Full-process tension partition cooperative control equipment and method of foil leveling unit

Abstract

The present application relates to foil leveling unit full-process tension partition collaborative control equipment and method, belongs to the field of metal foil precision machining. The equipment includes a central control system, a transmission system and a tension detection feedback system. The central control system is configured to cooperatively control multiple tension control zones, independently control the tension of each tension control zone, and selectively switch between the elongation control mode and the tension control mode in at least one tension control zone according to the feedback signal. The transmission system includes a vector variable frequency motor and a corresponding driver for driving the unwinder, the transmission roller and the winder. The tension detection feedback system is used to detect the tension value in real time and feed back to the central control system. The present application also discloses a collaborative control method applied to the above-mentioned equipment. The problems of large tension fluctuation, difficult shape control, high risk of belt breakage and other problems in the leveling process of high-strength ultra-thin foil are solved, the tension of the whole process is cooperated, and the shape quality and the roll shape quality are improved.

Description

Technical Field

[0001] This invention belongs to the field of metal foil processing technology, specifically relating to a full-process tension zone coordinated control device and method for foil leveling units. Background Technology

[0002] Titanium, zirconium, nickel, and their alloy foils have broad application prospects in high-end manufacturing fields such as aerospace, precision electronics, and medical devices due to their excellent specific strength, corrosion resistance, and special functional properties. However, these materials typically exhibit high strength, low plasticity, and high resilience, which can lead to complex sheet shape defects after cold rolling. To obtain flat strips that meet downstream application requirements, precise tension straightening treatment is necessary.

[0003] The existing foil leveling units generally have the following problems in tension control: (1) Coarse and inconsistent tension control: They often only focus on the main tension of the process section, while lacking precise coordinated control of the tension in the uncoiling area and the winding area. (2) Single control mode: For extremely thin and high-strength foil, a single constant tension control or simple speed matching is difficult to simultaneously take into account the plate shape correction effect and the risk of strip breakage. (3) Insufficient dynamic response of the system: In production, the diameter of the steel coil changes continuously, and the weld seam needs to be started, stopped or speed changed when passing through. Traditional control systems are difficult to effectively compensate for the tension of these dynamic processes, resulting in sudden tension changes, which can easily cause the thin strip to deviate, wrinkle or even break. Summary of the Invention

[0004] The purpose of this invention is to provide a full-process tension zone coordinated control device and method for foil leveling units, so as to overcome the above-mentioned technical defects.

[0005] To solve the above-mentioned technical problems, the present invention provides a full-process tension zoned collaborative control device for foil leveling units, comprising: The central control system is configured to coordinate the control of multiple tension control zones of the foil leveling unit; The transmission system includes multiple vector frequency conversion motors and corresponding drivers, which are respectively connected to the central control system for driving the unwinder, drive rollers and winding machine in the foil leveling unit. The drive rollers include at least a tension roller group at the process zone entrance and a tension roller group at the process zone exit. The tension detection feedback system is communicatively connected to the central control system and is used to detect the real-time tension value of at least one tension control zone in the foil leveling unit and feed it back to the central control system. The central control system is further configured as follows: Based on a preset tension setting value, the tension of multiple tension control zones is independently controlled; and based on the feedback signal from the tension detection feedback system, in at least one of the tension control zones, the elongation control mode and the tension control mode are selectively switched.

[0006] According to the full-process tension zone collaborative control equipment of the foil leveling unit, the multiple tension control zones include the unwinding zone, the process zone and the winding zone; Both the inlet tension roller group and the outlet tension roller group of the process area are located in the process area. The central control system is also configured to: A first tension range is set for the unwinding area, a second tension range is set for the process area, and a third tension range is set for the winding area, wherein the maximum value of the second tension range is greater than the maximum value of the first tension range and the third tension range.

[0007] According to the full-process tension zone collaborative control equipment of the foil leveling unit, the elongation control mode includes: The first speed signal of the foil at the inlet side of the process zone and the second speed signal at the outlet side of the process zone are acquired. The actual elongation is calculated based on the first speed signal and the second speed signal, and the actual elongation is compared with the preset elongation target value. The driving parameters of the tension roller group at the inlet of the process zone are adjusted according to the comparison result so that the actual elongation approaches the preset elongation target value.

[0008] According to the full-process tension zone collaborative control equipment of the foil leveling unit, the tension control mode includes: The real-time tension value detected by the tension detection feedback system is obtained, and the real-time tension value is compared with the preset tension target value. Based on the comparison result, the driving torque of the tension roller group at the entrance of the process area is adjusted so that the real-time tension value approaches the preset tension target value.

[0009] According to the full-process tension zone collaborative control equipment of the foil leveling unit, the tension detection feedback system includes: A jumping roller device, disposed in the unwinding area, includes a floating roller and a loading mechanism for applying adjustable pressure to the floating roller; A tension meter is installed on the outlet side of the process zone to directly detect the tension in the process zone.

[0010] Based on the full-process tension zone coordinated control equipment of the foil leveling unit, the central control system is also configured as follows: When the foil thickness is less than the preset thickness threshold, the foil is made to run through the jumping roller device, and the jumping roller device is used for tension buffering and indirect control. When the foil thickness is greater than or equal to the preset thickness threshold, the foil is prevented from passing through the jumping roller device.

[0011] According to the full-process tension zone coordinated control equipment of the foil leveling unit, the central control system also includes: A roll diameter calculation module is used to calculate the current roll diameter of the uncoiler and / or the rewinder in real time; Inertia compensation module, used to compensate for rotational inertia of the uncoiler and / or the winding machine according to the current roll diameter change; The friction loss compensation module is used to compensate for mechanical friction loss of the uncoiler and / or the winding machine.

[0012] The full-process tension zone coordinated control equipment for the foil leveling unit also includes: A weld seam tracking device, which is communicatively connected to the central control system, is used to detect the position of the weld seam on the foil. The central control system automatically controls the unit to decelerate based on the weld position signal detected by the weld tracking device. When the weld reaches the preset shearing position, it controls the outlet shearing device to perform the shearing operation. After the shearing is completed, it automatically controls the unit to return to normal operating speed.

[0013] This invention also provides a full-process tension zone coordinated control method for foil leveling units, applicable to a full-process tension zone coordinated control device for foil leveling units. The control method includes the following steps: Set target tension values ​​for multiple tension control zones, and select either the elongation control mode or the tension control mode for at least one of the tension control zones; Coordinate the start-up of the unwinder, drive rollers and rewinder in the foil leveling unit to establish the initial tension for the entire process from unwinding to winding; The real-time tension value detected by the tension detection feedback system is acquired in real time; If the current selection is the elongation control mode, the actual elongation is calculated based on the rotation speed signals of the process zone inlet tension roller group and the process zone outlet tension roller group, and the drive parameters of the process zone inlet tension roller group are adjusted in a closed loop to make the actual elongation approach the preset elongation target value. If the current selection is tension control mode, the driving torque of the tension roller group at the entrance of the process area is adjusted in a closed loop according to the real-time tension value, so that the real-time tension value approaches the preset tension target value. During operation, the unwinder and / or the rewinder are subjected to roll diameter calculation and dynamic compensation to maintain stable tension in the unwinding and winding zones.

[0014] According to the full-process tension zone coordinated control method of the foil leveling unit, the foil material includes titanium, zirconium, nickel or their alloys, with a thickness range of 0.05mm-0.5mm and a width range of 200mm-600mm. The flatness of the leveled foil sheet should not exceed 0.5 mm / m.

[0015] The beneficial effects of this invention are as follows: (1) Full-process zoned coordinated tension control is achieved. This invention divides the leveling unit into an uncoiling zone, a process zone, and a winding zone. The tension of each zone is independently set and coordinated through a central control system, changing the traditional coarse control mode that only focuses on the tension of the process section. The tension of the uncoiling zone, process zone, and winding zone is seamlessly connected, ensuring that the strip is subjected to uniform and stable stress throughout the entire production line, fundamentally improving the coil shape quality of the finished steel coil, especially suitable for high-strength ultra-thin foil with a thickness between 0.05mm and 0.5mm.

[0016] (2) It provides a flexible control mode to adapt to complex processes. This invention integrates elongation control mode and tension control mode in the tension straightening process section, allowing operators to flexibly select or dynamically switch modes according to the shape of the incoming material, material characteristics, and finished product requirements. For materials with severe shape defects, the elongation control mode can be used to prioritize the straightening effect; for extremely thin or easily broken materials, the tension control mode can be used to prioritize production safety. This dual-mode design greatly enhances the unit's adaptability to different process requirements, balancing the accuracy of shape straightening with production stability.

[0017] (3) Significantly improved dynamic stability and robustness of the system. This invention integrates a coil diameter calculation module, an inertia compensation module, and a friction loss compensation module to provide real-time torque compensation for the uncoiler and coiler, effectively offsetting the changes in rotational inertia and mechanical losses caused by changes in the steel coil diameter. Simultaneously, the jumping roller device provides tension buffering and indirect control during the production of ultra-thin foil, and the weld seam tracking device enables automatic deceleration, shearing, and recovery operation. These mechanisms enable the system to effectively suppress tension impacts and fluctuations caused by dynamic processes such as speed increases / decreases, changes in steel coil diameter, and weld seam shearing, significantly reducing the risks of strip breakage, deviation, and wrinkling.

[0018] To make the above description of the present invention more apparent and understandable, preferred embodiments are described below in detail with reference to the accompanying drawings. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the full-process tension zone collaborative control equipment for the foil leveling unit.

[0020] Figure 2 This is a block diagram of the control system according to an embodiment of the present invention.

[0021] Figure 3 This is a flowchart of the full-process tension zone collaborative control method for foil leveling units.

[0022] Explanation of reference numerals in the attached figures: 101. Uncoiler; 102. Inlet pinch roll; 103. Jumping roll; 104. Inlet shear; 105. Welding machine; 201. Tension roller assembly at the entrance of the process area; 202. Tension straightener; 203. Multi-roll straightener; 204. Tension roller assembly at the exit of the process area; 205. Tension gauge; 301. Export shearing machine; 302. Export pinch roll and EPC device; 303. Winding machine. Detailed Implementation

[0023] The following specific embodiments illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification.

[0024] It should be noted that, in this invention, the upper, lower, left, and right in the figure are considered to be the upper, lower, left, and right of the full-process tension zone collaborative control device of the foil leveling unit described in this specification.

[0025] Exemplary embodiments of the present invention will now be described with reference to the accompanying drawings. However, the present invention may be embodied in many different forms and is not limited to the embodiments described herein. These embodiments are provided to fully and completely disclose the invention and to fully convey its scope to those skilled in the art. The terminology used in the exemplary embodiments illustrated in the drawings is not intended to limit the invention. In the drawings, the same units / elements are referred to by the same reference numerals.

[0026] Unless otherwise stated, the terms used herein (including technical terms) have their common meaning as understood by one of ordinary skill in the art. Furthermore, it is understood that terms defined in commonly used dictionaries should be understood to have a meaning consistent with the context of their relevant field, and not to be interpreted as having an idealized or overly formal meaning.

[0027] Please see Figure 1 The foil leveling unit in this embodiment includes an inlet section, a process section and an outlet section in sequence along the strip travel direction.

[0028] The inlet section includes an uncoiler 101, an inlet pinch roll 102, a jumping roll 103, an inlet shear 104, and a welder 105. The uncoiler 101 is used to carry and release the foil roll, the inlet pinch roll 102 is used to pinch the strip and assist in threading, the jumping roll 103 is used for tension buffering and indirect control, the inlet shear 104 is used to cut the head and tail or split the roll, and the welder 105 is used to weld the tail end of the previous roll of strip to the head end of the next roll of strip to achieve continuous production.

[0029] The process section includes a process zone inlet tension roller group 201, a tension leveler 202, a multi-roll straightener 203, a process zone outlet tension roller group 204, and a tension meter 205. The process zone inlet tension roller group 201 and the process zone outlet tension roller group 204 are used to establish and adjust the tension of the process section. The tension leveler 202 is used to induce elastic-plastic extension of the strip to release internal stress. The multi-roll straightener 203 is used to further straighten the strip shape. The tension meter 205 is used to directly detect the tension of the process section.

[0030] The exit section includes an exit shearing machine 301, an exit pinch roll and EPC (Edge Position Control) device 302, and a winding machine 303. The exit shearing machine 301 is used for slitting or cutting the weld seam, the exit pinch roll and EPC device 302 is used for pinching the strip and achieving edge centering control, and the winding machine 303 is used for winding the leveled strip into a coil.

[0031] Based on the above equipment layout, this invention divides the leveling unit into three tension control zones: an uncoiling zone, a process zone, and a winding zone. The uncoiling zone corresponds to the equipment involved in tension control in the inlet section, mainly including the uncoiler 101, inlet pinch roll 102, and jumper roll 103. The inlet shearer 104 and welding machine 105 in the inlet section are auxiliary equipment and are not included in the uncoiling zone. The process zone corresponds to all equipment in the process section, including the process zone inlet tension roll group 201, tension leveler 202, multi-roll straightener 203, process zone outlet tension roll group 204, and tension meter 205. The winding zone corresponds to the equipment involved in tension control in the outlet section, mainly including the outlet pinch roll and EPC device 302, and winding machine 303. The outlet shearer 301 in the outlet section is auxiliary equipment and is not included in the winding zone.

[0032] That is, multiple tension control zones refer to three tension control zones: unwinding zone, process zone, and winding zone.

[0033] Both the inlet tension roller group 201 and the outlet tension roller group 204 of the process area are located in the process area.

[0034] Please combine Figure 1 and Figure 2 The full-process tension zone collaborative control equipment of the foil leveling unit includes a central control system, a transmission system, and a tension detection and feedback system.

[0035] The central control system is configured to coordinate the control of multiple tension control zones of the foil leveling unit. It sends control commands to each actuator and receives feedback signals via an industrial network, enabling independent setting and unified coordination of tension in the unwinding zone, process zone, and winding zone.

[0036] In some embodiments, the central control system includes a programmable logic controller (PLC) and a human-machine interface (HMI). The PLC uses a Siemens S7-1516 series PLC, which communicates at high speed with the drive system, tension detection feedback system, weld seam tracking device, distributed I / O stations, and operator stations via PROFINET industrial Ethernet, forming a unified data interaction platform to ensure the real-time performance and synchronization of tension control commands and feedback signals. The HMI is connected to the PLC and provides parameter setting, status display, and operation interaction functions.

[0037] The transmission system includes multiple vector frequency converter motors and corresponding drivers, which are communicatively connected to the central control system. It drives the uncoiler 101, drive rollers, and rewinder 303 in the foil leveling unit. The drive rollers include at least an inlet tension roller group 201 and an outlet tension roller group 204. Each vector frequency converter motor independently drives its corresponding drive roller. Speed ​​and torque closed-loop control are used to achieve speed and torque control at each transmission point, providing the basis for tension zone control.

[0038] The tension detection feedback system is communicatively connected to the central control system to detect the real-time tension value of at least one tension control zone in the foil leveling unit and feed it back to the central control system. The tension detection feedback system includes a jumping roller device located in the uncoiling zone (i.e.,... Figure 1 The system includes a floating roller 103 and a tension meter 205 located on the outlet side of the process zone. The floating roller 103 reflects the inlet tension fluctuation through the position change of the floating roller, and the tension meter 205 directly measures the actual tension value on the outlet side of the process zone.

[0039] The jumping roller device, namely jumping roller 103, is located in the uncoiling area and includes a floating roller and a loading mechanism for applying adjustable pressure to the floating roller. In this embodiment, the loading mechanism is a cylinder, and the central control system adjusts the cylinder pressure through an electro-proportional valve to provide adjustable tension to the floating roller. The jumping roller device includes a floating roller, a swing arm, a cylinder, and an absolute encoder. The floating roller is mounted on the swing arm, which can swing around a fixed axis. The piston rod of the cylinder is connected to the swing arm, and the cylinder pressure applies adjustable tension to the floating roller. The absolute encoder is installed at the swing arm axis to detect the position of the floating roller. The central control system adjusts the cylinder pressure through the electro-proportional valve according to the inlet tension target set by the human-machine interface to provide initial tension to the strip. During operation, the position offset of the floating roller reflects the fluctuation of the inlet tension in real time. The central control system collects the absolute encoder signal in real time, and when the position deviates from the equilibrium point, it finely adjusts the speed of the uncoiling machine 101 to stabilize the floating roller at the preset position, thereby realizing indirect closed-loop control of the inlet tension.

[0040] When the foil thickness is less than the preset thickness threshold, the strip runs through the jumping roller device (i.e., jumping roller 103). The floating roller of jumping roller 103 applies an adjustable tension force to the strip under the action of the cylinder. The position offset of the floating roller reflects the inlet tension fluctuation in real time. The central control system finely adjusts the speed of the unwinder 101 according to the floating roller position signal to stabilize the floating roller at the preset position, thereby realizing the buffering and indirect closed-loop control of the inlet tension and preventing the thin strip from breaking or deviating due to sudden tension changes during startup, acceleration or deceleration.

[0041] When the foil thickness is greater than or equal to the preset thickness threshold, the strip does not pass through (i.e., the jumping roller 103) and is directly conveyed by the uncoiler 101 to the inlet pinch roller 102. At this time, the jumping roller 103 is bypassed and does not participate in the tension control, so as to meet the requirements of the tension response speed of the thick strip and avoid unnecessary damping interference of the jumping roller device on the tension control of the thick strip.

[0042] The preset thickness threshold can be 0.12 mm.

[0043] The central control system is also configured as follows: Based on the preset tension setting value, the tension of multiple tension control zones is independently controlled; and based on the feedback signal from the tension detection feedback system, the elongation control mode and the tension control mode are selectively switched in at least one tension control zone.

[0044] Specifically, based on the tension target value set by the human-machine interface, independent tension control is performed on the uncoiling area, the process area, and the coiling area. A first tension range is set for the uncoiling area to prevent the strip from stretching and deforming due to excessive tension or loosening between layers due to insufficient tension during the uncoiling process. A second tension range is set for the process area, and the maximum value of the second tension range is greater than the maximum values ​​of the first and third tension ranges to ensure that the process area has sufficient tension correction capacity to eliminate strip shape defects. A third tension range is set for the coiling area to ensure that the finished steel coil has a neat shape and that no wrinkles are generated in the inner layer.

[0045] Based on the signals from the tension detection feedback system, the system selectively switches between elongation control mode and tension control mode within the process zone. When elongation control mode is selected, the encoders installed on the tension roller group 201 at the process zone entrance and the tension roller group 204 at the process zone exit measure the strip speed in real time, calculate the actual elongation, and adjust the driving torque or speed of the tension roller group 201 at the process zone entrance to make the actual elongation approach the preset target value, thereby achieving direct control of the strip shape correction amount. When tension control mode is selected, the real-time tension value measured by the tension meter 205 is used as feedback. By adjusting the driving torque of the tension roller group 201 at the process zone entrance, the real-time tension value is stabilized at the preset tension target value, prioritizing the safety of the strip under stress during the straightening process and reducing the risk of strip breakage in ultra-thin foil.

[0046] The elongation control mode includes: acquiring the first speed signal of the foil at the inlet side of the process zone and the second speed signal at the outlet side of the process zone; calculating the actual elongation based on the first speed signal and the second speed signal; comparing the actual elongation with the preset elongation target value; and adjusting the driving parameters of the tension roller group 201 at the inlet of the process zone according to the comparison result, so that the actual elongation approaches the preset elongation target value.

[0047] Specifically, the elongation control mode uses encoders installed on the inlet tension roller group 201 and the outlet tension roller group 204 of the process zone to acquire the first speed signal of the foil at the inlet side and the second speed signal at the outlet side of the process zone in real time. The inlet tension roller group 201 and the outlet tension roller group 204 of the process zone are driven by independent vector frequency conversion motors. The encoders feed the speed signals back to the central control system in real time. The central control system calculates the actual elongation based on the first and second speed signals. The formula for calculating the actual elongation is that the elongation equals the difference between the outlet speed and the inlet speed divided by the inlet speed. The calculated actual elongation is compared with the preset elongation target value set by the human-machine interface. The driving torque or speed setpoint of the inlet tension roller group 201 of the process zone is dynamically adjusted through a closed-loop adjustment algorithm to create a speed difference between the inlet tension roller group 201 and the outlet tension roller group 204 of the process zone. This causes the strip to produce the set elastic-plastic elongation in the tension straightener 202 and the multi-roll straightener 203. The actual elongation approaches the preset elongation target value, thereby achieving control of the strip shape correction amount.

[0048] The tension control mode includes: acquiring the real-time tension value detected by the tension detection feedback system, comparing the real-time tension value with the preset tension target value, and adjusting the driving torque of the tension roller group 201 at the inlet of the process area according to the comparison result, so that the real-time tension value approaches the preset tension target value.

[0049] Specifically, the tension control mode uses the real-time tension value measured by tension meter 205 as the feedback signal. Tension meter 205 is set on the exit side of the process zone to directly detect the actual tension value of the strip at the exit of the process zone and transmit the real-time tension value to the central control system in real time. The central control system compares the received real-time tension value with the preset tension target value set by the human-machine interface, and dynamically adjusts the driving torque of the tension roller group 201 at the entrance of the process zone through a closed-loop control algorithm. When the real-time tension value is lower than the preset tension target value, the driving torque of the tension roller group 201 at the entrance of the process zone is increased to increase the tension in the process zone. When the real-time tension value is higher than the preset tension target value, the driving torque of the tension roller group 201 at the entrance of the process zone is decreased to reduce the tension in the process zone, so that the real-time tension value is stabilized near the preset tension target value. Priority is given to ensuring the safety of the strip under stress in the tension straightener 202 and the multi-roll straightener 203, and reducing the risk of strip breakage of ultra-thin foil during the straightening process.

[0050] The central control system also includes a roll diameter calculation module, an inertia compensation module, and a friction loss compensation module. The roll diameter calculation module calculates the current roll diameter in real time based on the rotational speed and linear velocity of the uncoiler 101 and the winding machine 303. The roll diameter of the uncoiler 101 gradually decreases during the unwinding process, while the roll diameter of the winding machine 303 gradually increases during the winding process. The roll diameter calculation module sends the real-time roll diameter data to the inertia compensation module and the friction loss compensation module. The inertia compensation module compensates for the rotational inertia of the uncoiler 101 and the winding machine 303 based on the current roll diameter change. When the roll diameter increases, the rotational inertia increases; when the roll diameter decreases, the rotational inertia decreases. The inertia compensation module calculates the rotational inertia caused by the change in roll diameter in real time. The additional torque required for the change in dynamic inertia is added to the given value of the drive torque to offset the effect of the change in coil diameter on tension control; the friction loss compensation module compensates for the mechanical friction loss of the uncoiler 101 and the coiler 303. It calculates the compensation torque required for mechanical friction loss in real time according to the equipment operating speed and transmission chain characteristics and adds it to the given value of the drive torque. Through the coordinated compensation of the above three modules, the tension is kept constant throughout the entire process of the steel coil diameter changing from full roll to small roll, and the tension fluctuation caused by the change in coil diameter, change in inertia and change in friction loss is suppressed.

[0051] The full-process tension zone collaborative control equipment of the foil leveling unit also includes a weld seam tracking device, which is connected to the central control system to detect the position of the weld seam on the foil. The weld seam tracking device uses photoelectric sensors or ultrasonic sensors to detect the weld seam on the strip surface in real time. When a weld seam signal is detected, the weld seam position signal is immediately sent to the central control system. According to the weld seam position signal detected by the weld seam tracking device, the central control system automatically controls the unit to decelerate along the S-shaped deceleration curve to the shearing speed to avoid strip breakage or deviation caused by sudden tension change due to rapid deceleration. When the weld seam reaches the preset shearing position, the central control system controls the exit shearing device (exit shearing machine 301) to perform the shearing operation, cutting off the weld seam to achieve rewinding or rejection of defective weld seams. After the shearing is completed, the central control system automatically controls the unit to return to the normal operating speed along the S-shaped acceleration curve, realizing continuous and uninterrupted production when the weld seam passes through without manual intervention.

[0052] The following examples illustrate the specific implementation of the present invention using a leveling production line designed for a maximum speed of 100m / min, used to process titanium alloy foil with a thickness of 0.05-0.5mm and a width of 200-600mm.

[0053] (I) Overall Structure and Control Architecture of the Unit: The foil leveling unit in this embodiment includes an inlet section, a process section, and an outlet section along the strip travel direction, forming a continuous production line. The corresponding tension coordination control system adopts a central control and zoned coordinated execution architecture.

[0054] The central control system is based on a Siemens S7-1516 PLC. This PLC communicates at high speed with the entire drive system, distributed I / O stations (ET200SP), operator stations, and dedicated instruments via PROFINET industrial Ethernet to ensure the real-time performance and synchronization of tension control commands and feedback signals.

[0055] (II) Implementation of tension control in the inlet section: Please refer to Figure 1 The inlet section mainly includes an uncoiler 101, an inlet pinch roll 102, a jumping roll 103, an inlet shear 104, and a welding machine 105.

[0056] Uncoiling tension establishment: The uncoiler 101 adopts a single-cantilever hydraulic expansion and contraction structure, driven by a vector frequency conversion motor. The PLC sends a torque setpoint to the driver of the uncoiler 101 via PROFINET. This setpoint is composed of three parts: the base torque based on the uncoiling tension set by the human-machine interface and the real-time roll diameter calculation; the inertia compensation torque calculated by the roll diameter calculation module and the inertia compensation module; and the mechanical friction loss compensation torque calculated by the friction loss compensation module. The encoder at the motor shaft end of the uncoiler 101 provides real-time feedback of the rotational speed for roll diameter calculation and speed closed-loop control.

[0057] Tension buffering and detection of bounce rollers: Please continue reading Figure 1 The floating roller of the jumping roller 103 is supported by a swing arm, and an absolute encoder is installed at its shaft. The jumping roller 103 is activated when the strip thickness is less than 0.12mm. The PLC sets the cylinder pressure via an electro-proportional valve based on the inlet tension target set on the human-machine interface, providing initial tension to the strip. During operation, the positional offset of the floating roller directly reflects the fluctuation of the inlet tension. The PLC collects encoder signals in real time, and when the position deviates from the equilibrium point, it finely adjusts the speed of the uncoiler 101 or the inlet pinch roller 102 to stabilize the floating roller at the preset position, achieving indirect closed-loop control of the inlet tension. The jumping roller 103 adopts an aluminum alloy roller body and low-friction bearing design to ensure high sensitivity to changes in the tension of thin strips.

[0058] Threading and shearing assistance: The inlet pinch roller 102 and the inlet shear 104 work during threading and shearing, and are sequentially controlled by PLC. The speed of their drive motors is coordinated with the speed of the uncoiler 101 to avoid drastic changes in tension during this process.

[0059] (III) Implementation of tension and elongation control in the process section: Please refer to Figure 1 The process section includes the process area inlet tension roller group 201, tension straightener 202, multi-roll straightener 203, process area outlet tension roller group 204, and tension meter 205.

[0060] Speed ​​control and tension establishment of the drive roller groups: Both the process zone inlet tension roller group 201 and the process zone outlet tension roller group 204 are "four-roller" structures with four drive rollers and two pressure rollers. The drive rollers are driven by independent vector frequency converter motors, and each drive roller group is equipped with a high-precision encoder. The PLC sends the master speed setpoint to the driver of each drive roller via PROFINET. The process zone inlet tension roller group 201 is the actuator for establishing and adjusting the tension of the process section. The pressure roller is pressed down by a cylinder to ensure sufficient friction between the strip and the drive roller to transmit the required tension.

[0061] Dual-mode control of the tension straightening machine: The tension straightening machine 202 has a "two-bending and two-straightening" structure, and its control logic is implemented by the control function block in the PLC.

[0062] When the elongation control mode is selected, the PLC uses the encoders of the process zone inlet tension roller group 201 and the process zone outlet tension roller group 204 as measurement references. Within one scan cycle, it calculates the pulse increments ΔP_in and ΔP_out of the two encoders respectively, and the actual elongation ε = (ΔP_out - ΔP_in) / ΔP_in. The actual elongation is compared with the target elongation set by the human-machine interface (e.g., 0.8%), and after PID calculation, it outputs a correction amount ΔV for the overall speed of the process zone inlet tension roller group 201. The tensile deformation of the strip is controlled by increasing or decreasing the inlet speed.

[0063] When tension control mode is selected, the PLC reads the signal from tension meter 205, converts it into the actual tension value F_act, compares it with the target tension value F_set set by the human-machine interface, and outputs the correction amount ΔT for the total driving torque of tension roller group 201 at the entrance of the process area after PID calculation. The tension of the process section is stabilized by directly adjusting the driving torque.

[0064] In both modes, the pressing amount of the upper bending roller box, lower bending roller box, and straightening roller box of the tension straightener 202 is controlled by an independent hydraulic system. The set value is given by the human-machine interface according to the material specifications and works in conjunction with the tension control system.

[0065] Precision shape control of the multi-roll straightener: The multi-roll straightener 203 is integrated into the process section, located after the tension straightener 202. Its roll gap adjustment motor, upper roll system yaw motor, and lower roll system crown adjustment motor are all controlled by small vector frequency converters, receiving PLC commands. The PLC can automatically or manually set different roll gap and crown modes according to the characteristics of the incoming material's shape defects, combining with elongation control or tension control to achieve a final shape target of no more than 0.5 mm / m. The precision assembly and high-hardness surfaces of its work rolls, intermediate rolls, and support rolls provide precise stretching and straightening for thin foils.

[0066] Direct tension detection: Please refer to Figure 1At the end of the process section, adjacent to the tension roller group 204 at the process area exit, there is a guide roller with a tension meter 205. The tension meter 205 provides direct and high-precision feedback on the tension of the process section and is an important sensor in the tension control mode. At the same time, it serves as an important safety monitoring parameter in the elongation control mode.

[0067] (iv) Implementation of tension and winding control at the exit section: Please refer to Figure 1 The export section mainly includes the export shearing machine 301, the export pinch roll and EPC device 302, and the winding machine 303.

[0068] Winding tension control: The winding machine 303 is driven by a vector frequency converter motor for tension control at the exit section. The torque command sent by the PLC to the driver of the winding machine 303 also includes three parts: the base torque calculated based on the set winding tension and real-time coil diameter, the inertia compensation torque caused by changes in coil diameter, and the mechanical friction loss compensation torque. In addition, the system also introduces a tension taper control function. As the diameter of the steel coil increases, the PLC gradually reduces the tension set value according to a preset curve to prevent excessive pressure on the inner layer and the formation of wrinkles.

[0069] EPC Automatic Edge Position Control: To ensure neat winding, the winding machine 303 is equipped with an EPC (Edge Position Control) system. A photoelectric scanning head detects the edge position of the strip, and its controller calculates the deviation signal, sending it to the PLC. The PLC then controls the servo hydraulic cylinders that drive the overall lateral movement of the winding machine 303 via an analog output module. During high-speed winding, the EPC system and the winding tension control system operate independently yet cooperate to jointly ensure the roll shape quality.

[0070] Export shearing: The export shearing machine 301 is used for slitting or cutting weld seams. Its operation is automatically triggered by the PLC based on the signal from the weld seam tracking device. During the shearing process, the PLC coordinates the speed of the winding machine 303 and the exit tension roller group 204 in the process area to maintain the basic stability of the tension in the exit section and avoid loosening of the roll layer due to a sudden drop in tension caused by the shearing action.

[0071] This invention also provides a method for full-process tension zone coordinated control of a foil leveling unit, applicable to a full-process tension zone coordinated control device for a foil leveling unit. Please refer to [link to relevant documentation]. Figure 3 The control method includes the following steps: Step S1: Parameter setting.

[0072] The tension target values ​​for the uncoiling area, process area, and coiling area are set through the human-machine interface. A first tension range is set for the uncoiling area to prevent the strip from stretching and deforming due to excessive tension or loosening between layers due to insufficient tension during uncoiling. A second tension range is set for the process area, and the maximum value of the second tension range is greater than the maximum values ​​of the first and third tension ranges to ensure that the process area has sufficient tensile correction capacity to eliminate strip shape defects. A third tension range is set for the coiling area to ensure that the finished steel coil is neat and that no wrinkles are generated in the inner layer. At the same time, either the elongation control mode or the tension control mode is selected for the process area. If the elongation control mode is selected, the target elongation rate is also set.

[0073] Step S2: Collaborative Start-up and Setup.

[0074] The central control system coordinates the start of the uncoiling machine 101, drive roller and winding machine 303 in the foil leveling unit according to the set parameters. It adopts an S-shaped speed ramp function to achieve smooth acceleration and avoid tension impact caused by sudden acceleration. It sequentially establishes the initial tension of the whole process from the uncoiling area to the winding area to ensure that the strip is subjected to uniform force on the whole production line.

[0075] Step S3: Real-time data acquisition.

[0076] The system acquires real-time tension values ​​detected by the tension detection feedback system, including the floating roller position signal of the jumping roller 103 and the real-time tension value of the tension meter 205. At the same time, it acquires the speed signals of the encoders on the tension roller group 201 at the entrance of the process area and the tension roller group 204 at the exit of the process area, providing a data basis for tension closed-loop control and elongation calculation.

[0077] Step S4: Execution of elongation control mode.

[0078] If the current selection is the elongation control mode, the actual elongation is calculated based on the rotational speed signals of the inlet tension roller group 201 and the outlet tension roller group 204 of the process zone. The formula for calculating the actual elongation is that the elongation is equal to the difference between the outlet speed and the inlet speed divided by the inlet speed. The actual elongation is compared with the preset elongation target value, and the driving torque or speed setpoint of the inlet tension roller group 201 of the process zone is dynamically adjusted through the closed-loop adjustment algorithm to create a speed difference between the inlet tension roller group 201 and the outlet tension roller group 204 of the process zone. This causes the strip to produce the set elastic-plastic elongation in the tension leveler 202 and the multi-roll straightener 203, and the actual elongation approaches the preset elongation target value, thereby achieving precise control of the strip shape correction amount.

[0079] Step S5: Tension control mode is executed.

[0080] If the current selected mode is tension control, the real-time tension value detected by the tension meter 205 is compared with the preset tension target value. The driving torque of the tension roller group 201 at the process zone entrance is dynamically adjusted through a closed-loop control algorithm. When the real-time tension value is lower than the preset tension target value, the driving torque of the tension roller group 201 at the process zone entrance is increased to improve the tension in the process zone. When the real-time tension value is higher than the preset tension target value, the driving torque of the tension roller group 201 at the process zone entrance is decreased to reduce the tension in the process zone, so that the real-time tension value is stabilized near the preset tension target value. Priority is given to ensuring the safety of the strip material under stress in the tension leveler 202 and the multi-roller straightener 203, and reducing the risk of strip breakage during the straightening process of ultra-thin foil.

[0081] Step S6: Dynamic compensation.

[0082] During operation, the coil diameter of uncoiler 101 and coiler 303 is calculated and dynamically compensated. The current coil diameter is calculated in real time based on the rotational speed and linear speed of uncoiler 101 and coiler 303. The coil diameter of uncoiler 101 gradually decreases during the unwinding process, while the coil diameter of coiler 303 gradually increases during the winding process. The rotational inertia of uncoiler 101 and coiler 303 is compensated based on the current coil diameter change. When the coil diameter increases, the rotational inertia increases; when the coil diameter decreases, the rotational inertia decreases. The additional torque required due to the change in rotational inertia is calculated in real time and added to the drive torque setpoint. At the same time, mechanical friction loss is compensated for in uncoiler 101 and coiler 303. The compensation torque required for mechanical friction loss is calculated in real time based on the equipment operating speed and transmission chain characteristics and added to the drive torque setpoint. Through the above compensation, the tension in the unwinding and coiling areas is kept stable throughout the entire process of the steel coil diameter changing from full coil to small coil, and tension fluctuations caused by changes in coil diameter, inertia, and friction loss are suppressed.

[0083] In this embodiment, the foil material includes titanium, zirconium, nickel or their alloys, with a thickness ranging from 0.05mm to 0.5mm and a width ranging from 200mm to 600mm. The above materials have the characteristics of high strength, low plasticity and high resilience. After cold rolling, they are prone to complex plate shape defects. The full-process tension zone collaborative control equipment and method of the present invention are used for leveling.

[0084] The flatness of the leveled foil sheet is no greater than 0.5 mm / m, meaning that within any 1-meter length along the strip's length, the maximum deviation between the strip surface and the reference plane does not exceed 0.5 mm. This indicator is ensured by the following technical features: zoned tension coordination control in the uncoiling zone, process zone, and winding zone ensures uniform stress on the strip along its entire length; selective switching between elongation control mode and tension control mode in the process zone achieves a balance between sheet shape correction accuracy and production safety; precise speed control of the inlet tension roller group 201 and the outlet tension roller group 204 in the process zone enables the strip to achieve the set elastic-plastic elongation; the roller gap, sway, and crown adjustment of the multi-roll straightener 203 further straightens the sheet shape; dynamic compensation from the roll diameter calculation module, inertia compensation module, and friction loss compensation module maintains constant tension, avoiding the impact of tension fluctuations on sheet shape quality. Through the combined effect of the above technical solutions, high-precision leveling of high-strength ultra-thin foil is ultimately achieved, with a sheet shape flatness of no more than 0.5 mm / m, a superior level.

[0085] From a spatial perspective, this invention achieves seamless connection and independent control of tension in the uncoiling zone, process zone, and coiling zone. In the uncoiling zone, a stable inlet tension is established through the coordinated operation of the uncoiler 101, the inlet pinch roller 102, and the jumping roller 103. In the process zone, high-precision adjustment of process tension is achieved through the cooperation of the process zone inlet tension roller group 201, the tension leveler 202, the multi-roll straightener 203, the process zone outlet tension roller group 204, and the tension meter 205. In the coiling zone, the coil shape quality of the finished steel coil is ensured through the coordinated control of the outlet pinch roller, the EPC device 302, and the coiler 303. The tension control systems of the three zones are independently set yet mutually coordinated under the unified coordination of the central control system, ensuring uniform and stable stress on the strip throughout the entire production line.

[0086] In terms of control modes, this invention provides flexible selection and dynamic switching capabilities between elongation control mode and tension control mode in the process zone. For materials with severe shape defects, the elongation control mode can be selected to prioritize the shape correction effect by controlling the elastic-plastic elongation of the strip. For extremely thin or easily broken materials, the tension control mode can be selected to prioritize production safety and reduce the risk of strip breakage by stabilizing the tension in the process section. This dual-mode design enables the unit to flexibly adapt to the foil leveling needs of different materials, specifications, and process requirements.

[0087] From a temporal perspective, this invention smoothly handles all transient processes, including threading, acceleration, speed stabilization, deceleration, shearing, and diameter changes, through dynamic compensation and intelligent sequential control. The coil diameter calculation module, inertia compensation module, and friction loss compensation module provide real-time torque compensation for the uncoiler 101 and coiler 303, effectively suppressing tension fluctuations caused by changes in the steel coil diameter. The jumping roller 103 provides tension buffering and indirect control during the production of ultra-thin foil materials. The weld seam tracking device enables automatic deceleration, shearing, and recovery operation, ensuring stable tension as the weld seam passes through. These mechanisms ensure that the system maintains stable tension throughout the dynamic process, significantly reducing the risks of strip breakage, deviation, and wrinkling.

[0088] In summary, this invention deeply integrates advanced automated control software with precision mechanical equipment specially designed for foil materials, forming a dedicated hardware and software integrated solution. It achieves high-precision coordinated control of tension in high-strength foil materials such as titanium, zirconium, nickel and their alloys throughout the entire process from unwinding to winding. After leveling, the flatness of the strip is no more than 0.5 mm / m, which significantly improves product quality and production efficiency.

[0089] Those skilled in the art will understand that the above embodiments are specific examples of implementing the present invention, and in practical applications, various changes in form and detail may be made without departing from the spirit and scope of the present invention.

Claims

1. A full-process tension partition cooperative control device of a foil material flattening unit, characterized in that, include: The central control system is configured to coordinate the control of multiple tension control zones of the foil leveling unit; The transmission system includes multiple vector frequency conversion motors and corresponding drivers, which are respectively connected to the central control system for driving the unwinder (101), transmission rollers and winding machine (303) in the foil leveling unit. The transmission rollers include at least the process area inlet tension roller group (201) and the process area outlet tension roller group (204). The tension detection feedback system is communicatively connected to the central control system and is used to detect the real-time tension value of at least one tension control zone in the foil leveling unit and feed it back to the central control system. The central control system is further configured as follows: Based on the preset tension setting value, the tension of the multiple tension control zones is independently controlled; and based on the feedback signal of the tension detection feedback system, the tension control zone is selectively switched between the elongation control mode and the tension control mode.

2. The full-process tension partition collaborative control device of the foil leveling unit according to claim 1, characterized in that, The multiple tension control zones include an unwinding zone, a process zone, and a winding zone; The inlet tension roller group (201) and the outlet tension roller group (204) of the process area are both located in the process area; The central control system is also configured to: A first tension range is set for the unwinding area, a second tension range is set for the process area, and a third tension range is set for the winding area, wherein the maximum value of the second tension range is greater than the maximum value of the first tension range and the third tension range.

3. The full-process tension partition collaborative control device of the foil leveling unit according to claim 2, characterized in that, The elongation control mode includes: The first speed signal of the foil at the entrance side of the process zone and the second speed signal at the exit side of the process zone are obtained. The actual elongation is calculated based on the first speed signal and the second speed signal. The actual elongation is compared with the preset elongation target value. The driving parameters of the tension roller group (201) at the entrance of the process zone are adjusted according to the comparison result so that the actual elongation approaches the preset elongation target value.

4. The full-process tension partition collaborative control device of the foil leveling unit according to claim 2, characterized in that, The tension control modes include: The real-time tension value detected by the tension detection feedback system is obtained, and the real-time tension value is compared with the preset tension target value. The driving torque of the tension roller group (201) at the entrance of the process area is adjusted according to the comparison result so that the real-time tension value approaches the preset tension target value.

5. The full-process tension zone coordinated control equipment for the foil leveling unit according to claim 3, characterized in that, The tension detection feedback system includes: A jumping roller device, disposed in the unwinding area, includes a floating roller and a loading mechanism for applying adjustable pressure to the floating roller; Tension meter (205) is installed on the outlet side of the process zone to directly detect the tension in the process zone.

6. The full-process tension zone coordinated control equipment for the foil leveling unit according to claim 5, characterized in that, The central control system is also configured to: When the foil thickness is less than the preset thickness threshold, the foil is made to run through the jumping roller device, and the jumping roller device is used for tension buffering and indirect control. When the foil thickness is greater than or equal to the preset thickness threshold, the foil is prevented from passing through the jumping roller device.

7. The full-process tension zone coordinated control equipment for the foil leveling unit according to claim 1, characterized in that, The central control system also includes: A roll diameter calculation module is used to calculate the current roll diameter of the uncoiler (101) and / or the rewinder (303) in real time; An inertia compensation module is used to compensate for the rotational inertia of the uncoiler (101) and / or the winding machine (303) based on the current roll diameter change. The friction loss compensation module is used to compensate for mechanical friction loss of the uncoiler (101) and / or the winding machine (303).

8. The full-process tension zone coordinated control equipment for the foil leveling unit according to claim 1, characterized in that, Also includes: A weld seam tracking device, which is communicatively connected to the central control system, is used to detect the position of the weld seam on the foil. The central control system automatically controls the unit to decelerate based on the weld position signal detected by the weld tracking device. When the weld reaches the preset shearing position, it controls the outlet shearing device to perform the shearing operation. After the shearing is completed, it automatically controls the unit to return to normal operating speed.

9. A method for full-process tension zone coordinated control of a foil leveling unit, applied to the full-process tension zone coordinated control equipment of the foil leveling unit as described in any one of claims 1-8, characterized in that, Includes the following steps: Set target tension values ​​for multiple tension control zones, and select either the elongation control mode or the tension control mode for at least one of the tension control zones; Coordinate the start-up of the unwinder (101), drive roller and winding machine (303) in the foil leveling unit to establish the initial tension for the entire process from unwinding to winding; The real-time tension value detected by the tension detection feedback system is acquired in real time; If the current selection is the elongation control mode, the actual elongation is calculated based on the rotation speed signals of the process zone inlet tension roller group (201) and the process zone outlet tension roller group (204), and the drive parameters of the process zone inlet tension roller group (201) are adjusted in a closed loop so that the actual elongation approaches the preset elongation target value. If the current selection is tension control mode, the driving torque of the tension roller group (201) at the entrance of the process area is adjusted in a closed loop according to the real-time tension value, so that the real-time tension value approaches the preset tension target value. During operation, the unwinder (101) and / or the rewinder (303) are subjected to roll diameter calculation and dynamic compensation to maintain the tension stability of the unwinding zone and the winding zone.

10. The full-process tension zone coordinated control method for foil leveling units according to claim 9, characterized in that, The foil material includes titanium, zirconium, nickel or their alloys, with a thickness ranging from 0.05mm to 0.5mm and a width ranging from 200mm to 600mm; The flatness of the leveled foil sheet should not exceed 0.5 mm / m.

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