An intelligent control system for drying aluminum foil composite paper semi-finished products and a control method thereof

Abstract

The application discloses an intelligent regulation and control system for drying aluminum foil composite paper semi-finished products and a regulation and control method thereof, relates to the technical field of aluminum foil composite paper production and manufacturing, and realizes accurate control over the drying process by dividing a preheating temperature rising zone, a constant temperature curing zone and a gradient temperature dropping balancing zone, and arranging an independent air supply and return subsystem and a temperature control subsystem; meanwhile, in combination with working condition parameters and material online state parameters collected in real time by a multi-source sensing acquisition unit and a multi-target collaborative optimization regulation and control model built in a central intelligent regulation and control unit, the system can dynamically adjust drying parameters according to preset product quality thresholds, ensures that an adhesive is fully crosslinked and cured, harmful solvents are completely volatilized, and the water content of a paper base is accurately controlled, and thus the aluminum foil composite paper has better physical and mechanical properties and safety; in addition, the system also has a heat energy recycling mechanism and self-diagnosis and self-adaptive regulation and control capabilities, effectively reduces energy consumption and operation cost, and improves production efficiency and product quality stability.

Description

Technical Field

[0001] This invention relates to the field of aluminum foil composite paper production and manufacturing technology, specifically to an intelligent control system and control method for drying semi-finished aluminum foil composite paper. Background Technology

[0002] With the widespread application of aluminum foil composite paper in food packaging, pharmaceutical packaging, and other fields, the drying process has become a key factor affecting product quality and production efficiency. After the aluminum foil composite paper semi-finished product is coated with adhesive, it needs to undergo a drying process to ensure that the adhesive is fully cross-linked and cured, while ensuring that harmful solvents completely evaporate and the moisture content of the paper base is precisely controlled, so as to meet the final physical properties and hygiene and safety requirements of the product.

[0003] Traditional aluminum foil composite paper drying technology often employs fixed process parameters, making it difficult to dynamically adjust based on the actual state of the material and changes in operating conditions during the drying process. This drying method often results in low drying efficiency and inconsistent product quality. For example, excessively high drying temperatures may cause premature curing of the adhesive layer, affecting interlayer peel strength; excessively low drying temperatures may lead to incomplete solvent evaporation, affecting product hygiene and safety. Furthermore, traditional drying technologies lack effective heat recovery mechanisms, resulting in significant heat loss and high energy consumption, increasing production costs. In addition, traditional drying systems often lack self-diagnostic and adaptive adjustment capabilities, making it difficult to respond quickly to malfunctions or changes in operating conditions, impacting the continuity and stability of production.

[0004] In view of the problems of low drying efficiency, unstable product quality and high energy consumption in traditional aluminum foil composite paper drying technology, the present invention proposes an intelligent control system and control method for drying semi-finished aluminum foil composite paper, which is of particular importance. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of existing technologies and provide an intelligent control system and method for drying semi-finished aluminum foil composite paper. This system achieves precise control of the drying process by dividing the process into preheating zones, constant-temperature curing zones, and gradient cooling equilibrium zones, and by setting up independent air supply and return subsystems and temperature control subsystems. Simultaneously, by combining real-time data collected from multi-source sensing units with online material status parameters, and the multi-objective collaborative optimization control model built into the central intelligent control unit, the system can dynamically adjust drying parameters according to preset product quality thresholds. This ensures sufficient cross-linking and curing of the adhesive, complete evaporation of harmful solvents, and precise control of the paper base moisture content, thereby giving the aluminum foil composite paper better physical and mechanical properties and safety. Furthermore, the system also features a heat recovery mechanism and self-diagnosis and adaptive adjustment capabilities, effectively reducing energy consumption and operating costs, and improving production efficiency and product quality stability.

[0006] To solve the above-mentioned technical problems, the present invention provides the following technical solution: In one aspect, an intelligent control system for drying semi-finished aluminum foil composite paper, the system comprising the following components:

[0007] The drying chamber unit is divided into a preheating zone, a constant temperature curing zone, and a gradient cooling balance zone along the conveying direction of the aluminum foil composite paper semi-finished product. Each zone is equipped with an independent air supply and return subsystem and a temperature control subsystem.

[0008] The material conveying unit is used to pull the aluminum foil composite paper semi-finished product through the various functional areas of the drying chamber unit at a preset linear speed.

[0009] The multi-source sensor acquisition unit is connected to the central intelligent control unit for real-time acquisition of operating parameters and material online status parameters during the drying process, and transmits the acquired real-time data to the central intelligent control unit.

[0010] The central intelligent control unit has a built-in multi-objective collaborative optimization control model, which is used to receive real-time data from multi-source sensor acquisition units, combine it with preset product quality thresholds, generate multi-dimensional control instructions, and send them to multi-dimensional execution units.

[0011] The multi-dimensional execution unit communicates with the central intelligent control unit to receive control commands and perform real-time closed-loop adjustment of the drying parameters of each zone of the drying chamber unit.

[0012] Furthermore, each functional zone of the drying chamber unit is equipped with a symmetrical air supply static pressure chamber and a return air chamber. The air outlet of the air supply static pressure chamber is equipped with a uniform air distribution plate. The opening ratio of the uniform air distribution plate changes gradually from the feeding end to the discharging end along the material conveying direction. The opening ratio of the preheating zone decreases from 30% to 20%, the opening ratio of the constant temperature curing zone remains stable at 20%, and the opening ratio of the gradient cooling balance zone increases from 20% to 30%. A circulating air duct is set between the return air chamber and the air supply static pressure chamber of each zone. A heat exchange device is installed in the circulating air duct to recover the waste heat of the return air and preheat the fresh air, thereby reducing the heat loss during the drying process. At the same time, each zone's cavity is equipped with a thermal insulation layer. The thermal insulation layer is made of 100mm thick aluminum silicate refractory fiber cotton to avoid temperature crosstalk between zones and ensure the independent control accuracy of the drying parameters of each zone.

[0013] Furthermore, the servo traction mechanism of the material conveying unit is equipped with active traction rollers at the feeding end and the discharging end of the drying chamber, respectively. The active traction rollers at the feeding end and the discharging end are synchronously servo driven to ensure stable conveying tension of the material in the drying chamber. A tension controller is set at the front end of the active traction roller at the feeding end to collect the conveying tension data of the material in real time and transmit the data synchronously to the central intelligent control unit. Linear speed encoders are respectively installed on the roller shafts of the active traction rollers at the feeding end and the discharging end to collect the actual conveying linear speed of the two traction rollers in real time. The central intelligent control unit adjusts the output speed of the servo motors of the two active traction rollers according to the difference between the two linear speed encoders to eliminate the stretching deformation of the material during the drying process and ensure uniform and stable material conveying.

[0014] Furthermore, the material state acquisition module of the multi-source sensing acquisition unit has an initial state detection component at the feed inlet of the drying chamber, with three sets of detection probes evenly spaced along the width of the material, corresponding to the left, middle, and right edges of the material, respectively, to simultaneously collect the initial moisture content and adhesive application amount data of the entire material width. The process detection components at the outlets of each functional zone and the final inspection components at the discharge outlet are each equipped with five sets of detection probes evenly spaced along the width of the material, to collect the moisture content, adhesive curing degree, and solvent residue data of the entire material width in real time. All detection probes maintain a fixed detection distance of 150mm from the material surface, and the sampling frequency of the detection data is set to 10Hz, accurately capturing the drying uniformity deviation in the width of the material, and providing data support for the fine-tuning of the drying parameters across the entire width.

[0015] Furthermore, the multi-objective collaborative optimization control model built into the central intelligent control unit solves for the optimal drying parameters through a multi-objective comprehensive optimization objective function, the expression of which is: ,in To comprehensively optimize the target value, the larger the value, the better the overall drying effect. The target value is to be the maximum value of this value. The real-time curing degree of the adhesive layer is obtained in real time by the online detection device for the curing degree of the adhesive layer of the multi-source sensing acquisition unit; A target threshold for the curing degree of the adhesive layer is preset, which is set in advance according to the product process requirements; The real-time residual amount of solvent is obtained in real time by an online gas chromatograph solvent residue detector; An upper limit threshold for solvent residue is preset, which is set in advance by the product's hygiene and safety standards. The real-time moisture content of the paper base is obtained in real time by an online infrared moisture content analyzer. A target center value for the moisture content of the paper base is preset, which is determined in advance based on the product's physical performance requirements. The real-time energy consumption of the drying system is collected in real time by the power acquisition module of each zone execution unit; The baseline energy consumption value for traditional fixed processes under the same production capacity is calibrated in advance by offline production testing; , , , The weighting coefficients for curing degree, solvent residue, moisture content, and energy consumption are respectively, with the sum of the four weighting coefficients being 1. These coefficients were determined through a 3-factor, 4-level orthogonal experiment combined with range analysis. , , , The weighting coefficients are determined based on the production priority of aluminum foil composite paper for food packaging, with hygiene and safety and adhesion performance as the core priority, physical properties as the second priority, and energy consumption optimization as an auxiliary constraint.

[0016] Furthermore, the adaptive closed-loop control module of the central intelligent control unit generates a real-time control amount through a control deviation correction formula that provides feedforward compensation for material input. The expression of the correction formula is as follows: ,in The real-time adjustment parameters for drying, corresponding to the adjustment range of temperature, wind speed, and air volume, are directly sent to the multi-dimensional execution unit. The real-time deviation value of the core drying parameters is the difference between the preset threshold and the real-time value of the multi-objective comprehensive optimization target value, which is calculated in real time by the multi-objective collaborative optimization control model. This is the proportional gain coefficient, with a value ranging from 0.8 to 1.2, obtained through offline step response testing and calibration of the system. The integral gain coefficient, with a value ranging from 0.1 to 0.3, is obtained through offline step response testing and calibration of the system. The differential gain coefficient, with a value ranging from 0.05 to 0.15, is obtained through offline step response testing and calibration of the system. This is the feedforward compensation coefficient for incoming materials, ranging from 0.8 to 1.5. It is calculated in real time from the deviation between the incoming material's adhesive application amount and initial moisture content, collected by the initial state detection component at the feed inlet, and the reference value. When the incoming material's adhesive application amount or initial moisture content is higher than the reference value, The amount of adjustment of drying parameters is increased synchronously and compensated in advance to eliminate the adjustment deviation caused by the large lag characteristic of the drying process.

[0017] Furthermore, the model self-iteration module of the central intelligent control unit receives offline quality inspection data of the finished products in real time. The offline quality inspection data includes the moisture content of the finished products, the curing degree of the adhesive layer, the solvent residue, the interlayer peel strength, and the number of folding cycles. The module compares the offline inspection data with the online data collected during the drying process and the model prediction data, and calculates the prediction deviation value of the model. When the prediction deviation value exceeds the preset 5% threshold, the module automatically starts the model iteration optimization process, and updates the neural network weights of the key parameter prediction module using incremental learning. During the update process, 90% of the original basic weights of the model are retained, and only the 10% weights corresponding to the deviation are adjusted to avoid overfitting problems in model iteration. At the same time, the iteratively optimized model parameters are synchronously updated to the system runtime library to continuously improve the model's control accuracy and scene adaptability.

[0018] Furthermore, the temperature execution module and wind speed and air volume execution module of the multi-dimensional execution unit form a single-zone independent closed-loop control link with the sensing and acquisition components of the corresponding zone. The temperature execution module of each zone adopts a grouped electric heating tube layout, and the electric heating tube is divided into 3 groups of independent control units. The output power of the corresponding heating unit is adjusted according to the real-time temperature distribution in the zone. The variable frequency fan and air valve actuator of the wind speed and air volume execution module adopt a linkage control mode. The fan frequency adjustment range is 10-50Hz, and the air valve opening adjustment range is 0-100%. The fan frequency and air valve opening are adjusted synchronously according to the control command to ensure stable matching of the air supply speed and circulating air volume in the zone, avoid air pressure fluctuations caused by single parameter adjustment, and improve the control stability of drying parameters.

[0019] Furthermore, the central intelligent control unit is equipped with a dual-machine hot standby redundancy architecture, including a main controller and a backup controller. The main controller and the backup controller adopt a real-time data synchronization mode, synchronously receiving collected data and issuing control commands. When the main controller fails and stops, the backup controller automatically switches to the main control state within 100ms, taking over all control functions of the system to avoid production interruption. At the same time, the system is equipped with an abnormal early warning and safety shutdown module to monitor the system's operating status in real time. When the collected data shows abnormal changes or the execution unit fails, the module issues an audible and visual warning immediately and executes the corresponding safety handling procedure according to the fault level. The fault levels are divided into three levels: Level 1 faults execute speed reduction operation, Level 2 faults execute constant temperature standby operation, and Level 3 faults execute emergency shutdown operation to ensure the safety and stability of system operation.

[0020] On the other hand, a method for intelligent control of drying semi-finished aluminum foil composite paper includes the following specific steps:

[0021] S1. System initialization and parameter calibration: Based on the substrate specifications, adhesive type and product quality requirements of the aluminum foil composite paper semi-finished product to be produced, preset the product quality target threshold and drying benchmark process parameters, and complete the calibration of the multi-source sensor acquisition unit and the system's full-link self-test.

[0022] S2. Real-time online data acquisition: During the continuous drying process of aluminum foil composite paper semi-finished products, the working condition parameters of each functional zone of the drying chamber, as well as the online status parameters of the material at the feed inlet, each zone outlet and discharge outlet are collected in real time through the multi-source sensor acquisition unit, and all collected data are synchronously transmitted to the central intelligent control unit.

[0023] S3. Multi-dimensional status assessment and deviation calculation: After preprocessing the real-time collected data, the central intelligent control unit comprehensively assesses the material status and system operating conditions of the current drying process through a multi-objective collaborative optimization control model, and calculates the deviation between the real-time status and the preset product quality target threshold.

[0024] S4. Generation of multi-objective collaborative optimization control instructions: Based on the state assessment results and deviation, with the core optimization objectives of fully cross-linking and curing of adhesives, complete evaporation of harmful solvents, and precise control of paper base moisture content, and with the minimum drying energy consumption as the constraint objective, the optimal control values ​​of drying parameters for each functional zone are obtained through multi-objective optimization algorithm, and corresponding multi-dimensional control instructions are generated.

[0025] S5. Closed-loop execution and dynamic feedback: The control command is sent to the multi-dimensional execution unit to adjust the temperature, air volume and wind speed of each functional zone in real time. At the same time, the adjusted working condition parameters and material status data are collected in real time through the multi-source sensor acquisition unit and fed back to the central intelligent control unit to form a full closed-loop dynamic control.

[0026] S6. Offline Quality Verification and Model Iteration: Offline quality inspection is performed on the dried aluminum foil composite paper products. The offline inspection results are fed back to the central intelligent control unit, and the multi-objective collaborative optimization control model is updated and iterated online through the model self-iteration module.

[0027] Compared with existing technologies, the intelligent control system and method for drying semi-finished aluminum foil composite paper have the following advantages:

[0028] I. This invention achieves precise control over the drying process of aluminum foil composite paper semi-finished products by dividing the process into a preheating zone, a constant-temperature curing zone, and a gradient cooling equilibrium zone, and by setting up independent air supply and return subsystems and temperature control subsystems. This zoned control method, combined with real-time acquisition of operating parameters and online material status parameters by a multi-source sensing unit, and a multi-objective collaborative optimization control model built into the central intelligent control unit, can generate and issue multi-dimensional control instructions based on preset product quality thresholds. This ensures that the adhesive is fully cross-linked and cured, harmful solvents are completely volatilized, and the moisture content of the paper base is precisely controlled, thereby giving the aluminum foil composite paper better physical and mechanical properties and safety, and significantly improving drying efficiency and product quality.

[0029] Second, this invention incorporates circulating air ducts and heat exchange devices in each functional zone of the drying chamber unit. By recovering waste heat from the return air to preheat the fresh air, it effectively reduces heat loss during the drying process. Simultaneously, the central intelligent control unit uses a multi-objective optimization algorithm, with the minimum drying energy consumption as the constraint objective, to solve for the optimal control values ​​of the drying parameters for each functional zone, further reducing energy consumption. Furthermore, the system also features a self-iterative model function, continuously optimizing the control model based on offline quality inspection data, improving control accuracy and scenario adaptability, avoiding unnecessary energy waste, and thus reducing overall operating costs. Attached Figure Description

[0030] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the accompanying drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are merely some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without any creative effort.

[0031] Figure 1 A flowchart illustrating the overall collaborative workflow of an intelligent control system for drying semi-finished aluminum foil composite paper.

[0032] Figure 2 A flowchart for solving a multi-objective collaborative optimization control model of an intelligent control system for drying semi-finished aluminum foil composite paper;

[0033] Figure 3 This is a flowchart of an intelligent control method for drying semi-finished aluminum foil composite paper. Detailed Implementation

[0034] To further illustrate the technical means and effects of the present invention in achieving its intended purpose, the following detailed description of the specific implementation methods, structures, features, and effects of the present invention, in conjunction with the accompanying drawings and preferred embodiments, is provided below.

[0035] Example

[0036] This embodiment is applied to the continuous drying production of aluminum foil composite paper for food packaging. The semi-finished aluminum foil composite paper to be processed uses 80g / m² food-grade virgin wood pulp base paper as the substrate, and is laminated with 7μm thick food-grade aluminum foil. Water-based acrylic environmentally friendly adhesive is used for coating and lamination. The dry basis adhesive amount is controlled at 4-6g / m². The product must meet the relevant safety standards for food contact materials and the physical performance requirements for packaging.

[0037] Before production begins, system initialization and parameter calibration are completed. Based on the substrate specifications, adhesive type, and quality requirements of the food packaging products to be produced, the corresponding product quality target thresholds and drying baseline process parameters are preset. The full-range calibration of the multi-source sensor acquisition unit and the system's full-link operation self-test are then completed. The drying chamber unit is divided into three independent functional zones along the material conveying direction: a preheating zone, a constant temperature curing zone, and a gradient cooling balancing zone. Each zone is equipped with an independent air supply and return subsystem and a temperature control subsystem. Each functional zone has a symmetrical air supply static pressure chamber and a return air chamber. The air outlet of the air supply static pressure chamber is equipped with a uniform air perforation plate. The opening rate of the uniform air perforation plate in the preheating zone gradually decreases from 30% to 20% from the feed end to the discharge end. The opening rate of the uniform air perforation plate in the constant temperature curing zone remains stable at 20% throughout the process. The opening rate of the uniform air perforation plate in the gradient cooling balancing zone gradually increases from 20% to 30% from the feed end to the discharge end. A circulating air duct with a heat exchange device is set between the return air chamber and the air supply static pressure chamber of each zone. All cavities in each zone are covered with a thermal insulation layer. The servo traction mechanism of the material conveying unit has active traction rollers at both the inlet and outlet ends of the drying chamber. These two sets of active traction rollers use a synchronous servo drive mode. A tension controller is installed at the front end of the active traction roller at the inlet end, and linear speed encoders are installed on the roller shafts of both the inlet and outlet ends. The multi-source sensing acquisition unit has an initial state detection component at the inlet of the drying chamber, with three sets of detection probes evenly spaced along the material width direction, corresponding to the left, middle, and right edges of the material, respectively. Process detection components are installed at the outlets of each functional zone, and a final inspection component is installed at the outlet. Both the process and final inspection components have five sets of detection probes evenly spaced along the material width direction. The central intelligent control unit adopts a dual-machine hot standby redundant architecture, configuring a main controller and a backup controller. It completes the loading of basic parameters for the multi-objective collaborative optimization control model, including the basic parameter configuration of the multi-objective comprehensive optimization objective function and the control deviation correction formula with feedforward compensation. Simultaneously, it completes the fault level threshold calibration of the abnormal warning and safety shutdown modules.

[0038] In the continuous drying process of aluminum foil composite paper semi-finished products, the material is pulled by the servo traction mechanism of the material conveying unit at a preset linear speed through the three functional zones of the drying chamber unit. At the same time, the online real-time data acquisition of the entire drying process is completed by the multi-source sensing acquisition unit. Specifically, the three sets of detection probes at the feed inlet simultaneously collect the initial moisture content and adhesive coating amount data of the entire material width. The five sets of detection probes at the outlet of each functional zone collect the moisture content, adhesive curing degree and solvent residue data of the entire material width at the corresponding position in real time. The five sets of detection probes at the final inspection component at the discharge outlet simultaneously collect the final moisture content, adhesive curing degree and solvent residue data of the entire material width at the final state. At the same time, the operating parameters of each functional zone of the drying chamber, the real-time tension data during the material conveying process and the actual conveying linear speed data of the active traction rollers at both ends are collected simultaneously. All collected real-time data are transmitted synchronously to the central intelligent control unit.

[0039] After receiving real-time collected data, the central intelligent control unit first filters and preprocesses the data. Then, through a built-in multi-objective collaborative optimization control model, it performs a multi-dimensional comprehensive evaluation of the material state and system operating conditions of the current drying process. Combined with preset product quality target thresholds, it calculates the deviation between the real-time state of the core drying parameters and the preset targets. During the evaluation process, the multi-objective comprehensive optimization objective function is invoked to complete the comprehensive weight calculation and state determination of four dimensions: degree of curing, solvent residue, moisture content, and energy consumption. The expression of the objective function is: ,in To comprehensively optimize the target value; This refers to the real-time curing degree of the adhesive layer; Preset a target threshold for the curing degree of the adhesive layer; This refers to the real-time residual amount of solvent. Preset an upper limit threshold for solvent residue; Real-time moisture content of the paper base; A target center value is preset for the moisture content of the paper base; Real-time energy consumption of the drying system; This is the baseline energy consumption value for traditional fixed processes under the same production capacity; , , , These are the weighting coefficients for curing degree, solvent residue, moisture content, and energy consumption, respectively.

[0040] Based on the comprehensive state assessment results and the calculated real-time deviation, the central intelligent control unit takes the full cross-linking and curing of the adhesive, the complete evaporation of harmful solvents, and the precise control of the paper base moisture content as the core optimization objectives, and the minimum drying energy consumption as the constraint objective. It uses a multi-objective optimization algorithm to obtain the optimal control values ​​of the drying parameters for each functional zone. During the process, it calls the control deviation correction formula with feedforward compensation to calculate the real-time adjustment of the drying parameters; the expression of the correction formula is: ,in This refers to the real-time adjustment of drying parameters; This represents the real-time deviation value of the core drying parameters; This is the proportional gain coefficient; This is the integral gain coefficient; The differential gain coefficient; The incoming material feedforward compensation coefficient is used to generate corresponding multi-dimensional control instructions and send them to the multi-dimensional execution unit.

[0041] After receiving control commands from the central intelligent control unit, the multi-dimensional execution unit performs real-time closed-loop adjustment of the drying parameters of each functional zone of the drying chamber. Each zone's temperature and airflow execution modules form an independent closed-loop control link with the corresponding zone's sensor acquisition components. The temperature execution module uses a grouped electric heating tube layout, with the electric heating tubes divided into three independent control units. It adjusts the output power of the corresponding heating unit based on the real-time temperature distribution within the zone. The variable frequency fan and airflow actuator of the airflow execution module use a linkage control mode, synchronously adjusting the fan frequency and airflow valve opening according to the control commands. Simultaneously, the material conveying unit, based on the numerical difference collected by the linear speed encoders at the inlet and outlet ends, adjusts the output speed of the servo motors of the two active traction rollers according to the commands from the central intelligent control unit. This ensures stable conveying tension of the material within the drying chamber and eliminates stretching deformation during the drying process. During the adjustment process, the multi-source sensor acquisition unit collects the adjusted operating parameters and material status data in real time and continuously feeds them back to the central intelligent control unit, forming a fully closed-loop dynamic control of the entire drying process.

[0042] During the drying production process, the main controller and backup controller of the central intelligent control unit adopt a real-time data synchronization mode, synchronously receiving collected data and issuing control commands. When the main controller fails and stops, the backup controller automatically switches to the main controller state within 100ms, taking over all control functions of the system. At the same time, the system's abnormal early warning and safety shutdown module monitors the entire system's operating status in real time. When the collected data shows abnormal changes or the execution unit fails, the module issues an audible and visual warning immediately and executes the corresponding safety handling procedures according to the preset three-level fault levels. The first-level fault executes the speed reduction operation, the second-level fault executes the constant temperature standby operation, and the third-level fault executes the emergency shutdown operation.

[0043] Offline quality inspection is performed on the dried aluminum foil composite paper products. Inspection indicators include the finished product's moisture content, adhesive layer curing degree, solvent residue, interlayer peel strength, and folding endurance. The offline quality inspection data is fed back to the model self-iteration module of the central intelligent control unit. The module compares the offline inspection data with the online data collected during the drying process and the model prediction data, calculating the model's prediction deviation. When the prediction deviation exceeds a preset 5% threshold, the module automatically initiates the model iterative optimization process. Incremental learning is used to update the neural network weights of the key parameter prediction module. During the update process, 90% of the original basic weights of the model are retained, and only the 10% weights corresponding to the deviation are adjusted. Simultaneously, the iteratively optimized model parameters are updated to the system runtime library, completing the intelligent control and model self-optimization of the entire production process.

[0044] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Without departing from the scope of the technical solution of the present invention, some modifications or alterations can be made to the above-disclosed technical content to create equivalent embodiments. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the technical solution of the present invention shall still fall within the scope of the technical solution of the present invention.

Claims

1. An intelligent control system for drying semi-finished aluminum foil composite paper, characterized in that, The system includes the following components: The drying chamber unit is divided into a preheating zone, a constant temperature curing zone, and a gradient cooling balance zone along the conveying direction of the aluminum foil composite paper semi-finished product. Each zone is equipped with an independent air supply and return subsystem and a temperature control subsystem. The material conveying unit is used to pull the aluminum foil composite paper semi-finished product through the various functional areas of the drying chamber unit at a preset linear speed. The multi-source sensor acquisition unit is connected to the central intelligent control unit for real-time acquisition of operating parameters and material online status parameters during the drying process, and transmits the acquired real-time data to the central intelligent control unit. The central intelligent control unit incorporates a multi-objective collaborative optimization control model. This model receives real-time data from multi-source sensor acquisition units, combines it with preset product quality thresholds, and uses a multi-objective optimization algorithm to obtain the optimal control values ​​for the drying parameters of each functional zone. It then generates multi-dimensional control commands and sends them to the multi-dimensional execution units. The multi-objective collaborative optimization control model solves for the optimal drying parameters through a multi-objective comprehensive optimization objective function. The expression of the objective function is as follows: ,in To comprehensively optimize the target value; This refers to the real-time curing degree of the adhesive layer; Preset a target threshold for the curing degree of the adhesive layer; This represents the real-time residual amount of solvent. Preset an upper limit threshold for solvent residue; Real-time moisture content of the paper base; A target center value is preset for the moisture content of the paper base; Real-time energy consumption of the drying system; This is the baseline energy consumption value for traditional fixed processes under the same production capacity; , , , These are the weighting coefficients for degree of curing, solvent residue, moisture content, and energy consumption, respectively. The multi-dimensional execution unit communicates with the central intelligent control unit to receive control commands and perform real-time closed-loop adjustment of the drying parameters of each zone of the drying chamber unit.

2. The intelligent control system for drying semi-finished aluminum foil composite paper according to claim 1, characterized in that, Each functional zone of the drying chamber unit is equipped with a symmetrical air supply static pressure chamber and a return air chamber. The air outlet of the air supply static pressure chamber is equipped with a uniform air distribution plate. The opening ratio of the uniform air distribution plate changes gradually from the feeding end to the discharging end along the material conveying direction. The opening ratio of the preheating zone decreases from 30% to 20%, the opening ratio of the constant temperature curing zone remains stable at 20%, and the opening ratio of the gradient cooling balance zone increases from 20% to 30%. A circulating air duct is set between the return air chamber and the air supply static pressure chamber of each zone. A heat exchange device is set in the circulating air duct to recover the waste heat of the return air and preheat the fresh air, thereby reducing the heat loss in the drying process. At the same time, each zone's cavity is equipped with a heat insulation layer.

3. The intelligent control system for drying semi-finished aluminum foil composite paper according to claim 1, characterized in that, The servo traction mechanism of the material conveying unit has active traction rollers installed at the feeding end and the discharging end of the drying chamber. The active traction rollers at the feeding end and the discharging end are synchronously servo driven to ensure stable conveying tension of the material in the drying chamber. A tension controller is installed at the front end of the active traction roller at the feeding end to collect the conveying tension data of the material in real time and transmit the data synchronously to the central intelligent control unit. Linear speed encoders are installed on the roller shafts of the active traction rollers at the feeding end and the discharging end, respectively, to collect the actual conveying linear speed of the two traction rollers in real time. The central intelligent control unit adjusts the output speed of the servo motors of the two active traction rollers according to the difference between the two linear speed encoders to eliminate the stretching deformation of the material during the drying process.

4. The intelligent control system for drying semi-finished aluminum foil composite paper according to claim 1, characterized in that, The material state acquisition module of the multi-source sensing acquisition unit has an initial state detection component set at the feed inlet of the drying chamber, with three sets of detection probes evenly spaced along the width of the material, corresponding to the left, middle, and right edges of the material, respectively, to simultaneously collect the initial moisture content and adhesive amount data of the entire material width. The process detection component set at the outlet of each functional zone and the final inspection component set at the discharge port each have five sets of detection probes evenly spaced along the width of the material to collect the moisture content, adhesive curing degree, and solvent residue data of the entire material width in real time.

5. The intelligent control system for drying semi-finished aluminum foil composite paper according to claim 1, characterized in that, The adaptive closed-loop control module of the central intelligent control unit generates real-time control quantities through a control deviation correction formula that provides feedforward compensation for feed materials. The expression of the correction formula is as follows: ,in This refers to the real-time adjustment of drying parameters; This represents the real-time deviation value of the core drying parameters; This is the proportional gain coefficient; This is the integral gain coefficient; The differential gain coefficient; This is the feedforward compensation coefficient for incoming materials.

6. The intelligent control system for drying semi-finished aluminum foil composite paper according to claim 1, characterized in that, The model self-iteration module of the central intelligent control unit receives offline quality inspection data of the finished products in real time. The offline quality inspection data includes the moisture content of the finished products, the degree of curing of the adhesive layer, the amount of solvent residue, the interlayer peel strength, and the number of folding cycles. The module compares the offline inspection data with the online data collected during the drying process and the model prediction data, and calculates the prediction deviation value of the model. When the prediction deviation value exceeds the preset 5% threshold, the module automatically starts the model iterative optimization process, and updates the neural network weights of the key parameter prediction module in an incremental learning manner. During the update process, 90% of the original basic weights of the model are retained, and only the 10% weights corresponding to the deviation are adjusted. At the same time, the iteratively optimized model parameters are synchronously updated to the system runtime library.

7. The intelligent control system for drying semi-finished aluminum foil composite paper according to claim 1, characterized in that, The temperature execution module and the wind speed and air volume execution module of the multi-dimensional execution unit form a single-zone independent closed-loop control link with the corresponding zone's sensing and acquisition components. The temperature execution module of each zone adopts a grouped electric heating tube layout, and the electric heating tube is divided into 3 groups of independent control units. The output power of the corresponding heating unit is adjusted according to the real-time temperature distribution in the zone. The variable frequency fan and the air valve actuator of the wind speed and air volume execution module adopt a linkage control mode, and the fan frequency and air valve opening are synchronously adjusted according to the control command.

8. The intelligent control system for drying semi-finished aluminum foil composite paper according to claim 1, characterized in that, The central intelligent control unit is equipped with a dual-machine hot standby redundancy architecture, including a main controller and a backup controller. The main controller and the backup controller adopt a real-time data synchronization mode, synchronously receiving collected data and issuing control commands. When the main controller fails and stops, the backup controller automatically switches to the main controller state within 100ms and takes over all control functions of the system. At the same time, the system is equipped with an abnormal early warning and safety shutdown module to monitor the operating status of the system in real time. When the collected data shows abnormal changes or the execution unit fails, the module issues an audible and visual warning immediately and executes the corresponding safety handling procedure according to the fault level. The fault levels are divided into three levels: level one faults execute speed reduction operation, level two faults execute constant temperature standby operation, and level three faults execute emergency shutdown operation.

9. A method for intelligent control of drying semi-finished aluminum foil composite paper, applicable to the intelligent control system for drying semi-finished aluminum foil composite paper as described in any one of claims 1-8, characterized in that, The specific steps of this method are as follows: Based on the substrate specifications, adhesive type and product quality requirements of the aluminum foil composite paper semi-finished product to be produced, preset the product quality target threshold and drying benchmark process parameters, and complete the calibration of the multi-source sensor acquisition unit and the system's full-link self-test. During the continuous drying process of aluminum foil composite paper semi-finished products, the operating parameters of each functional zone of the drying chamber and the online status parameters of the materials are collected in real time through a multi-source sensor acquisition unit, and all collected data are synchronously transmitted to the central intelligent control unit. After preprocessing the real-time collected data, the central intelligent control unit comprehensively evaluates the material state and system operating conditions of the current drying process through a multi-objective collaborative optimization control model, and calculates the deviation between the real-time state and the preset product quality target threshold. Based on the state assessment results and deviation, the optimal control values ​​of the drying parameters of each functional zone are obtained by solving the multi-objective optimization algorithm, and corresponding multi-dimensional control instructions are generated. The control commands are sent to the multi-dimensional execution unit to adjust the temperature, air volume and wind speed of each functional zone in real time. At the same time, the multi-source sensor acquisition unit collects the adjusted operating parameters and material status data in real time and feeds them back to the central intelligent control unit to form a closed-loop dynamic control. Offline quality inspection is performed on the finished aluminum foil composite paper after drying. The offline inspection results are fed back to the central intelligent control unit, and the multi-objective collaborative optimization control model is updated and iterated online through the model self-iteration module.

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