A method and system for managing and controlling an MES system based on copper foil production

Abstract

The present application relates to production management technical field, especially to a kind of MES system management and control method and system based on copper foil production intelligence manufacturing.The method includes the following steps: control cathode roller immersion electrolytic cell to carry out copper foil electrolytic foil, and synchronously collect thickness, rotating speed, temperature and current density and other key parameters upload MES system;Subsequently, based on thickness data, build circumferential fluctuation curve and generate periodic deviation data;Again, in combination with the analysis of surface attachment state of spray cleaning process, obtain deposition abnormal distribution;Further, linkage adjustment current density and roller speed realize closed-loop control, finally carry out constant tension winding and form production traceability data.The present application carries out multi-parameter acquisition, circumferential thickness fluctuation analysis and deposition state modeling to copper foil electrolytic foil whole process by MES system, and linkage adjusts current density and cathode roller rotating speed, realizes the dynamic closed-loop control of deposition abnormality, to improve copper foil thickness uniformity, production stability and product yield.

Description

Technical Field

[0001] This invention relates to the field of production management technology, and in particular to a method and system for controlling MES systems based on intelligent manufacturing of copper foil. Background Technology

[0002] In the electrolytic copper foil production process, the cathode roller, as a key forming carrier, is affected by the coupled effects of multiple factors, including fluctuations in current density, changes in electrolyte temperature, and unstable roller speed. This can easily lead to problems such as uneven thickness distribution and localized adhesion abnormalities, thus affecting the overall uniformity of the copper foil and the product yield. Existing MES systems are mainly used for centralized collection of production data and post-production traceability analysis, lacking the ability to perform refined modeling of the circumferential deposition process of the cathode roller. They also struggle to identify deposition anomalies in real time and implement process-level linkage control, resulting in lagging production process control and insufficient stability. The proposed technical problems are: first, how to achieve refined characterization of the circumferential deposition state of the cathode roller and identification of anomaly distribution; and second, how to construct a dynamic feedback control mechanism for the electrolytic foil production process based on the MES system to improve the stability of the production process and the consistency of copper foil quality. Summary of the Invention

[0003] Therefore, it is necessary to provide a method and system for managing MES systems based on intelligent manufacturing of copper foil production in order to solve at least one of the above-mentioned technical problems.

[0004] To achieve the above objectives, a method for managing and controlling an MES system based on intelligent manufacturing of copper foil production is provided, the method comprising the following steps: Step S1: Control the cathode roller to be immersed in the electrolytic cell to electrolyze and grow foil, and collect parameters such as copper foil thickness, cathode roller speed, electrolyte temperature and current density and upload them to the MES system; Step S2: Construct the circumferential thickness fluctuation curve of the cathode roller based on the copper foil thickness, and generate periodic thickness deviation data; Step S3: Control the spray assembly to perform spray cleaning on the cathode roller surface, and analyze the adhesion status of the cathode roller surface based on the periodic thickness deviation data to generate deposition anomaly distribution data; Step S4: Adjust the current density of the rectifier power supply by controlling the deposition anomaly distribution data, and adjust the cathode roller speed by controlling the drive motor; Step S5: Control the winding mechanism to perform constant tension winding of the copper foil and generate corresponding production traceability data.

[0005] This invention also provides a MES system management and control system based on intelligent copper foil production, used to execute the above-mentioned MES system management and control method based on intelligent copper foil production. The MES system management and control system based on intelligent copper foil production includes: The copper foil acquisition module is used to control the cathode roller to be immersed in the electrolytic cell for electrolytic copper foil production, and to collect parameters such as copper foil thickness, cathode roller speed, electrolyte temperature and current density and then upload them to the MES system. The thickness modeling module is used to construct the circumferential thickness fluctuation curve of the cathode roller based on the copper foil thickness and generate periodic thickness deviation data. The deposition analysis module is used to control the spray assembly to perform spray cleaning on the cathode roller surface, and analyze the adhesion status on the cathode roller surface based on periodic thickness deviation data to generate deposition anomaly distribution data. The parameter control module is used to control the rectifier power supply to adjust the current density and control the drive motor to adjust the cathode roller speed by using deposition anomaly distribution data. The winding traceability module is used to control the winding mechanism to perform constant tension winding of copper foil and generate corresponding production traceability data.

[0006] The beneficial effects of this invention lie in the real-time acquisition and closed-loop control of parameters throughout the entire process of copper foil electrolytic deposition via a MES system. Combined with the periodic analysis of the circumferential thickness fluctuation of the cathode roller, it enables refined identification and non-uniform partitioning modeling of the deposition state on the cathode roller surface. This transforms the originally difficult-to-quantify adhesion anomalies into calculable distribution data, and further drives the adaptive adjustment of current density and rotation speed, achieving dynamic equilibrium control of the electrolytic deposition process. Simultaneously, by combining constant tension winding and full-process traceability data construction, the production process exhibits higher stability, consistency, and traceability, effectively reducing thickness fluctuations and local deposition defects, and improving the uniformity and yield of copper foil products. Attached Figure Description

[0007] Figure 1 A schematic diagram of the steps of a MES system control method based on intelligent manufacturing of copper foil; Figure 2 for Figure 1 A detailed flowchart illustrating the implementation steps of step S3. Figure 3 This is a schematic diagram of an electrolytic foil production scenario according to one embodiment; Figure 4 This is a schematic diagram of an embodiment of the electrolytic foil production process; Figure 5 This is a schematic diagram of the module relationships of a MES system for intelligent manufacturing of copper foil. The realization of the objective, functional features and advantages of the present invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0008] The technical method of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0009] Furthermore, the accompanying drawings are merely illustrative of the invention and are not necessarily drawn to scale. The same reference numerals in the drawings denote the same or similar parts, and therefore repeated descriptions of them will be omitted. Some block diagrams shown in the drawings are functional entities and do not necessarily correspond to physically or logically independent entities. These functional entities can be implemented in software, in one or more hardware modules or integrated circuits, or in different network and / or processor methods and / or microcontroller methods.

[0010] It should be understood that although the terms "first," "second," etc., may be used herein to describe various units, these units should not be limited by these terms. These terms are used merely to distinguish one unit from another. For example, without departing from the scope of the exemplary embodiments, a first unit may be referred to as a second unit, and similarly, a second unit may be referred to as a first unit. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0011] To achieve the above objectives, please refer to Figures 1 to 5 A method for managing a MES system based on intelligent manufacturing of copper foil, the method comprising the following steps: Step S1: Control the cathode roller to be immersed in the electrolytic cell to electrolyze and grow foil, and collect parameters such as copper foil thickness, cathode roller speed, electrolyte temperature and current density and upload them to the MES system; Step S2: Construct the circumferential thickness fluctuation curve of the cathode roller based on the copper foil thickness, and generate periodic thickness deviation data; Step S3: Control the spray assembly to perform spray cleaning on the cathode roller surface, and analyze the adhesion status of the cathode roller surface based on the periodic thickness deviation data to generate deposition anomaly distribution data; Step S4: Adjust the current density of the rectifier power supply by controlling the deposition anomaly distribution data, and adjust the cathode roller speed by controlling the drive motor; Step S5: Control the winding mechanism to perform constant tension winding of the copper foil and generate corresponding production traceability data.

[0012] In one embodiment, a 6μm high-performance electrolytic copper foil production line of a lithium battery copper foil manufacturer is used as an example for illustration. The production line includes an electrolytic cell, cathode roller, anode plate, spray assembly, rectifier power supply, drive motor, online thickness gauge, winding mechanism, and MES system.

[0013] The cathode roller adopts a titanium alloy roller body structure with a roller diameter of approximately 2.2m. The lower half of the roller body is immersed in the electrolytic cell, and the outer surface of the cathode roller serves as a copper ion deposition carrier. The anode plate is fixedly installed inside the electrolytic cell and is spaced along the circumference of the cathode roller. The spray assembly is installed in the area above the cathode roller after it leaves the liquid surface, and includes multiple sets of high-pressure nozzles and circulating cleaning pipelines. The drive motor is connected to the main shaft of the cathode roller through a reduction mechanism to control the stable rotation of the cathode roller. The winding mechanism is located at the rear end of the cathode roller and includes a tension roller, a correction roller, and a winding roller to complete the continuous winding of the copper foil.

[0014] The online thickness gauge is installed at the copper foil peeling path after the cathode roller exits the foil, and is mounted across the copper foil running channel via a horizontal fixing bracket. The online thickness gauge includes a laser thickness transmitter and a laser receiver. The transmitter is positioned above the copper foil, and the receiver is positioned below the copper foil. They are arranged opposite each other along the thickness direction of the copper foil to form a through-type thickness detection structure. The online thickness gauge communicates with the MES system via industrial Ethernet and is synchronously connected to the drive motor encoder via a high-speed acquisition module. This allows for the establishment of a correspondence between thickness data and circumferential angles during the rotation of the cathode roller, preventing circumferential thickness mapping offsets caused by speed fluctuations.

[0015] The drive motor is located on one side of the cathode roller main shaft and is coaxially connected to the cathode roller main shaft via a reduction gearbox. The reduction gearbox contains a high-precision helical gear transmission mechanism to reduce speed pulsation during low-speed operation of the cathode roller. A rotary encoder is installed at the tail end of the drive motor, which is connected to the PLC controller via a pulse signal line for real-time feedback of the cathode roller's rotational speed and circumferential angular position. The PLC controller is further connected to the MES system via an industrial bus, enabling the MES system to synchronously acquire the cathode roller's angular position and copper foil thickness acquisition timestamps, thereby generating a cathode roller circumferential thickness fluctuation curve.

[0016] The rectifier power supply is located inside an independent electrical control cabinet on the side of the electrolytic cell. Its positive output terminal is connected to the anode plate busbar via a high-current copper busbar, and its negative output terminal is connected to the cathode roller main shaft via a conductive slip ring assembly. The conductive slip ring assembly is fixedly installed at the end of the cathode roller main shaft and slides in contact with the rotating conductive ring through a graphite conductive brush to ensure stable current conduction even when the cathode roller is rotating continuously. An insulating protective cover and a circulating air cooling structure are installed on the outside of the conductive slip ring to reduce local heat accumulation caused by high current conduction.

[0017] The anode plates are arranged in an arc shape with equal spacing around the circumference of the cathode roller and are fixed inside the electrolytic cell by an insulating support frame. Adjacent anode plates are connected in series by conductive copper busbars to form an anode power supply circuit. A constant electrode distance is maintained between each anode plate and the outer surface of the cathode roller to avoid fluctuations in copper foil thickness caused by uneven local electric field distribution. An electrolyte circulation channel is set at the bottom of the electrolytic cell, which is connected to an electrolyte circulation pump to drive the electrolyte to form a directional flow around the circumference of the cathode roller, thereby reducing the local copper ion concentration difference.

[0018] The winding mechanism includes a tension detection roller, a guide roller, a winding roller, and a winding servo motor. The tension detection roller is equipped with a pressure sensor to detect the running tension of the copper foil in real time. Edge position sensors are installed on both sides of the guide roller to detect the edge offset of the copper foil. The winding servo motor dynamically adjusts the winding torque and winding lateral position according to the tension detection data and edge offset data to avoid serpentine offset, edge wrinkles, or interlayer misalignment during the copper foil winding process.

[0019] In another embodiment, a liquid level detection component and a temperature detection component can also be installed inside the electrolytic cell. The liquid level detection component includes a float level sensor and an electric replenishing valve. The float level sensor is installed inside the liquid level detection chamber on the side wall of the electrolytic cell and is connected to a PLC controller via a signal line. When the liquid level is lower than a preset height, the PLC controller controls the electric replenishing valve to open, thereby replenishing electrolyte into the electrolytic cell and maintaining a constant immersion depth of the cathode roller. The temperature detection component includes multiple PT100 temperature sensors, which are respectively installed in the front, middle, and rear areas of the electrolytic cell to detect the temperature distribution in different areas of the electrolyte and upload the data to the MES system for temperature equalization analysis.

[0020] In another embodiment, the copper foil peeling mechanism can be located on the foil exit side of the cathode roller, including a peeling roller and a guide roller. The peeling roller contacts the surface of the cathode roller through an elastic clamping structure, and is used to continuously peel the deposited copper foil from the surface of the cathode roller. The guide roller is located behind the peeling roller and is used to adjust the copper foil conveying path so that the copper foil smoothly enters the winding mechanism. The outer layer of the peeling roller is coated with a wear-resistant ceramic coating to reduce roller surface wear during long-term operation.

[0021] In the actual production process, the control system first controls the cathode roller to rotate at a preset speed and immerse it in the electrolytic cell for electrolytic foil production. For example, the cathode roller rotates continuously at a linear speed of 1.8 m / min, and the rectified power supply outputs a stable current between the anode plate and the cathode roller, so that copper ions in the electrolyte are continuously deposited on the surface of the cathode roller to form a copper foil layer.

[0022] Meanwhile, an online thickness gauge installed at the cathode roll foil exit position monitors the copper foil thickness in real time, for example, by continuously collecting copper foil thickness data; the drive motor encoder provides real-time feedback on the cathode roll rotation speed; a temperature sensor located inside the electrolytic cell collects the electrolyte temperature; and the rectifier power supply provides feedback on the current density parameter. All of these parameters are uploaded to the MES system for centralized management.

[0023] Subsequently, the MES system establishes a circumferential thickness fluctuation curve for the cathode roller based on the copper foil thickness data. Specifically, the rotation angle of the cathode roller is used as the circumferential coordinate to map the continuously collected copper foil thickness to the corresponding circumferential position. For example, during each rotation of the cathode roller, a continuous increase in thickness is observed in the circumferential region between 210° and 240°, thereby generating corresponding periodic thickness deviation data.

[0024] Based on this, the spray assembly is controlled to perform spray cleaning on the surface of the cathode roller. For example, after the cathode roller rotates out of the liquid surface, multiple sets of high-pressure nozzles spray circulating cleaning fluid onto the roller surface to remove copper powder, crystalline particles, and residual electrolytic deposition layers adhering to the cathode roller surface. Simultaneously, the MES system analyzes the adhesion status of the cathode roller surface based on periodic thickness deviation data. For example, when a fixed circumferential area shows a long-term thickness anomaly, it is determined that there is a local deposition adhesion anomaly in that area, and deposition anomaly distribution data is generated.

[0025] Subsequently, the rectifier power supply and drive motor are controlled in conjunction with the data on the abnormal deposition distribution. For example, for the thicker deposition area in the circumferential region of 210° to 240°, the current density of the rectifier power supply is appropriately reduced in the corresponding stage, while the speed of the cathode roller of the drive motor is finely adjusted to shorten the residence time of this area in the electrolyte, thereby reducing the local deposition rate; while for the thinner deposition area, the corresponding current density is increased and the speed is appropriately reduced to enhance copper ion deposition.

[0026] Finally, the copper foil, after being peeled off, enters the winding mechanism. The tension rollers in the winding mechanism monitor the copper foil tension in real time and control the winding motor to maintain a constant tension during winding, preventing wrinkles or stretching deformation of the copper foil during the winding process. Simultaneously, the MES system generates production traceability data for the current production batch, including information such as copper foil thickness, cathode roller speed, current density, electrolyte temperature, abnormal deposition distribution, and winding status. This data is then linked and stored with the corresponding roll number for subsequent quality traceability and process analysis.

[0027] Preferably, controlling the immersion of the cathode roller in the electrolytic cell for electrolytic foil production specifically involves: The lifting mechanism is activated to lower the cathode roller from its initial position, gradually bringing it closer to the surface of the electrolytic cell. The cathode roller is controlled to enter the electrolytic cell smoothly at a preset speed and complete the full immersion positioning. The rectifier power supply is started at the same time as the cathode roller enters the electrolytic cell, so that a stable current loop is formed between the cathode roller and the anode. The cathode roller drive motor is controlled to rotate the cathode roller at a constant speed, so that copper ions are continuously deposited on its surface to form a copper foil layer; Start the electrolyte circulation pump and maintain continuous electrolyte flow, and control the liquid level adjustment mechanism to fine-tune the liquid level in the electrolytic cell so that the effective working area of ​​the cathode roller remains stably submerged.

[0028] In one embodiment, reference may be made to Figure 3 and Figure 4 The following explanation uses a 6μm electrolytic copper foil production line of a lithium battery copper foil manufacturer as an example. The electrolytic foil production unit in this production line includes an electrolytic cell, cathode roller, anode plate, lifting mechanism, rectifier power supply, drive motor, electrolyte circulation pump, and liquid level adjustment mechanism.

[0029] The cathode roller adopts a hollow titanium alloy roller body structure with a roller diameter of approximately 2.2m and is installed in the main support frame above the electrolytic cell. The lifting mechanism includes two sets of synchronous electric screw lifting modules, which are respectively connected to both ends of the cathode roller main shaft to control the overall lifting of the cathode roller. The anode plates are fixedly installed inside the electrolytic cell and are distributed at intervals along the circumference of the cathode roller. The drive motor is connected to the cathode roller main shaft through a reduction gearbox to drive the cathode roller to rotate continuously.

[0030] In the actual production process, the lifting mechanism is first activated to slowly lower the cathode roller from its initial standby position. For example, the cathode roller is initially located about 500 mm above the surface of the electrolytic cell. After receiving the production start command, the lifting mechanism drives the cathode roller to move downwards as a whole through the synchronous lead screw, so that the cathode roller gradually approaches the surface of the electrolytic cell.

[0031] Subsequently, the control system continues to control the cathode roller to smoothly enter the electrolytic cell at a preset speed. For example, the cathode roller is slowly immersed in the electrolyte at a descent speed of about 15 mm / s, and stops descending after reaching the preset immersion depth, so that the lower half of the cathode roller is stably immersed in the electrolyte, thereby completing the full immersion positioning.

[0032] Simultaneously with the cathode roller entering the electrolytic cell, the rectifier power supply is started. For example, the rectifier power supply is connected to the cathode roller through a conductive slip ring and outputs a stable DC current between the anode plate and the cathode roller, forming a stable current loop between the cathode roller and the anode, which promotes the migration of copper ions in the electrolyte to the surface of the cathode roller.

[0033] Subsequently, the cathode roller drive motor is started and operated. For example, the drive motor drives the cathode roller to rotate continuously at a constant speed through a reduction mechanism, so that the surface of the cathode roller continuously passes through the electrolytic deposition area, thereby causing copper ions to be continuously deposited on the outer surface of the cathode roller to form a uniform copper foil layer.

[0034] Simultaneously, the electrolyte circulation pump located on the side of the electrolytic cell starts. For example, the circulation pump continuously draws electrolyte through the circulation pipeline and returns it to the inside of the electrolytic cell, keeping the electrolyte in a flowing state to reduce local fluctuations in copper ion concentration. At the same time, the liquid level adjustment mechanism fine-tunes the liquid level in the electrolytic cell based on feedback from the liquid level sensor, for example, by adjusting the liquid level height through the replenishment valve or drain valve, so that the effective working area of ​​the cathode roller remains stably submerged, thereby ensuring continuous and stable growth of copper foil.

[0035] As an example of the present invention, reference is made to... Figure 2 As shown, step S3 in this example includes: Step S31: Start the spray pump and open the spray valve assembly to allow the cleaning solution to be delivered to the nozzles through the spray pipeline; Step S32: Control the spray arm to reciprocate along the axial direction of the cathode roller, and at the same time control the nozzle to spray cleaning liquid onto the surface of the cathode roller in sections; Step S33: Control the cathode roller to rotate at a low speed, so that its surface enters the spraying area segment by segment to complete the cleaning and covering; Step S34: Divide the thickness fluctuations at different circumferential positions into segments based on the periodic thickness deviation data; Step S35: Determine the adhesion state distribution at corresponding positions on the cathode roller surface based on the differences in section thickness fluctuations; Step S36: Generate cathode roller deposition anomaly distribution data based on the adhesion state distribution.

[0036] In one embodiment, a 6μm electrolytic copper foil production line of a lithium battery copper foil manufacturing company is used as an example for illustration. The spray cleaning system in this production line is located in the area above the cathode roller after it leaves the electrolytic cell liquid surface, and mainly includes a spray pump, a spray valve group, a spray pipeline, a spray swing arm, and multiple sets of fan-shaped nozzles.

[0037] The spray arm is horizontally positioned along the axial direction of the cathode roller. Its two ends are mounted on the support frame via slide rails and are driven by a servo drive module to reciprocate along the axial direction of the cathode roller. Multiple sets of nozzles are evenly installed at the bottom of the spray arm, with the nozzles spraying towards the outer surface of the cathode roller. The spray pump is connected to the cleaning fluid storage tank via a circulation pipeline to continuously deliver cleaning fluid to the nozzles.

[0038] In actual operation, the spray pump is first started and the spray valve assembly is opened. For example, the cleaning fluid is transported to each branch spray pipe through the main spray pipeline under the action of the spray pump, and finally enters the nozzle to form a stable spray pressure.

[0039] Subsequently, the spray arm is controlled to reciprocate along the axial direction of the cathode roller. For example, the servo drive module drives the spray arm to move gradually from the left end to the right end of the cathode roller, while controlling the nozzles in different areas to spray cleaning fluid in sections, so that all areas along the axial direction of the cathode roller can be sprayed and covered.

[0040] At the same time, the cathode roller is controlled to rotate at a low speed. For example, the cathode roller drive motor is switched to a low-speed cleaning mode, so that different circumferential areas on the cathode roller surface enter the spraying area in sequence, thereby completing continuous cleaning and coverage of the entire circumference surface to remove locally attached copper powder, crystal residue and deposited layers.

[0041] During the cleaning process, the MES system divides the thickness fluctuations at different circumferential positions into segments based on the previously generated periodic thickness deviation data. For example, the cathode roller is divided into multiple circumferential segments, and the copper foil thickness fluctuations corresponding to each segment are statistically analyzed.

[0042] Subsequently, the adhesion state on the cathode roller surface was analyzed based on the thickness fluctuation differences in different sections. For example, when a certain section consistently corresponds to a thicker copper foil, it was determined that there may be localized deposition adhesion in that section; when a certain section corresponds to a thinner copper foil and the fluctuation is unstable, it was determined that there may be localized surface contamination or abnormal conductivity, thus forming the distribution of the adhesion state on the cathode roller surface.

[0043] Finally, cathode roll deposition anomaly distribution data is generated based on the adhesion state distribution. For example, the location and anomaly level of different anomaly areas are marked in the form of a cathode roll circumferential unfolded diagram in the MES interface, which is used for subsequent linkage adjustment of rectified current density and cathode roll speed to improve copper foil deposition uniformity.

[0044] Preferably, step S34 includes: Extract the periodic characteristics of periodic thickness deviation data and identify repetitive fluctuation feature points within a single rotation cycle; Phase synchronization mapping of thickness deviation data is performed based on cathode roller rotation speed to establish the correspondence between thickness fluctuation and circumferential angle; Based on the phase interval changes between repetitive wave characteristic points, the circumferential division boundary position is determined, and a non-uniform segmentation result is formed; The periodic thickness deviation data within each non-uniform segment division result are clustered and merged to generate a set of thickness fluctuation sequences for the corresponding segment.

[0045] In one embodiment, a continuous production line for 6μm electrolytic copper foil from a lithium-ion battery copper foil manufacturer is used as an example. In this production line, the cathode roller rotates at a constant speed, and an online thickness gauge continuously samples the thickness of the copper foil formed on the surface of the cathode roller. The MES system performs periodic processing on the sampled data to identify deposition differences in different circumferential regions of the cathode roller.

[0046] Specifically, step S34 begins with the structured analysis of the "periodic thickness deviation data". First, periodic features are extracted from the thickness deviation sequence. For example, based on the rotation signal output by the cathode roller encoder, the continuous thickness data is divided into "single rotation cycle", and recurring fluctuation feature points are identified in each rotation cycle, including local thickness peak points (positions with thicker deposition), valley points (positions with thinner deposition), and slope abrupt change points (positions where deposition changes accelerate).

[0047] For example, if repeated thickness peaks are detected at approximately 85°, 170° and 255° circumferentially in a certain continuous cycle, these positions are marked as repetitive fluctuation feature points, and their repetition frequency in multiple cycles is recorded to characterize whether there is an instability anomaly at this position.

[0048] Subsequently, the thickness deviation data is phase-synchronized and mapped based on the cathode roller rotation speed. For example, by using the real-time angle increment data output by the drive motor encoder, each thickness sampling point is accurately mapped to the circumferential angle coordinate system of the cathode roller, thus converting the thickness data from a "time series" to an "angle series", thereby establishing a one-to-one correspondence between thickness fluctuations and circumferential angles.

[0049] For example, if sampling point t1 corresponds to a cathode roller rotation angle of 92° at a certain moment, then the thickness value at that point is mapped to the 92° position; if t2 corresponds to 215°, then it is mapped to the 215° position, thus forming a complete circumferential thickness distribution function.

[0050] Based on this, the phase interval changes between recurring fluctuation feature points are analyzed. For example, if the peak interval between 85° and 170° remains stable in multiple cycles, while the interval between 170° and 255° shows significant fluctuations, it is determined that there is a discontinuity in the sedimentation state in this interval, and the circumferential boundary position is determined accordingly.

[0051] Furthermore, based on the abrupt changes in phase interval, the circumferential direction of the cathode roller is divided into multiple non-uniform sections. For example, 0°–90° is divided into a stable deposition zone, 90°–200° into a fluctuating deposition zone, and 200°–300° into an abnormal deposition zone, so that the section division no longer depends on uniform angle division, but on the actual process deposition characteristics.

[0052] Subsequently, the thickness deviation data within each non-uniform segment are clustered and merged. For example, within the same "fluctuating deposition zone," similarity clustering methods (such as similarity measures based on fluctuation amplitude and trend slope) are used to classify the thickness curves in multiple cycles, forming multiple sets of thickness fluctuation sequences, each set corresponding to a stable or semi-stable deposition mode.

[0053] Preferably, determining the circumferential boundary position based on the phase interval change between repetitive wave feature points includes: Peak and valley detection are performed on periodic thickness deviation data to extract multiple recurring fluctuation feature points; Calculate the phase difference between adjacent repeating wave feature points to form a phase interval sequence; Perform a difference operation on the phase interval sequence to obtain the phase interval change; The phase interval change is compared with a preset change threshold. When the change exceeds the preset change threshold, it is determined as a candidate boundary point. The circumferential positions corresponding to all candidate boundary points are taken as the circumferential division boundary positions.

[0054] In one embodiment, a continuous production line for 6μm electrolytic copper foil from a lithium-ion battery copper foil manufacturer is used as an example. Based on periodic thickness deviation data collected by an online thickness gauge, the circumferential deposition state of the cathode roller is divided into non-uniform sections to identify the true boundary locations of deposition anomaly areas.

[0055] Specifically, peak and valley detection is first performed on the periodic thickness deviation data. For example, in the thickness distribution curve of each rotation of the cathode roller, a sliding window method is used to scan the thickness sequence. When the thickness value of a sampling point is simultaneously greater than its immediate and neighboring points, it is identified as a peak point; when the thickness value of a sampling point is simultaneously less than its immediate and neighboring points, it is identified as a valley point. In this way, multiple recurring fluctuation feature points are extracted within a single rotation cycle, such as peak points P1, P2, and P3 and valley points V1 and V2, to characterize the circumferential deposition fluctuation structure.

[0056] Subsequently, the phase difference between adjacent repeating wave characteristic points is calculated. For example, using the circumferential angle of the cathode roller as a unified coordinate reference, the angle difference between P1 and P2, the angle difference between P2 and P3, and the angle difference between adjacent valley points are calculated to form a phase interval sequence. This sequence is used to reflect the spatial distribution pattern of deposition waves in different circumferential regions of the cathode roller.

[0057] Based on this, a difference operation is performed on the phase interval sequence. For example, by performing term-by-term difference processing on adjacent phase interval values, the change in phase interval is obtained, which is used to characterize whether the wave structure between different circumferential segments undergoes abrupt changes.

[0058] For example, if the phase interval in a certain circumferential region suddenly changes from a stable 30° to 70°, the corresponding difference result increases significantly, indicating that there is a sudden change in the depositional structure at that location.

[0059] Subsequently, the phase interval change is compared with a preset change threshold. For example, if the threshold is set to a change of 20°, when the difference result exceeds this threshold, the position is identified as a candidate boundary point to distinguish different sedimentary characteristic zones.

[0060] Finally, the circumferential positions corresponding to all candidate boundary points are summarized. For example, all angle positions (such as 95°, 185°, 260°, etc.) that meet the threshold conditions in the circumferential direction of the cathode roller are uniformly used as the circumferential division boundary positions, thereby dividing the cathode roller surface into multiple non-uniform segments with different deposition characteristics, providing a basis for subsequent thickness fluctuation clustering analysis and spray cleaning zoning control.

[0061] Preferably, step S35 includes: Obtain the thickness fluctuation sequence of each circumferential segment, and calculate the average deviation value and fluctuation energy value of the segment to form the segment thickness feature vector; Based on the phase intervals corresponding to the boundary positions in the circumferential division, the thickness feature vectors of each segment are mapped by boundary constraints to obtain a thickness distribution sequence with boundary constraints. Differential alignment of the thickness distribution sequences of adjacent circumferential segments at the boundary position is performed to extract the abrupt change intensity parameter at the boundary; Based on the joint determination of mutation intensity parameters and internal fluctuation stability of the segment, the circumferential segment is divided into attachment enhancement zone, attachment transition zone and attachment weakening zone. The adhesion state classification results of each circumferential section are reconstructed according to the circumferential position to generate the adhesion state distribution of the corresponding position on the cathode roller surface.

[0062] In one embodiment, a continuous production line for 6μm electrolytic copper foil from a lithium-ion battery copper foil manufacturer is used as an example. Based on the circumferential non-uniform segment division results and periodic thickness deviation data obtained in the previous steps, the adhesion state of the cathode roller surface is finely classified to guide the spray cleaning and current density adjustment strategies.

[0063] Specifically, the thickness fluctuation sequence of each circumferential segment is first obtained. For example, the circumferential direction of the cathode roller is divided into multiple segments according to a defined boundary (e.g., segment A: 0°~95°, segment B: 95°~185°, segment C: 185°~270°, etc.). The copper foil thickness data sequence corresponding to each segment within multiple rotation cycles is statistically analyzed, and the average deviation value and fluctuation energy value of each segment are calculated. Among them, the average deviation value is used to characterize the overall deposition trend of the segment being too thick or too thin, and the fluctuation energy value is used to characterize the severity of the thickness change, thus forming a segment thickness feature vector.

[0064] For example, if the thickness of segment A remains consistently high and fluctuates little over multiple periods, it will exhibit a higher average deviation value and lower fluctuation energy; if the thickness of segment B fluctuates frequently and the peaks and troughs alternate significantly, it will exhibit a medium average deviation value and higher fluctuation energy.

[0065] Subsequently, based on the phase intervals corresponding to the boundary positions along the circumference, boundary constraint mapping is applied to the thickness feature vectors of each segment. For example, the feature vector of each segment is limited to its corresponding circumferential angle range, ensuring that the thickness features strictly correspond to the physical spatial positions, forming a thickness distribution sequence with boundary constraints, thereby avoiding feature overlap between different segments.

[0066] Based on this, the thickness distribution sequences of adjacent circumferential segments at the boundary are compared differentially. For example, the mean thickness and fluctuation energy of segments A and B at the 95° boundary are calculated differentially to extract the abrupt change intensity parameter at the boundary, which is used to characterize the degree of drastic change in depositional state on both sides of the boundary. If the abrupt change intensity is large, it indicates that the difference in adhesion state on both sides of the boundary is significant.

[0067] Subsequently, a joint determination is made based on the abrupt change intensity parameter and the stability of fluctuations within the section. For example, when the fluctuation energy within a section is low and the boundary abrupt change intensity is small, the area is determined to be an enhanced adhesion zone, indicating that the deposition is relatively stable and the adhesion is relatively strong; when both the fluctuations within the section and the boundary abrupt changes are at a moderate level, it is determined to be an adhesion transition zone; when the fluctuations within the section are severe and the boundary abrupt changes are obvious, it is determined to be an weakened adhesion zone, indicating that the deposition state is unstable or the adhesion is weak.

[0068] Finally, the adhesion status classification results of each circumferential section are remapped and reconstructed according to the circumferential position of the cathode roller. For example, the cathode roller is unfolded into a 360° annular diagram in the MES interface, and different regions are distinguished by color or labels as adhesion enhancement zone, transition zone and weakening zone, thereby generating a complete cathode roller surface adhesion status distribution map, which provides a direct basis for subsequent spray cleaning intensity allocation and rectifier current adjustment.

[0069] Preferably, the adhesion state classification results of each circumferential section are reconstructed according to the circumferential position to generate the adhesion state distribution at the corresponding position on the cathode roller surface, specifically as follows: Obtain the attachment status classification results and their circumferential position coordinates for each circumferential segment; The attachment status classification results of each circumferential segment are sequentially spliced ​​according to the arrangement order of the circumferential position coordinates. Perform continuity checks on the attachment state boundaries between adjacent circumferential sections and perform boundary corrections on state transition locations; The corrected adhesion state of each circumferential section is mapped to the corresponding circumferential region of the cathode roller to form a circumferential adhesion state distribution map on the surface of the cathode roller. The circumferential adhesion state distribution map is periodically expanded based on the rotation trajectory of the cathode roller to generate adhesion state distribution data at corresponding positions on the cathode roller surface.

[0070] In one embodiment, a continuous production line for 6μm electrolytic copper foil from a lithium-ion battery copper foil manufacturer is used as an example. After classifying the adhesion state of each circumferential section, the MES system performs circumferential reconstruction of the adhesion state on the cathode roller surface to form a complete cathode roller adhesion state distribution result.

[0071] Specifically, the first step is to obtain the classification results of the adhesion state and its circumferential position coordinates for each circumferential segment. For example, the cathode roller has been divided into multiple segments circumferentially, where the 0° to 90° segment is identified as the adhesion enhancement zone, the 90° to 180° segment is identified as the adhesion transition zone, and the 180° to 260° segment is identified as the adhesion weakening zone. The starting and ending angle coordinates of each segment are recorded simultaneously.

[0072] Subsequently, the adhesion state classification results of each circumferential segment are sequentially spliced ​​according to the arrangement order of the circumferential position coordinates. For example, taking the 0° position of the cathode roller as the starting reference point, the states of each segment are connected in sequence according to the circumferential angle to form a complete circumferential adhesion state arrangement sequence, so that the adhesion state of the entire circumferential surface of the cathode roller can be continuously expressed.

[0073] Based on this, a continuity check is performed on the attachment state boundaries between adjacent circumferential segments. For example, when the thickness fluctuation at the boundary between the 0°–90° segment and the 90°–180° segment is relatively gentle, the boundary transition is determined to be continuous; however, when a sudden change in thickness fluctuation occurs near 180°, it is identified as a state transition location. Subsequently, the boundary is corrected at this location based on the thickness change trend within the boundary neighborhood, such as performing local smoothing or boundary offset correction on abrupt boundary changes, to avoid misjudgment of segment boundaries due to instantaneous sampling fluctuations.

[0074] Subsequently, the corrected adhesion states of each circumferential section are mapped to the corresponding circumferential regions of the cathode roller. For example, a circumferential unfolding model of the cathode roller is established in the MES system interface, and the adhesion enhancement zone, adhesion transition zone, and adhesion weakening zone are mapped to the corresponding angular regions, thereby forming a circumferential adhesion state distribution map of the cathode roller surface.

[0075] For example, the MES interface can display the adhesion enhancement area on the left side of the cathode roller unfolded diagram and the adhesion weakening area on the lower right side, allowing maintenance personnel to intuitively view the adhesion status at different circumferential positions of the cathode roller.

[0076] Finally, the circumferential adhesion state distribution map is periodically expanded based on the cathode roller rotation trajectory. For example, the adhesion state within multiple consecutive rotation cycles of the cathode roller is superimposed and expanded in chronological order, allowing simultaneous observation of the adhesion changes in the same circumferential area in different production cycles. This generates adhesion state distribution data for the corresponding position on the cathode roller surface, which is then stored in the MES database.

[0077] Preferably, the method for obtaining the rotation trajectory of the cathode roller includes: The rotary encoder is fixedly installed on the end of the cathode roller main shaft, and the output shaft of the rotary encoder rotates synchronously with the cathode roller main shaft. The control encoding acquisition module continuously receives the angle pulse signal output by the rotary encoder; When the cathode roller drive motor drives the cathode roller to rotate, the corresponding number of pulses is recorded according to the preset sampling period; The number of pulses in each sampling period is transmitted to the MES system and converted into the corresponding circumferential rotation position of the cathode roller. By arranging the circumferential rotation positions in the continuous rotation sequence of the cathode roller, the rotation trajectory data of the cathode roller is generated.

[0078] In one embodiment, an electrolytic copper foil continuous production line of a lithium battery copper foil manufacturing company is used as an example. A rotary encoder is installed at the right end of the cathode roller spindle in this production line to acquire the circumferential rotation trajectory data of the cathode roller in real time and upload it to the MES system for circumferential deposition analysis.

[0079] Specifically, the rotary encoder is first fixedly installed on the end of the cathode roller main shaft. For example, a coupling mounting base is set on the outside of the cathode roller main shaft, and the output shaft of the rotary encoder is coaxially connected to the cathode roller main shaft through a flexible coupling, so that the output shaft of the rotary encoder can be synchronously driven to rotate synchronously when the cathode roller rotates, thereby ensuring that the angle acquisition is consistent with the actual rotation state of the cathode roller.

[0080] The rotary encoder can be an incremental high-precision encoder, whose encoder housing is fixedly installed on the side of the cathode roller support frame, and whose output end is connected to the encoding acquisition module through a shielded signal line.

[0081] Subsequently, the control encoding and acquisition module continuously receives the angle pulse signals output by the rotary encoder. For example, when the cathode roller rotates a certain angle, the rotary encoder outputs a corresponding number of pulse signals. The encoding and acquisition module counts the pulse changes in real time and buffers the corresponding sampled data.

[0082] When the cathode roller drive motor drives the cathode roller to rotate continuously, the corresponding number of pulses is recorded according to a preset sampling period. For example, the MES system reads the pulse count value from the encoding acquisition module once every 10ms sampling period to obtain the actual rotation amount of the cathode roller in the current time period.

[0083] Subsequently, the number of pulses in each sampling period is transmitted to the MES system and converted into the corresponding circumferential rotation position of the cathode roller. For example, when the encoder outputs 10,000 pulses, the cathode roller rotates 360°. The MES system then calculates the current circumferential angle position of the cathode roller, such as 45°, 120°, or 270°, based on the cumulative number of pulses in the sampling period.

[0084] Based on this, the MES system arranges the circumferential rotation positions according to the continuous rotation sequence of the cathode roller. For example, it records the circumferential angles corresponding to each sampling point in chronological order and establishes a continuous circumferential trajectory sequence, so that the complete rotation process of the cathode roller in multiple production cycles can be continuously expressed.

[0085] Finally, the cathode roller rotation trajectory data is generated and synchronously correlated with the copper foil thickness data collected by the online thickness gauge. For example, when the online thickness gauge detects an abnormality in the copper foil thickness at a certain moment, the MES system can quickly locate the circumferential area where the abnormality occurred based on the cathode roller rotation trajectory at the corresponding time point.

[0086] Preferably, when the cathode roller drive motor drives the cathode roller to rotate, recording the corresponding number of pulses according to a preset sampling period further includes: When the cathode roller drive motor drives the cathode roller to rotate, a zero-position trigger sampling window is established based on the reference pulse output by the cathode roller spindle zero-position sensor, and this trigger sampling window is used as the first counting starting point. The rotary encoder A / B phase signals are simultaneously input in each sampling period, and the pulses are counted in dual-channel phase direction determination, and the count value is accumulated according to the direction. The pulse count within the sampling period is cross-locked with the spindle zero-position trigger sequence. When zero-position signal drift is detected, the current sampling window is automatically re-segmented at the boundary.

[0087] In one embodiment, an electrolytic copper foil continuous production line of a lithium battery copper foil manufacturing company is used as an example for illustration. To improve the accuracy of circumferential position acquisition of the cathode roller, in addition to installing a rotary encoder at the cathode roller spindle end, a spindle zero-position sensor is also synchronously installed to establish a stable circumferential zero-position reference.

[0088] The spindle zero-position sensor is fixedly mounted on the side bracket of the cathode roller spindle, and a zero-position trigger block is set on the outer circumferential surface of the cathode roller spindle. When the cathode roller rotates one revolution, the zero-position trigger block passes through the detection area of ​​the spindle zero-position sensor, thereby outputting a corresponding zero-position reference pulse. The rotary encoder adopts an A / B dual-phase signal output structure, and its output terminal is connected to the encoding and acquisition module.

[0089] During actual operation, when the cathode roller drive motor drives the cathode roller to rotate continuously, a zero-position trigger sampling window is first established based on the reference pulse output by the spindle zero-position sensor. For example, when the zero-position trigger block passes the zero-position sensor for the first time, this moment is determined as the 0° circumferential position of the cathode roller, and this trigger moment is used as the counting start point of the first sampling window, thereby ensuring that all subsequent circumferential angles are calculated based on a unified zero-position reference.

[0090] Subsequently, within each sampling cycle, the encoding acquisition module synchronously receives the A / B phase signals of the rotary encoder. For example, the A and B phase signals output pulse waveforms with a 90° phase difference, and the encoding acquisition module determines the current rotation direction of the cathode roller based on the phase order of the A / B phase signals.

[0091] For example, when the A-phase signal leads the B-phase signal, it is determined that the cathode roller is rotating in the forward direction, and the number of pulses in the current sampling period is accumulated in the forward direction; when the B-phase signal leads the A-phase signal, it is determined that the rotation is in the reverse direction, and the count is accumulated in the reverse direction.

[0092] During this process, the pulse count results within the sampling period are cross-locked with the spindle zero-position trigger sequence. For example, whenever the cathode roller completes a full rotation and triggers the zero-position signal again, the MES system automatically checks whether the current cumulative pulse count matches the theoretical circumferential pulse value.

[0093] If a deviation is detected between the zero-point trigger time and the theoretical circumferential position, such as due to pulse omissions caused by high-speed operation or zero-point drift caused by mechanical jitter, the current sampling window is automatically re-divided. For example, the starting boundary of the current sampling period is redefined, and the subsequent circumferential angle mapping relationship is corrected, thereby ensuring that the cathode roller rotation trajectory data remains synchronized with the actual circumferential position.

[0094] Finally, the MES system generates high-precision cathode roller rotation trajectory data based on the corrected sampling window and dual-channel orientation counting results, and synchronously correlates it with copper foil thickness fluctuation data for subsequent circumferential deposition anomaly analysis.

[0095] Of particular importance, step S32 also includes: Control the spray swing arm to move along the cathode roller axis to the preset starting spray position and establish the corresponding axial spray section; The spray arm is controlled to move intermittently in a step-by-step reciprocating motion according to the axial section sequence of the cathode roller, so that the nozzles switch between adjacent spray sections one by one. When the spray arm moves to the corresponding spray section, it controls the nozzle group corresponding to that section to start spraying, and simultaneously closes the nozzle group of non-corresponding sections. The nozzle spraying sequence is switched according to the current moving direction of the spray arm, so that the spray coverage trajectory and the rotation direction of the cathode roller form an interlaced coverage path; After the spray arm completes a single axial reciprocating movement, the control nozzle group performs overlapping spraying on adjacent spray sections to form a continuous spray coverage area.

[0096] In one embodiment, an electrolytic copper foil continuous production line of a lithium battery copper foil manufacturing company is used as an example for illustration. The spray cleaning system is installed in the area above the cathode roller after it has detached from the electrolyte, and mainly includes a spray swing arm, a linear guide, a servo slide, multi-component zone nozzles, and a spray control valve assembly.

[0097] The spray arm is arranged laterally along the axial direction of the cathode roller, and its two ends are mounted on the linear guide rail via sliders. The servo slide is fixedly installed on the top of the cathode roller equipment frame and drives the spray arm to move along the axial direction of the cathode roller via a synchronous belt mechanism. The nozzle groups are arranged in sections according to the axial width of the cathode roller and installed at the bottom of the spray arm. Each nozzle group corresponds to a different axial spray section of the cathode roller.

[0098] During operation, the spray arm is first controlled to move along the axial direction of the cathode roller to the preset starting spray position. For example, before cleaning starts, the servo slide first drives the spray arm to move to the starting position at the left end of the cathode roller, and establishes multiple axial spray sections according to the axial width of the cathode roller, such as dividing it into the left section, the middle section and the right section.

[0099] Subsequently, the spray arm is controlled to move intermittently in a step-by-step reciprocating motion according to the axial segment sequence of the cathode roller. For example, the spray arm moves a fixed distance along the axial direction each time and then pauses briefly to allow the nozzle to complete spraying in the current spray segment before continuing to move to the next spray segment, thereby achieving segment-by-segment switching of the nozzle between adjacent segments.

[0100] When the spray arm moves to the corresponding spray section, only the nozzle group corresponding to that section is activated. For example, when the spray arm is located in the left area of ​​the cathode roller, only the left nozzle group is activated to perform spraying, while the middle and right nozzle groups are closed to avoid ineffective diffusion of the cleaning fluid; when the spray arm moves to the middle section, the middle nozzle group is switched on.

[0101] At the same time, the nozzle spraying sequence is switched according to the current moving direction of the spray arm. For example, when the spray arm moves from left to right, the nozzle group opens sequentially from front to back; while when the spray arm returns from right to left, the nozzle opening sequence is switched in the opposite direction, so that the spray coverage trajectory and the cathode roller's own rotation direction form an interlaced coverage path.

[0102] Because the surface of the cathode roller constantly changes its spray contact position during rotation, the staggered coverage path allows the spray liquid to wash the surface layer of the cathode roller from different angles, reducing local spray blind spots.

[0103] After the spray arm completes a single axial reciprocating movement, the nozzle group is further controlled to perform overlapping spraying on adjacent spray sections. For example, at the junction of the left and middle sections, the nozzle groups on both sides are controlled to open simultaneously for a short time, so that a partially overlapping spray area is formed between adjacent sections, thereby avoiding the appearance of uncleaned areas at the junction of axial sections, and finally forming a continuous spray coverage area.

[0104] Most importantly, the nozzle spraying sequence is switched according to the current moving direction of the spray arm, so that the spray coverage trajectory and the rotation direction of the cathode roller form an interlaced coverage path. Specifically: Obtain the current axial movement direction of the spray arm, the real-time rotation direction of the cathode roller, and the current circumferential position of the cathode roller surface in the spray area; The direction of liquid film tailing on the surface of the cathode roller is predetermined based on the rotation direction of the cathode roller, and the nozzle group is divided into a front nozzle group and a rear nozzle group. When the spray arm moves along the direction of the liquid film trailing, the front nozzle group is controlled to start spraying in advance and the rear nozzle group is delayed in closing, so that adjacent spray areas form axially overlapping liquid films. When the spray arm moves against the direction of the liquid film trailing, the rear nozzle group is controlled to start spraying in advance, and the front nozzle group is closed in a stepped delay to change the direction of liquid film coverage and extension. The spraying start time of adjacent nozzle groups is controlled to be synchronously and staggered with the circumferential rotation position of the cathode roller, so that a cross-distributed spiral spray coverage trajectory is formed on the surface of the cathode roller. At the reversing position of the spray arm, the corresponding nozzle group is controlled to perform short-time pulse enhanced spraying to establish a transition spray zone in the reversing area.

[0105] In one embodiment, an electrolytic copper foil continuous production line of a lithium battery copper foil manufacturing company is used as an example. The spray arm in the spray system is positioned above the cathode roller, which is continuously rotated by a drive motor. The spray arm is driven by a servo slide to move left and right reciprocally along the cathode roller axis. During rotation, a cleaning liquid film extending in the rotation direction forms on the surface of the cathode roller. Therefore, by dynamically switching the nozzle spray sequence, the spray trajectory and the cathode roller rotation direction form an interlaced coverage path.

[0106] During operation, the system first acquires the current axial movement direction of the spray arm, the real-time rotation direction of the cathode roller, and the circumferential position of the cathode roller surface currently entering the spray area. For example, the MES system reads the servo slide movement status and the circumferential angle data output by the rotary encoder in real time to determine that the spray arm is currently moving from left to right, while the cathode roller is rotating clockwise, and determines that the circumferential position of the cathode roller currently entering the spray area is the 120° region.

[0107] Subsequently, the direction of liquid film trailing on the surface of the cathode roller is predetermined based on the rotation direction of the cathode roller. For example, when the cathode roller rotates clockwise, the cleaning liquid will trail and spread backward along the tangential direction of rotation. Therefore, the nozzles on the front side of the spray arm's movement direction are divided into the front nozzle group, and the nozzles on the rear side are divided into the rear nozzle group.

[0108] As the spray arm moves along the direction of the liquid film trailing, for example, when the spray arm moves from left to right and the liquid film also trails to the right, the front nozzle group is controlled to open and spray in advance, so that the cleaning fluid preferentially covers the surface of the cathode roller that is about to enter the spray area; at the same time, the rear nozzle group is closed with a delay, so that the liquid film behind continues to extend, thereby forming an axially overlapping liquid film between adjacent spray areas. This can avoid liquid film breakage during axial movement.

[0109] When the spray arm moves against the direction of the liquid film trailing, for example, when the spray arm returns from right to left while the liquid film still trails along the right side, the rear nozzle group is controlled to start spraying earlier, and the front nozzle group is closed in a stepped delay. Specifically, the nozzles near the tail of the arm open first, while the nozzles near the front close sequentially, so that the liquid film coverage direction gradually extends towards the return flow direction, thereby changing the spreading path of the liquid film on the cathode roller surface.

[0110] Simultaneously, the spray activation timing of adjacent nozzle groups is synchronized with the circumferential rotation position of the cathode roller. For example, when the cathode roller rotates a certain angle, adjacent nozzle groups sequentially switch spray states according to a preset time difference, causing the spray liquid to form a cross-distributed spiral spray coverage trajectory on the rotating surface of the cathode roller. This trajectory allows the same circumferential area to be sprayed and scourd at different angles during different rotation cycles, thereby improving the uniformity of cleaning and coverage of localized deposited areas.

[0111] In addition, when the spray arm moves to the axial reversal position, the corresponding nozzle group is controlled to perform short-time pulse enhanced spraying. For example, when the spray arm reaches the right end of the cathode roller and is ready to move in the reverse direction, the right-end nozzle group will briefly increase the spray pressure and spray frequency to form a locally enhanced spray band in the reversal area, thereby avoiding the problem of reduced spray coverage caused by the deceleration stage of the arm reversal, and forming a stable and continuous transition spray area at the axial end.

[0112] This invention also provides a MES system control system based on intelligent manufacturing of copper foil, referring to... Figure 5 The system is used to implement the above-mentioned MES system control method for intelligent manufacturing of copper foil production. The MES system control system for intelligent manufacturing of copper foil production includes: The copper foil acquisition module is used to control the cathode roller to be immersed in the electrolytic cell for electrolytic copper foil production, and to collect parameters such as copper foil thickness, cathode roller speed, electrolyte temperature and current density and then upload them to the MES system. The thickness modeling module is used to construct the circumferential thickness fluctuation curve of the cathode roller based on the copper foil thickness and generate periodic thickness deviation data. The deposition analysis module is used to control the spray assembly to perform spray cleaning on the cathode roller surface, and analyze the adhesion status on the cathode roller surface based on periodic thickness deviation data to generate deposition anomaly distribution data. The parameter control module is used to control the rectifier power supply to adjust the current density and control the drive motor to adjust the cathode roller speed by using deposition anomaly distribution data. The winding traceability module is used to control the winding mechanism to perform constant tension winding of copper foil and generate corresponding production traceability data.

[0113] Therefore, the embodiments should be considered as exemplary and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of the equivalents of the application are intended to be included within the invention.

[0114] The above description is merely a specific embodiment of the present invention, enabling those skilled in the art to understand or implement the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features of the invention herein.

Claims

1. A method for managing and controlling an MES system based on intelligent manufacturing of copper foil, characterized in that, Includes the following steps: Step S1: Control the cathode roller to be immersed in the electrolytic cell to electrolyze and grow foil, and collect parameters such as copper foil thickness, cathode roller speed, electrolyte temperature and current density and upload them to the MES system; Step S2: Construct the circumferential thickness fluctuation curve of the cathode roller based on the copper foil thickness, and generate periodic thickness deviation data; Step S3: Control the spray assembly to perform spray cleaning on the cathode roller surface, and analyze the adhesion status of the cathode roller surface based on the periodic thickness deviation data to generate deposition anomaly distribution data; Step S4: Adjust the current density of the rectifier power supply by controlling the deposition anomaly distribution data, and adjust the cathode roller speed by controlling the drive motor; Step S5: Control the winding mechanism to perform constant tension winding of the copper foil and generate corresponding production traceability data.

2. The MES system control method based on intelligent manufacturing of copper foil production according to claim 1, characterized in that, The specific steps for controlling the immersion of the cathode roller in the electrolytic cell for electrolytic foil production are as follows: The lifting mechanism is activated to lower the cathode roller from its initial position, gradually bringing it closer to the surface of the electrolytic cell. The cathode roller is controlled to enter the electrolytic cell smoothly at a preset speed and complete the full immersion positioning. The rectifier power supply is started at the same time as the cathode roller enters the electrolytic cell, so that a stable current loop is formed between the cathode roller and the anode. The cathode roller drive motor is controlled to rotate the cathode roller at a constant speed, so that copper ions are continuously deposited on its surface to form a copper foil layer; Start the electrolyte circulation pump and maintain continuous electrolyte flow, and control the liquid level adjustment mechanism to fine-tune the liquid level in the electrolytic cell so that the effective working area of ​​the cathode roller remains stably submerged.

3. The MES system control method based on intelligent manufacturing of copper foil production according to claim 1, characterized in that, Step S3 includes the following steps: Step S31: Start the spray pump and open the spray valve assembly to allow the cleaning solution to be delivered to the nozzles through the spray pipeline; Step S32: Control the spray arm to reciprocate along the axial direction of the cathode roller, and at the same time control the nozzle to spray cleaning liquid onto the surface of the cathode roller in sections; Step S33: Control the cathode roller to rotate at a low speed, so that its surface enters the spraying area segment by segment to complete the cleaning and covering; Step S34: Divide the thickness fluctuations at different circumferential positions into segments based on the periodic thickness deviation data; Step S35: Determine the adhesion state distribution at corresponding positions on the cathode roller surface based on the differences in section thickness fluctuations; Step S36: Generate cathode roller deposition anomaly distribution data based on the adhesion state distribution.

4. The MES system control method for intelligent manufacturing of copper foil production according to claim 3, characterized in that, Step S34 includes: Extract the periodic characteristics of periodic thickness deviation data and identify repetitive fluctuation feature points within a single rotation cycle; Phase synchronization mapping of thickness deviation data is performed based on cathode roller rotation speed to establish the correspondence between thickness fluctuation and circumferential angle; Based on the phase interval changes between repetitive wave characteristic points, the circumferential division boundary position is determined, and a non-uniform segmentation result is formed; The periodic thickness deviation data within each non-uniform segment division result are clustered and merged to generate a set of thickness fluctuation sequences for the corresponding segment.

5. The MES system control method for intelligent manufacturing of copper foil production according to claim 4, characterized in that, Determining the circumferential boundary position based on the phase interval change between repetitive wave feature points includes: Peak and valley detection are performed on periodic thickness deviation data to extract multiple recurring fluctuation feature points; Calculate the phase difference between adjacent repeating wave feature points to form a phase interval sequence; Perform a difference operation on the phase interval sequence to obtain the phase interval change; The phase interval change is compared with a preset change threshold. When the change exceeds the preset change threshold, it is determined as a candidate boundary point. The circumferential positions corresponding to all candidate boundary points are taken as the circumferential division boundary positions.

6. The MES system control method for intelligent manufacturing of copper foil production according to claim 4, characterized in that, Step S35 includes: Obtain the thickness fluctuation sequence of each circumferential segment, and calculate the average deviation value and fluctuation energy value of the segment to form the segment thickness feature vector; Based on the phase intervals corresponding to the boundary positions in the circumferential division, the thickness feature vectors of each segment are mapped by boundary constraints to obtain a thickness distribution sequence with boundary constraints. Differential alignment of the thickness distribution sequences of adjacent circumferential segments at the boundary position is performed to extract the abrupt change intensity parameter at the boundary; Based on the joint determination of mutation intensity parameters and internal fluctuation stability of the segment, the circumferential segment is divided into attachment enhancement zone, attachment transition zone and attachment weakening zone. The adhesion state classification results of each circumferential section are reconstructed according to the circumferential position to generate the adhesion state distribution of the corresponding position on the cathode roller surface.

7. The MES system control method for intelligent manufacturing of copper foil production according to claim 6, characterized in that, The adhesion state classification results of each circumferential section are reconstructed according to the circumferential position to generate the adhesion state distribution at the corresponding position on the cathode roller surface as follows: Obtain the attachment status classification results and their circumferential position coordinates for each circumferential segment; The attachment status classification results of each circumferential segment are sequentially spliced ​​according to the arrangement order of the circumferential position coordinates. Perform continuity checks on the attachment state boundaries between adjacent circumferential sections and correct the boundaries at state transition locations; The corrected adhesion state of each circumferential section is mapped to the corresponding circumferential region of the cathode roller to form a circumferential adhesion state distribution map on the surface of the cathode roller. The circumferential adhesion state distribution map is periodically unfolded based on the rotation trajectory of the cathode roller to generate adhesion state distribution data at corresponding positions on the cathode roller surface.

8. The MES system control method for intelligent manufacturing of copper foil production according to claim 7, characterized in that, Methods for obtaining the rotation trajectory of the cathode roller include: The rotary encoder is fixedly installed on the end of the cathode roller main shaft, and the output shaft of the rotary encoder rotates synchronously with the cathode roller main shaft. The control encoding acquisition module continuously receives the angle pulse signal output by the rotary encoder; When the cathode roller drive motor drives the cathode roller to rotate, the corresponding number of pulses is recorded according to the preset sampling period; The number of pulses in each sampling period is transmitted to the MES system and converted into the corresponding circumferential rotation position of the cathode roller. By arranging the circumferential rotation positions in the continuous rotation sequence of the cathode roller, the rotation trajectory data of the cathode roller is generated.

9. The MES system control method for intelligent manufacturing of copper foil production according to claim 8, characterized in that, When the cathode roller drive motor drives the cathode roller to rotate, the number of pulses recorded according to the preset sampling period also includes: When the cathode roller drive motor drives the cathode roller to rotate, a zero-position trigger sampling window is established based on the reference pulse output by the cathode roller spindle zero-position sensor, and this trigger sampling window is used as the first counting starting point. The rotary encoder A / B phase signals are simultaneously input in each sampling period, and the pulses are counted in dual-channel phase direction determination, and the count value is accumulated according to the direction. The pulse count within the sampling period is cross-locked with the spindle zero-position trigger sequence. When zero-position signal drift is detected, the current sampling window is automatically re-segmented at the boundary.

10. A MES system control system based on intelligent manufacturing of copper foil, characterized in that, The MES system for managing and controlling copper foil-based intelligent manufacturing, as described in claim 1, comprises: The copper foil acquisition module is used to control the cathode roller to be immersed in the electrolytic cell for electrolytic copper foil production, and to collect parameters such as copper foil thickness, cathode roller speed, electrolyte temperature and current density and then upload them to the MES system. The thickness modeling module is used to construct the circumferential thickness fluctuation curve of the cathode roller based on the copper foil thickness and generate periodic thickness deviation data. The deposition analysis module is used to control the spray assembly to perform spray cleaning on the cathode roller surface, and analyze the adhesion status on the cathode roller surface based on periodic thickness deviation data to generate deposition anomaly distribution data. The parameter control module is used to control the rectifier power supply to adjust the current density and control the drive motor to adjust the cathode roller speed by using deposition anomaly distribution data. The winding traceability module is used to control the winding mechanism to perform constant tension winding of copper foil and generate corresponding production traceability data.

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