a human-machine interface screen 22 for operators to set parameters. The PLC control cabinet 21 calculates the cutting length and pressing parameters according to the profile contour, and at the same time controls the film roll switching chamber 60 to unwind at the set speed. When the aluminum profile 90 travels to the predetermined length, the protective film cutter 71 accurately cuts the protective film according to the PLC instructions. The cut protective film covers the aluminum profile 90. On the surface of the aluminum profile 90, the flexible horizontal pressing roller 40 moves along the horizontal pressing roller guide 41, and the flexible vertical pressing roller 51 moves along the vertical pressing roller guide 54, respectively, to perform contour pressing on the protective film from the horizontal and vertical directions, so that the protective film tightly adheres to the irregular cross section of the aluminum profile 90; finally, the film-coated profile is output by the unloading mechanism; this process realizes fully automatic closed-loop control from feeding, inspection, cutting, pressing to unloading, has good adaptability to irregular cross section aluminum profiles, the film application efficiency can be increased to 10-15 meters / minute, the film material loss is reduced to less than 5%, and the bonding quality is stable, without bubbles, wrinkles and misalignment.

[0024] In a specific embodiment, the flexible horizontal pressing roller 40 is slidably mounted on the horizontal pressing roller guide rail 41 via the horizontal pressing roller slider 42, and is connected to the horizontal pressing roller adjusting rod 43. The horizontal pressing roller adjusting rod 43 adjusts the horizontal pressing distance of the flexible horizontal pressing roller 40 by turning the screw thread.

[0025] In this embodiment, the operator precisely adjusts the position of the horizontal pressing roller slider 42 on the horizontal pressing roller guide rail 41 by turning the horizontal pressing roller adjustment rod 43, utilizing the screw thread's screw-in and screw-out principle. This changes the pressing distance between the flexible horizontal pressing roller 40 and the side of the aluminum profile 90, achieving manual pre-adjustment of the horizontal pressing pressure. During automatic operation, the PLC control cabinet 21 adaptively controls the flexible horizontal pressing roller 40 to move along the horizontal pressing roller guide rail 41 based on the aluminum profile 90 contour data fed back in real time by the industrial camera 31, dynamically adjusting the pressure and position to achieve horizontal contour pressing of aluminum profiles 90 with different widths and cross-sectional shapes. This screw thread adjustment structure is simple, reliable, and highly accurate, ensuring the convenience of manual pre-adjustment and effectively preventing protective film displacement or wrinkling caused by uneven pressure.

[0026] In a specific embodiment, the flexible horizontal pressing rollers 40 are arranged in pairs, and at least four pairs are provided.

[0027] In this embodiment, multiple pairs of flexible horizontal pressing rollers 40 are arranged sequentially along the conveying direction of the aluminum profile 90. As the aluminum profile 90 passes through each pair of rollers, the protective film is pressed multiple times and gradually. Each pair of rollers applies uniform horizontal pressure in sequence to ensure that the protective film gradually degassing and bonding from the center of the profile to both sides, greatly reducing the generation of bubbles and wrinkles. At the same time, the arrangement of multiple pairs of rollers improves the stability and redundancy of the pressing process. Even if a pair of rollers experiences a brief pressure fluctuation, the subsequent rollers can compensate in time, ensuring the consistency of bonding quality in continuous production.

[0028] In a specific embodiment, the flexible vertical pressing roller 51 is slidably mounted on the vertical pressing roller bracket 50 via a vertical pressing roller slider 55 and is connected to a vertical pressing roller adjusting rod 52. The vertical pressing roller adjusting rod 52 adjusts the vertical pressing distance of the flexible vertical pressing roller 51 by turning the screw thread. The vertical pressing roller bracket 50 is also provided with a synchronous shaft 53 for synchronously adjusting the vertical pressing roller sliders 55 on both sides. The synchronous shaft 53 realizes the synchronous lifting and lowering of the vertical pressing roller sliders 55 on both sides through shaft and gear meshing.

[0029] In this embodiment, the operator precisely adjusts the position of the vertical pressing roller slider 55 on the vertical pressing roller guide rail 54 by turning the vertical pressing roller adjusting rod 52, utilizing the screw thread's screw-in and screw-out principle. This changes the pressing distance between the flexible vertical pressing roller 51 and the upper surface of the aluminum profile 90, achieving manual pre-adjustment of the vertical pressing pressure. The synchronous shaft 53 passes through the vertical pressing roller brackets 50 on both sides, and its two ends are equipped with gears that mesh with the racks or gears on the vertical pressing roller slider 55. When the synchronous shaft 53 rotates, the gears mesh... The transmission drives the vertical pressing roller sliders 55 on both sides to move up and down precisely and synchronously in the vertical direction, ensuring that the flexible vertical pressing rollers 51 on both sides move in unison, avoiding the protective film from being skewed or wrinkled due to lag on one side; during automatic operation, the PLC control cabinet 21 controls the flexible vertical pressing rollers 51 to move up and down along the vertical pressing roller guide rail 54 according to the contour data of the aluminum profile 90, adaptively pressing the upper surface and irregular protrusions of the aluminum profile 90, realizing vertical contour film application, which is especially suitable for complex cross-section profiles with grooves or reinforcing ribs.

[0030] In a specific embodiment, the flexible vertical pressing rollers 51 are arranged in pairs, and at least two pairs are provided.

[0031] In this embodiment, a pair of flexible vertical pressing rollers 51 are provided on each of the left and right sides of the aluminum profile 90 in the conveying direction. The pairs of rollers can simultaneously press the symmetrical parts of the aluminum profile 90 from top to bottom, ensuring the uniformity of the protective film in the width direction. The two pairs of vertical pressing rollers are arranged back and forth along the conveying direction to form a secondary pressing effect, further removing any residual air bubbles and enhancing the adhesion between the protective film and the surface of the aluminum profile 90. For irregular cross-sections with large height variations, multiple pairs of vertical rollers can adapt to the height profile of the profile in segments, achieving more precise contour-following bonding.

[0032] In a specific embodiment, the membrane roll switching chamber 60 is provided with multiple membrane roll mounting shafts and a switching drive device for switching working membrane rolls.

[0033] In this embodiment, protective film rolls of different or the same specifications can be installed simultaneously on multiple film roll mounting shafts. When the currently working film roll is about to run out, the PLC control cabinet 21 automatically issues a command to switch the drive device (such as a cylinder or motor) to drive the turntable or slide table to move, and switch the spare film roll to the unwinding station, while realizing the rapid connection between the old and new film rolls. This structure avoids stopping the machine to change rolls due to the exhaustion of film rolls, realizes long-term continuous automated production, greatly improves the overall efficiency of the equipment, and reduces manual intervention and film material waste.

[0034] In a specific embodiment, the protective film cutter 71 is mounted on the protective film cutting bracket 70 and can reciprocate along the protective film cutting guide rail 72.

[0035] In this embodiment, the protective film cutter 71 includes a cutting blade and a drive motor. When the aluminum profile 90 is transported to the predetermined position, the PLC control cabinet 21 accurately calculates the cutting timing based on the profile length signal detected by the industrial camera 31 and issues a cutting command. The protective film cutter 71 moves along the protective film cutting guide rail 72 and quickly cuts the protective film covering the surface of the aluminum profile 90. Since the cutting action is synchronized with the transport of the aluminum profile 90, online cutting is realized, eliminating the need for pre-cutting the film roll, thus eliminating the length error and material waste caused by pre-cutting. This ensures that the length of the protective film applied each time matches the actual length of the aluminum profile 90, significantly reducing the loss rate.

[0036] In a specific embodiment, the industrial camera 31 is fixedly mounted above the film applicator frame 20 via an industrial camera bracket 30, with its data acquisition end facing the aluminum profile 90 fed by the feeding mechanism.

[0037] In this embodiment, the industrial camera 31 uses a CCD or CMOS sensor, along with a lens and light source, to clearly capture the outline, edge position, and geometric features of the irregular cross-section of the aluminum profile 90. The captured image data is transmitted to the PLC control cabinet 21 in real time, and key parameters such as the width, height, and groove position of the profile are extracted through image processing algorithms. This visual inspection solution is non-contact, will not damage the surface of the aluminum profile 90, and has a fast response speed, which can meet the needs of high-speed film lamination production lines, providing an accurate data basis for subsequent cutting length calculation and roller pressure adaptive control.

[0038] In a specific embodiment, the feeding mechanism includes a feeding guide rail bracket 10 and multiple feeding rollers 11 disposed on the feeding guide rail bracket 10.

[0039] In this embodiment, multiple feed rollers 11 are arranged parallel to each other along the feeding direction and are driven to rotate synchronously by a motor or chain to smoothly feed the aluminum profile 90 into the laminating frame 20. Lateral guide wheels can also be set on the feed guide rail bracket 10 to prevent the aluminum profile 90 from tilting during the conveying process. The design of multiple rollers enables the long aluminum profile 90 to obtain uniform support and driving force, avoiding uneven feeding caused by its own weight, thereby ensuring the accuracy of the contour data collected by the industrial camera 31 and the precision of subsequent pressing and alignment.

[0040] In a specific embodiment, the discharge mechanism includes a discharge guide rail bracket 80 and multiple discharge rollers 81 disposed on the discharge guide rail bracket 80.

[0041] In this embodiment, after the aluminum profile 90 with the protective film applied is output from the film application machine frame 20, it is received by multiple discharge rollers 81 and continues to be conveyed forward. The surface of the discharge rollers 81 is covered with a soft material (such as rubber) to prevent scratching the newly applied protective film. Multiple rollers jointly support the film-applied profile to prevent the suspended part of the profile from bending due to gravity and pulling the applied protective film, thus preventing stretching deformation or edge lifting. The length of the discharge guide bracket 80 can be customized according to actual production needs to connect with subsequent collection devices or downstream processes.

[0042] The above description is merely an embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural or procedural transformations made based on the content of the present invention's specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. An automatic film applicator for aluminum profiles, characterized in that, include: Film applicator frame (20); The feeding mechanism located at one end of the film application frame (20) is used to convey aluminum profiles (90); The discharge mechanism located at the other end of the film-applying frame (20) is used to output the film-applied aluminum profiles; An industrial camera (31) positioned above the film application frame (20) is used to collect contour data of the aluminum profile (90); A film roll switching chamber (60) is used to supply protective film and can unwind it at a predetermined speed; A pressing assembly for pressing the cut protective film onto the surface of an aluminum profile (90); The pressing assembly includes at least one set of flexible horizontal pressing rollers (40) and at least one set of flexible vertical pressing rollers (51). The flexible horizontal pressing rollers (40) are movably mounted on the horizontal pressing roller guide (41) in the horizontal direction, and the flexible vertical pressing rollers (51) are movably mounted on the vertical pressing roller guide (54) in the vertical direction. The PLC control cabinet (21) is electrically connected to the industrial camera (31), the film roll switching chamber (60), the flexible horizontal pressing roller (40) and the flexible vertical pressing roller (51), respectively. The protective film cutter (71) is electrically connected to the PLC control cabinet (21) and is used to cut the protective film according to the instructions of the PLC control cabinet (21).

2. The automatic protective film applicator for aluminum profiles according to claim 1, characterized in that, The flexible horizontal pressing roller (40) is slidably mounted on the horizontal pressing roller guide rail (41) via the horizontal pressing roller slider (42) and is connected to the horizontal pressing roller adjusting rod (43). The horizontal pressing roller adjusting rod (43) adjusts the horizontal pressing distance of the flexible horizontal pressing roller (40) by turning the screw thread.

3. The automatic aluminum profile protective film applicator according to claim 2, characterized in that, The flexible horizontal pressing rollers (40) are arranged in pairs, and there are at least 4 pairs.

4. The automatic film applicator for aluminum profiles according to claim 1, characterized in that, The flexible vertical pressing roller (51) is slidably mounted on the vertical pressing roller bracket (50) via the vertical pressing roller slider (55) and is connected to the vertical pressing roller adjusting rod (52). The vertical pressing roller adjusting rod (52) adjusts the vertical pressing distance of the flexible vertical pressing roller (51) by turning the screw thread. The vertical pressing roller bracket (50) is also provided with a synchronous shaft (53) for synchronously adjusting the vertical pressing roller sliders (55) on both sides. The synchronous shaft (53) realizes the synchronous lifting and lowering of the vertical pressing roller sliders (55) on both sides through shaft and gear meshing.

5. The automatic protective film applicator for aluminum profiles according to claim 4, characterized in that, The flexible vertical pressing rollers (51) are arranged in pairs, and at least two pairs are provided.

6. The automatic protective film applicator for aluminum profiles according to claim 1, characterized in that, The membrane roll switching chamber (60) is equipped with multiple membrane roll mounting shafts and a switching drive device for switching working membrane rolls.

7. The automatic protective film applicator for aluminum profiles according to claim 1, characterized in that, The protective film cutter (71) is mounted on the protective film cutting bracket (70) and can reciprocate along the protective film cutting guide rail (72).

8. The automatic protective film applicator for aluminum profiles according to claim 1, characterized in that, The industrial camera (31) is fixedly mounted above the film applicator frame (20) via an industrial camera bracket (30), with its data acquisition end facing the aluminum profile (90) fed by the feeding mechanism.

9. The automatic protective film applicator for aluminum profiles according to claim 1, characterized in that, The feeding mechanism includes a feeding guide rail bracket (10) and multiple feeding rollers (11) disposed on the feeding guide rail bracket (10).

10. The automatic film applicator for aluminum profiles according to claim 1, characterized in that, The discharge mechanism includes a discharge guide rail bracket (80) and multiple discharge rollers (81) disposed on the discharge guide rail bracket (80).

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