Multimodal control device and method for wrinkle-free bonding of spherical films

Abstract

This application belongs to the field of curved surface functional structure optimization, specifically relating to a multimodal control device and method for wrinkle-free bonding of spherical films. The device includes a support frame, a multi-axis robotic arm, a multi-point adjustable support structure, a support base, an infrared heater, a cooling unit, and a sliding base. The multi-axis robotic arm, with its end effector centered on the sphere, can perform flexible multi-degree-of-freedom movements along the X, Y, Z axes and rotational axes, enabling omnidirectional scanning of the sphere. The strip-shaped airbags of the multi-point adjustable support structure bond to the sphere. Pressure sensors monitor the stress distribution across the entire surface of the film in real time, causing the infrared heater to soften, followed by cooling by the cooling unit. Furthermore, the through-holes in the grooves of the support base, connected to a vacuum pump via pipes, are used to remove air bubbles between the film and the sphere, thus eliminating wrinkles on the functional film bonded to the spherical surface and optimizing its bonding structure.

Description

Technical Field

[0001] This application belongs to the field of surface functional structure optimization, specifically relating to a multimodal control device and method for wrinkle-free bonding of spherical films. It is used to eliminate wrinkles on functional films bonded to a spherical surface, thereby optimizing the bonding structure. Background Technology

[0002] With the continuous advancement of technology, the demand for non-developable surfaces with functional thin films is increasing. As a typical non-developable surface, the sphere can meet the needs of various applications by attaching a thin film with specific functions to its surface, such as optical devices (VR / AR lenses), electronic devices (spherical sensor packaging), and aerospace (satellite radome film covering).

[0003] Currently, the main technologies for attaching thin films to spherical surfaces include spray printing, physical and chemical vapor deposition (PCVD), and lamination. Among these, spray printing and PCVD are limited in application due to their complex processes, high costs, and slow production speeds. Lamination, on the other hand, has become the primary method for attaching thin films to spherical surfaces because of its relatively simple operation, low cost, and ability to achieve large-scale production.

[0004] Thin-film bonding technologies are mainly classified into: manual bonding, mechanical pressing, vacuum adsorption bonding, and thermoforming bonding. While manual bonding allows for adjustments based on the film's bonding state, its limited bonding precision and uneven stress result in a high wrinkle rate on the spherical surface, making it difficult to meet the bonding requirements of precision components. Mechanical pressing, although a mature process suitable for mass production, limits the film's ability to dynamically adapt to changes in the spherical curvature, easily causing localized stress concentrations that can lead to film breakage after bonding or rebound wrinkling later in use. Vacuum adsorption bonding, while able to better adhere the film to the spherical surface by removing most air bubbles, cannot eliminate residual stress within the film, leaving minor localized deformations that affect its normal performance. Thermoforming bonding, while able to adhere the film to irregular parts of the spherical surface through heating and applying pressure, is prone to shrinkage and deformation during softening due to the sphere's non-extensibility, resulting in wrinkles and potentially micro-cracks due to localized overheating.

[0005] In summary, due to the geometric mismatch between the non-stretchable spherical surface and the planar film, the stress cannot be evenly distributed when the film is bonded to the spherical surface, inevitably resulting in wrinkles. Although current solutions reduce wrinkle formation to some extent, they cannot completely eliminate them, thus affecting the normal service life and performance of the film.

[0006] Therefore, in order to eliminate the wrinkles generated when the film is bonded to a spherical surface, there is an urgent need to develop a multimodal control device and method for wrinkle-free bonding of spherical films.

[0007] The statements herein provide only background information relevant to this application and do not necessarily constitute prior art. Summary of the Invention

[0008] To overcome the shortcomings of existing technologies, the purpose of this application is to provide a multimodal control device and method for wrinkle-free bonding of spherical films, thereby achieving high-precision, wrinkle-free bonding between the film and the surface of the sphere, while effectively controlling the stress distribution during the bonding process, avoiding the generation of wrinkles and bubbles, eliminating residual stress, and improving the bonding quality and the stability of the finished product.

[0009] To achieve the above objectives, this application employs the following technical solution: In some embodiments of this application, a multimodal control device for wrinkle-free bonding of spherical thin films is provided, the device comprising: The support frame has a control panel located on one side, which integrates a master switch, parameter adjustment buttons, and a display screen. A multi-axis robotic arm is connected to a support frame via a support bracket and is housed within the support frame. The multi-axis robotic arm is capable of multiple degrees of freedom of movement along the X, Y, Z axes and the rotation axis, and is used to scan the contour of a sphere and collect data on the surface of the sphere. A multi-point adjustable support structure is located within a support frame and includes 16 support rods arranged in a circular array around the sphere. Each support rod has a pressure sensor on its outer side, which is electrically connected to a data processing module. Each support rod has a strip-shaped airbag on its inner side, which is in direct contact with the membrane and the sphere. The strip-shaped airbag is equipped with an inlet pipe and an outlet pipe, which are connected to a pressure control system. A support base is located directly below a multi-point adjustable support structure. A groove is provided in the middle of the support base to hold a sphere. Multiple evenly distributed through holes are provided in the groove. The through holes are connected to a vacuum pump through pipes for suction of air bubbles between the membrane and the sphere. The vacuum pump is located below the air pressure control system. An infrared heater is located inside the support frame and includes a lifting plate, a multi-wheel rod, a universal ball joint, and a heating plate. The lifting plate is connected to the support frame, and one end of the lifting plate is connected to the multi-wheel rod. The other end of the multi-wheel rod is connected to the heating plate via the universal ball joint. The infrared heater is located outside the multi-point adjustable support structure, forming a heating zone. The cooling unit includes a U-shaped coolant pipe and a coolant circulation tank. The coolant circulation tank is connected to the U-shaped coolant pipe through a coolant inlet and a coolant outlet. The U-shaped coolant pipe is located within a support frame, and the U-shaped cooling zone formed therein is used to accommodate the heated sphere and film, allowing the film to cool and solidify. A sliding base is located below the support frame, and the support base is disposed on the sliding base. The sliding base drives the support base to slide between the heating zone and the cooling zone via a slide rail.

[0010] In some embodiments of this application, the support frame is generally arranged in a double three-dimensional frame layout, with the heating zone located in the first three-dimensional frame and the cooling zone located in the second three-dimensional frame.

[0011] In some embodiments of this application, the top of the multi-axis robotic arm is a drive motor, which is mounted on a support frame via a top plate below it. A three-axis is also connected below the drive motor, and a horizontal bar is connected below the three-axis. Two symmetrically distributed scanning plates are connected to the two ends of the horizontal bar. The three-axis and the motor at the ends of the axes drive the scanning plates to perform omnidirectional scanning of the sphere and the thin film.

[0012] In some embodiments of this application, the three-axis system integrates the transmission of three linear axes: X, Y, and Z. Each of the three axes has an independently installed drive motor at its end. The movement of each axis is independently driven by the motor at the corresponding end of the axis. In conjunction with the transmission of the horizontal bar, the independent movement of the three axes or multi-axis linkage can be realized. At the same time, it can also realize rotational movement around the corresponding axis. Ultimately, the end effector of the multi-axis robotic arm can complete multi-degree-of-freedom flexible movement of the X, Y, Z axes and rotation axis with the sphere as the center, realizing omnidirectional scanning of the sphere.

[0013] In some embodiments of this application, a multi-axis robotic arm extends vertically downward for scanning the outline of a sphere; the sphere is positioned directly below the multi-axis robotic arm.

[0014] In some embodiments of this application, the strip-shaped airbags inside the multi-point adjustable support structure expand outwards when inflated, contacting the membrane and stretching and extending, and wrapping and fitting the sphere; as the airbags inflate and deflate to different degrees, they can fit the spheres of different sizes, and through subsequent vibration, they can release the residual stress inside the membrane, eliminating the slight deformation that may occur in the membrane.

[0015] In some embodiments of this application, there are two infrared heaters, which are symmetrically distributed on both sides of the multi-point adjustable support structure.

[0016] In some embodiments of this application, the sliding base includes a sliding drive motor, an internal threaded slider, a drive screw, and a shaft seat. The motor drives the sliding plate to move back and forth between the heating zone and the cooling zone via the slide rail.

[0017] In some embodiments of this application, the pressure sensor is a DMD-466 pressure sensor. By setting a pressure sensor on the outside of each support rod, the stress distribution of the entire film is monitored in real time, so that the infrared heater can be accurately aimed and heated, reducing energy consumption.

[0018] In some embodiments of this application, the infrared heaters symmetrically distributed on both sides have a support structure composed of multiple connecting rods. The ends of the multiple connecting rods are connected to the heating plate via universal balls. This allows for adjustment of the irradiation angle and distance of the infrared heaters according to actual conditions, achieving precise heating and avoiding problems such as shrinkage and deformation of the film.

[0019] In some embodiments of this application, a vacuum pump is connected to a support base via a pipe and uniformly distributed micropores to draw out residual air bubbles between the film and the sphere, thereby achieving a vacuum negative pressure and eliminating the air bubbles left between the film and the sphere.

[0020] In some embodiments of this application, the coolant outlet and coolant inlet are located in the middle of the U-shaped coolant pipe and connected to the coolant circulation tank; the coolant that flows into the pipe circulates once and then returns to the outlet to dissipate heat, and then circulates again. While ensuring the cooling effect, it also makes the temperature gradually decrease in a step-like manner to prevent the film from being damaged due to large differences in temperature.

[0021] In some embodiments of this application, a drive motor is installed in the sliding base. The motor is connected to a lead screw, and the moving plate is moved by the slide rails on both sides. When the motor rotates forward, the moving plate and the ball move to the cooling area; when the motor rotates in reverse, the moving plate and the ball return to the scanning and monitoring heating area.

[0022] In some embodiments of this application, the movable plate, along with the support base and the multi-point adjustable support structure, moves to the cooling zone.

[0023] In other embodiments of this application, a method for operating the multimodal control device for adjusting the wrinkle-free bonding of a thin film on a spherical surface as described above is provided, comprising the following steps: Press the master switch to start the device. On the control panel of the device, set the bonding parameters, including the selected film material type and the size of the ball. At the same time, confirm that the parameter settings are correct through the display screen and set the operating mode. Place the target ball with the bonded film on the support base. Press the start switch, and the multi-axis robotic arm extends vertically downward from the top center of the device. Multiple motors drive the multi-axis robotic arm to move along the X, Y, Z axes and the rotation axis, scanning and capturing the outline of the sphere from all directions to obtain surface data information of the sphere. The multi-axis robotic arm transmits the scanned data to the control system, and the control system drives the air pressure control system to inflate the strip-shaped airbags according to the data, so that the 16 strip-shaped airbags tightly wrap the sphere. After the strip-shaped airbag completely encloses the sphere, multiple pressure sensors monitor the stress distribution over the entire membrane and transmit the monitored stress data to the data processing module. The data processing module analyzes the received stress data. For the high-stress areas of the membrane detected by the pressure sensors, infrared heaters are used to directionally heat and soften the high-stress areas by adjusting the angle and distance. After the heating and softening process is completed, the vacuum pump is started to draw the air between the film and the sphere through the micropores. At the same time, the strip airbag vibrates at 20Hz for 5 minutes to release the residual stress inside the film and prevent demolding rebound from causing secondary wrinkles. After the vibration ends, the motor of the sliding base rotates forward, and the moving plate moves the softened and bonded film sphere towards the cooling zone, where it stops to gradually cool down, allowing the film to set and completing the bonding process with the sphere. After the shape is set, the motor reverses and the ball returns to the scanning and monitoring heating area; at this time, the device automatically stops running, and the main switch is pressed to turn off the power; carefully remove the bonded finished product to avoid damage; finally, check and clean the device to prepare for the next use.

[0024] Compared with the prior art, this application has at least the following advantages: This application discloses a multimodal control device for adjusting the wrinkle-free bonding of a film on a spherical surface. It utilizes the multi-degree-of-freedom motion characteristics of a multi-axis robotic arm to precisely scan and acquire data along the X, Y, Z axes and the rotation axis of the target sphere. Based on the acquired data, a pneumatic control system precisely regulates the internal air pressure of the array-type strip-shaped airbag units, causing the airbag units to expand orderly in all directions, forming a contoured, wrapping contact with the spherical substrate. Through the uniform transmission of gas pressure, a tensile and stretching force is applied to the film, thereby improving the film's adaptability within the spherical bonding range, effectively alleviating the stress concentration problem caused by the geometric mismatch between the non-developable curved surface and the planar film, and enhancing the bonding stability of the film on the spherical surface.

[0025] This application discloses a multimodal control device for adjusting the wrinkle-free bonding of a thin film on a spherical surface. Its multi-point adjustable support structure features an outer ring configuration of a pressure sensor array based on the piezoresistive effect, enabling real-time monitoring of the film's stress data across its entire surface. A data processing module performs in-depth analysis of the collected data, accurately identifying high-stress areas requiring heating and softening. An infrared heater operates based on the principle of thermal radiation, achieving precise directional heating of high-stress areas through an adjustable bracket combining multi-wheel rods and a universal ball joint. This heating method can control the range and intensity of heat transfer, effectively avoiding shrinkage and deformation of the film due to improper heating. Simultaneously, this method effectively softens the film, reducing its internal stress, thereby reducing energy consumption and improving heating efficiency.

[0026] This application discloses a multimodal control device for adjusting the wrinkle-free bonding of films on a spherical surface, which integrates a synergistic mechanism of vacuum adsorption and micro-vibration. A vacuum pump generates negative pressure through micropores on its bottom support plate, achieving directional suction of air between the film and the sphere from the top of the sphere downwards, based on Bernoulli's principle in fluid dynamics, rapidly eliminating air bubbles. Simultaneously, a strip-shaped airbag performs micro-vibration at a frequency of 20 Hz for 5 minutes. Based on the principle of vibration aging, this induces minute displacements within the film, releasing residual stress, eliminating minor deformations, effectively preventing secondary wrinkles caused by film springback after demolding, and ensuring the long-term stability of the film bonding effect.

[0027] This application discloses a multimodal control device for adjusting the wrinkle-free bonding of a film on a spherical surface. It features dual functional zones: a heating zone and a cooling zone. A sliding base facilitates the movement of the sphere between these zones. Infrared heating softens the film to promote bonding, while vacuum adsorption and micro-vibration eliminate air bubbles and residual stress. The cooling zone utilizes circulating coolant to create a stepped temperature gradient, allowing the film to set. These interconnected and coordinated processes achieve a wrinkle-free, tight bonding of the film on the sphere, significantly shortening the production cycle and meeting the demands of large-scale industrial production.

[0028] This application discloses a multimodal control device for adjusting the wrinkle-free bonding of thin films on a spherical surface, which is widely applicable to various types of functional films and spheres of various sizes. This control device not only has significant application value in the flexible electronics industry but also demonstrates unique advantages in multiple fields such as optics and packaging. Due to its design flexibility and adaptability, the device possesses strong practicality and versatility, meeting the diverse needs of different industries for precise film bonding. Attached Figure Description

[0029] The accompanying drawings, which form part of this application, are used to provide a further understanding of this application. The illustrative embodiments of this application and their descriptions are used to explain this application and do not constitute an undue limitation of this application.

[0030] Figure 1 This is a schematic diagram of the overall structure of the sphere located in the heating zone in the multimodal control device in some embodiments of this application; Figure 2 This is a schematic diagram of the overall structure of the sphere located in the cooling zone in the multimodal control device in some embodiments of this application; Figure 3 This is a front view of a multimodal control device in some embodiments of this application; Figure 4 This is a schematic diagram of the multi-axis robotic arm structure of the multimodal control device in some embodiments of this application; Figure 5 This is a schematic diagram of a multi-point adjustable support structure in some embodiments of this application; Figure 6 This is a schematic diagram of the structure of the support base in some embodiments of this application; Figure 7 This is a schematic diagram of the infrared heater structure of the multimodal control device in some embodiments of this application; Figure 8 This is a schematic diagram of the sliding base structure of the multimodal control device in some embodiments of this application; Figure 9 This is a schematic diagram of the cooling unit in some embodiments of this application; The diagram exaggerates the spacing or dimensions between parts to show their positions; the diagram is for illustrative purposes only. The components are as follows: 1. Heating zone; 2. Cooling zone; 3. Drive motor; 4. Top plate; 5. Support frame; 6. Air pressure control system; 7. Moving plate; 8. U-shaped coolant pipe; 9. Coolant circulation tank; 10. Control panel; 11. Multi-axis robotic arm; 12. Horizontal bar; 13. Scanning plate; 14. Multi-point adjustable support structure; 15. Strip-shaped airbag; 16. Pressure sensor; 17. Inlet pipe; 18. Outlet pipe; 19. Vacuum pump; 20. Shaft seat; 21. Support base; 22. Through hole; 23. Heating plate; 24. Universal ball; 25. Multi-wheel rod; 26. Lifting plate; 27. Sliding drive motor; 28. Internal threaded slider; 29. ​​Sliding base; 30. Drive screw. Detailed Implementation

[0031] It should be noted that the following detailed descriptions are illustrative and intended to provide further explanation of this application. Unless otherwise specified, all technical and scientific terms used in this application have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains.

[0032] The following is in conjunction with the instruction manual appendix. Figure 1-9 The technical solution of this application will be further explained and described.

[0033] In some embodiments of this application, a multimodal control device for wrinkle-free bonding of spherical thin films is provided, the device comprising: The support frame has a control panel 10 located on one side, which integrates a master control switch, parameter adjustment buttons, and a display screen. A multi-axis robotic arm 11 is connected to a support frame via a support bracket 5 and is housed within the support frame. The multi-axis robotic arm 11 is capable of moving along the X, Y, Z axes and the rotation axis with multiple degrees of freedom, and is used to scan the contour of a sphere and collect surface data of the sphere. The multi-point adjustable support structure 14 is located within the support frame and includes 16 support rods arranged in a ring array around the sphere. Each support rod has a pressure sensor 16 on its outer side, which is electrically connected to the data processing module. Each support rod has a strip-shaped airbag 15 on its inner side, which is in direct contact with the membrane and the sphere. The strip-shaped airbag 15 is provided with an air inlet pipe 17 and an air outlet pipe 18, which are connected to the air pressure control system 6. A support base 21 is located directly below the multi-point adjustable support structure 14. A groove is provided in the middle of the support base 21 for placing a sphere. A plurality of evenly distributed through holes 22 are provided in the groove. The through holes 22 are connected to a vacuum pump 19 through pipes for suction of air bubbles between the membrane and the sphere. The vacuum pump 19 is located below the air pressure control system 6. An infrared heater, located inside the support frame, includes a lifting plate 26, a multi-wheel rod 25, a universal ball joint 24, and a heating plate 23. The lifting plate 26 is connected to the support frame, and one end of the lifting plate 26 is connected to the multi-wheel rod 25. The other end of the multi-wheel rod 25 is connected to the heating plate 23 via the universal ball joint 24. The infrared heater is located outside the multi-point adjustable support structure 14, forming a heating zone 1. The cooling unit includes a U-shaped coolant pipe 8 and a coolant circulation tank 9. The coolant circulation tank 9 is connected to the U-shaped coolant pipe 8 through a coolant inlet and a coolant outlet. The U-shaped coolant pipe 8 is located within the support frame, and the U-shaped cooling zone 2 formed therein is used to accommodate the heated sphere and film, so that the film can be cooled and shaped. A sliding base 29 is located below the support frame, and the support base 21 is disposed on the sliding base 29. The sliding base 29 drives the support base 21 to slide between the heating zone 1 and the cooling zone 2 via a slide rail.

[0034] In some embodiments of this application, the top of the multi-axis robotic arm 11 is a drive motor 3, which is mounted on the support frame 5 via a top plate 4 below it. A three-axis is also connected below the drive motor 3, and a horizontal bar 12 is connected below the three-axis. Two symmetrically distributed scanning plates 13 are connected to both ends of the horizontal bar 12. The three-axis and the motor at the ends of the axes drive the scanning plates 13 to perform omnidirectional scanning of the sphere and the thin film.

[0035] In some embodiments of this application, the three-axis system integrates the transmission of three linear axes: X, Y, and Z. Each of the three axes is independently equipped with a drive motor 3, and the movement of each axis is independently driven by the motor at the corresponding axis end. In conjunction with the transmission of the horizontal bar 12, the independent movement of the three axes or multi-axis linkage can be realized. At the same time, it can also realize the rotational movement around the corresponding axis. Ultimately, the end of the multi-axis robotic arm 11 can complete the flexible movement of the X, Y, Z axes and the rotation axis with the sphere as the center, and realize the all-round scanning of the sphere.

[0036] In some embodiments of this application, the multi-axis robotic arm 11 extends vertically downward for scanning the outline of a sphere; the sphere is positioned directly below the multi-axis robotic arm 11.

[0037] In some embodiments of this application, the strip-shaped airbag 15 inside the multi-point adjustable support structure 14 expands outwards when inflated, contacts the film, and plays a role in stretching and extending, and wraps and fits the sphere; as the airbag is inflated and deflated to different degrees, it can fit the sphere of different sizes, and through subsequent vibration, it can cause the residual stress inside the film to be released, eliminating the slight deformation that may occur in the film.

[0038] In some embodiments of this application, there are two infrared heaters, which are symmetrically distributed on both sides of the multi-point adjustable support structure 14.

[0039] In some embodiments of this application, the sliding base 29 includes a sliding drive motor 27, an internal threaded slider 28, a drive screw 30, and a shaft seat 20. The motor drives forward and reverse rotation, so that the moving plate 7 can move back and forth between the heating zone 1 and the cooling zone 2 via the slide rail.

[0040] In some embodiments of this application, the pressure sensor 16 is a DMD-466 pressure sensor 16. By providing a pressure sensor 16 on the outer side of each support rod, the stress distribution of the entire film can be monitored in real time, enabling the infrared heater to be precisely aimed and heated, thus reducing energy consumption.

[0041] In some embodiments of this application, the infrared heaters symmetrically distributed on both sides have a support structure formed by connecting multiple wheel rods 25. The ends of the multiple wheel rods 25 are connected to the heating plate 23 via universal balls 24. This allows the irradiation angle and distance of the infrared heaters to be adjusted according to actual conditions, achieving precise heating and avoiding problems such as shrinkage and deformation of the film.

[0042] In some embodiments of this application, the vacuum pump 19 is connected to the uniformly distributed micropores on the support base 21 through a pipe, and sucks up the residual air bubbles between the film and the spherical surface of the sphere to achieve a vacuum negative pressure and eliminate the air bubbles left between the film and the sphere.

[0043] In some embodiments of this application, the coolant outlet and coolant inlet are located in the middle of the U-shaped coolant pipe 8 and connected to the coolant circulation tank 9; the coolant that flows into the pipe circulates once and then returns to the outlet to dissipate heat, and then circulates again. While ensuring the cooling effect, the temperature also gradually decreases in a step-like manner to prevent the film from being damaged due to large differences in temperature.

[0044] In some embodiments of this application, a drive motor 3 is installed in the sliding base 29. The motor is connected to a lead screw and the movable plate 7 is moved by the slide rails on both sides. When the motor rotates forward, the movable plate 7 and the ball move to the cooling zone 2; when the motor rotates in reverse, the movable plate 7 and the ball return to the scanning and monitoring heating zone 1.

[0045] In other embodiments of this application, a method for operating the multimodal control device for adjusting the wrinkle-free bonding of a thin film on a spherical surface as described above is provided, comprising the following steps: Press the master switch to start the device. On the control panel 10 of the device, set the bonding parameters, including the selected film material type and the size of the ball. At the same time, confirm that the parameter settings are correct through the display screen and set the operating mode. Place the target ball with the bonded film on the support base 21. When the start switch is pressed, the multi-axis robotic arm 11 extends vertically downward from the center of the top of the device. Multiple motors drive the multi-axis robotic arm 11 to move along the X, Y, Z axes and the rotation axis, scanning and capturing the outline of the sphere from all directions to obtain surface data information of the sphere. The multi-axis robotic arm 11 transmits the scanned data to the control system. The control system drives the air pressure control system 6 to inflate the strip-shaped airbags 15 according to the data, so that the 16 strip-shaped airbags 15 tightly wrap the sphere. After the strip-shaped airbag 15 completely wraps the sphere, multiple pressure sensors 16 monitor the stress distribution over the entire area of ​​the membrane and transmit the monitored stress data to the data processing module. The data processing module analyzes the received stress data. For the high-stress areas of the membrane detected by the pressure sensors 16, the infrared heater is used to directionally heat and soften the high-stress areas by adjusting the angle and distance. After the heating and softening process is completed, the vacuum pump 19 is started to draw air from between the film and the sphere through the micropores. At the same time, the strip airbag 15 runs at 20Hz for 5 minutes to release the residual stress inside the film and prevent secondary wrinkles caused by demolding rebound. After the vibration ends, the motor of the sliding base 29 rotates forward, and the moving plate 7 moves the softened and bonded film ball to the cooling zone 2, so that it stops in the cooling zone 2 for gradual cooling, so that the film is shaped and the bonding process with the sphere is completed. After the shape is set, the motor reverses and the ball returns to heating zone 1; at this time, the device automatically stops running, and the main switch is pressed to turn off the power; carefully remove the finished product after bonding to avoid damage to the finished product; finally, check and clean the device to prepare for the next use.

[0046] The above embodiments are merely preferred embodiments of the present invention and are not intended to limit the scope of protection of the present invention. Any changes made based on the design principles of the present invention, or any non-creative modifications made thereon, shall fall within the scope of protection of the present invention.

Claims

1. A multimodal control device for wrinkle-free lamination of spherical films, characterized in that, The device includes: The support frame has a control panel located on one side, which integrates a master switch, parameter adjustment buttons, and a display screen. A multi-axis robotic arm is connected to a support frame via a support bracket and is housed within the support frame. The multi-axis robotic arm is capable of multiple degrees of freedom of movement along the X, Y, Z axes and the rotation axis, and is used to scan the contour of a sphere and collect data on the surface of the sphere. A multi-point adjustable support structure is located within a support frame and includes 16 support rods arranged in a circular array around the sphere. Each support rod has a pressure sensor on its outer side, which is electrically connected to a data processing module. Each support rod has a strip-shaped airbag on its inner side, which is in direct contact with the membrane and the sphere. The strip-shaped airbag is equipped with an inlet pipe and an outlet pipe, which are connected to a pressure control system. A support base is located directly below a multi-point adjustable support structure. A groove is provided in the middle of the support base to hold a sphere. Multiple evenly distributed through holes are provided in the groove. The through holes are connected to a vacuum pump through pipes for suction of air bubbles between the membrane and the sphere. The vacuum pump is located below the air pressure control system. An infrared heater is located inside the support frame and includes a lifting plate, a multi-wheel rod, a universal ball joint, and a heating plate. The lifting plate is connected to the support frame, and one end of the lifting plate is connected to the multi-wheel rod. The other end of the multi-wheel rod is connected to the heating plate via the universal ball joint. The infrared heater is located outside the multi-point adjustable support structure, forming a heating zone. The cooling unit includes a U-shaped coolant pipe and a coolant circulation tank. The coolant circulation tank is connected to the U-shaped coolant pipe through a coolant inlet and a coolant outlet. The U-shaped coolant pipe is located within a support frame, and the U-shaped cooling zone formed therein is used to accommodate the heated sphere and film, allowing the film to cool and solidify. A sliding base is located below the support frame, and the support base is disposed on the sliding base. The sliding base drives the support base to slide between the heating zone and the cooling zone via a slide rail.

2. The multimodal control device for wrinkle-free bonding of spherical films according to claim 1, characterized in that, The top of the multi-axis robotic arm is a drive motor, which is mounted on a support frame via a top plate below it. Three axes are connected below the drive motor, and horizontal bars are connected below the three axes. Two symmetrically distributed scanning plates are connected to the two ends of the horizontal bars. The three axes and the motors at the ends of the axes drive the scanning plates to perform omnidirectional scanning of the sphere and the thin film.

3. The multimodal control device for wrinkle-free bonding of spherical films according to claim 2, characterized in that, The three-axis system integrates the transmission of three linear axes: X, Y, and Z. Each of the three axes has an independent drive motor installed at its end. The movement of each axis is independently driven by the motor at the corresponding end of the axis. In conjunction with the transmission of the horizontal bar, it can realize the independent movement of the three axes or the linkage of multiple axes. At the same time, it can also realize the rotational movement around the corresponding axis. Ultimately, the end effector of the multi-axis robotic arm can complete the flexible movement of multiple degrees of freedom of the X, Y, Z axes and the rotation axis with the sphere as the center, and realize the all-round scanning of the sphere.

4. The multimodal control device for wrinkle-free bonding of spherical films according to claim 1, characterized in that, The multi-axis robotic arm extends vertically downwards to scan the outline of the sphere; the sphere is positioned directly below the multi-axis robotic arm.

5. The multimodal control device for wrinkle-free bonding of spherical films according to claim 1, characterized in that, There are two infrared heaters, which are symmetrically distributed on both sides of the multi-point adjustable support structure.

6. The multimodal control device for wrinkle-free bonding of spherical films according to claim 1, characterized in that, The sliding base includes a sliding drive motor, an internal threaded slider, a drive screw, and a shaft seat. The motor drives the plate to move back and forth between the heating and cooling zones via the slide rail.

7. The multimodal control device for wrinkle-free bonding of spherical films according to claim 1, characterized in that, The pressure sensor is a DMD-466 pressure sensor. Each support rod has a pressure sensor installed on its outer side to monitor the stress distribution of the entire film in real time, so that the infrared heater can be aligned for heating and reduce energy consumption.

8. A multimodal control device for wrinkle-free bonding of spherical films according to claim 1, characterized in that, The coolant outlet and coolant inlet are located in the middle of the U-shaped coolant pipe and are connected to the coolant circulation tank. The coolant that enters the pipe circulates once and then returns to the outlet for heat dissipation, and then circulates again.

9. A multimodal control device for wrinkle-free bonding of spherical thin films according to claim 1, characterized in that, The sliding drive motor in the sliding base is connected to the lead screw. The moving plate is moved by the slide rails on both sides. When the motor rotates forward, the moving plate and the ball move to the cooling zone; when the motor rotates in reverse, the moving plate and the ball return to the heating zone.

10. A method for operating a multimodal control device for adjusting the wrinkle-free bonding of a thin film on a spherical surface, characterized in that, Using the multimodal control device for wrinkle-free bonding of spherical films as described in any one of claims 1-9, the method includes the following steps: Press the master switch to start the device. On the control panel of the device, set the bonding parameters, including the selected film material type and the size of the ball. At the same time, confirm that the parameter settings are correct through the display screen and set the operating mode. Place the target ball with the bonded film on the support base. Press the start switch, and the multi-axis robotic arm extends vertically downward from the top center of the device. Multiple motors drive the multi-axis robotic arm to move along the X, Y, Z axes and the rotation axis, scanning and capturing the outline of the sphere from all directions to obtain surface data information of the sphere. The multi-axis robotic arm transmits the scanned data to the control system, and the control system drives the air pressure control system to inflate the strip-shaped airbags according to the data, so that the 16 strip-shaped airbags tightly wrap the sphere. After the strip-shaped airbag completely encloses the sphere, multiple pressure sensors monitor the stress distribution over the entire membrane and transmit the monitored stress data to the data processing module. The data processing module analyzes the received stress data. For the high-stress areas of the membrane detected by the pressure sensors, infrared heaters are used to directionally heat and soften the high-stress areas by adjusting the angle and distance. After the heating and softening process is completed, the vacuum pump is started to draw the air between the film and the sphere through the micropores. At the same time, the strip airbag vibrates at 20Hz for 5 minutes to release the residual stress inside the film and prevent demolding rebound from causing secondary wrinkles. After the vibration ends, the sliding drive motor rotates forward, and the moving plate moves the softened and bonded film sphere towards the cooling zone, where it stops to gradually cool down, allowing the film to set and completing the bonding process with the sphere. After the shape is set, the sliding drive motor reverses and the ball returns to the heating zone; at this time, the device automatically stops running, and the main switch is pressed to turn off the power; carefully remove the bonded finished product to avoid damage; finally, check and clean the device to prepare for the next use.

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