An automatic loading and unloading edge material control system

Abstract

This invention discloses an automatic edge material loading and unloading device control system. The system includes: a PLC central control unit, responsible for logic operations, instruction issuance, and status monitoring, installed in the workshop electrical control cabinet and connected to a pneumatic actuation subsystem and a sensing detection subsystem via cables; a pneumatic actuation subsystem responsible for pushing loosened edge material away from the winding shaft in case of abnormalities; a sensing detection subsystem that monitors the copper foil edge material's position in real time, triggering alarm and reset signals; a communication and interface module for signal interaction with the foil production machine's early warning system; and a human-machine interface and remote monitoring module for status display, parameter setting, and fault diagnosis. This invention achieves automatic edge material rejection and winding recovery upon alarm triggering through pneumatic and electronic sensing linkage, requiring no manual intervention and ensuring the continuity and stability of foil production. It also reduces the risk of edge material entanglement and equipment damage, reduces copper foil loss, improves material utilization, is compatible with existing foil production lines, has low modification costs, and strong compatibility.

Description

Technical Field

[0001] This invention relates to the field of electrolytic copper foil production technology, and in particular to an automatic loading and unloading edge material control system. Background Technology

[0002] In the continuous production process of lithium-ion battery copper foil, the slitting process generates copper foil scrap. When the alarm light flashes due to thickness deviation, abnormal tension, or equipment failure, traditional processes usually require manual intervention to stop the machine. This not only affects production efficiency but also easily leads to scrap entanglement, equipment damage, or copper foil waste. Existing technologies lack automated scrap identification, rejection, and rewinding mechanisms, making it impossible to achieve integrated control of "alarm-rejection-rewinding-rewinding".

[0003] To address this issue, we propose an automatic loading and unloading edge material control system. Summary of the Invention

[0004] The purpose of this invention is to provide an automatic edge material loading and unloading device control system, which realizes automatic rejection and rewinding of edge material upon alarm triggering through pneumatic and electronic induction linkage, without manual intervention, thus ensuring the continuity and stability of foil production.

[0005] To achieve the above objectives, the present invention provides the following technical solution: An automatic loading and unloading edge material control system, the system comprising: The PLC central control unit is responsible for logic operations, instruction issuance and status monitoring. It is installed in the workshop electrical control cabinet and connected to the pneumatic actuation subsystem and sensing detection subsystem via cables. The pneumatic actuator subsystem is responsible for pushing the loosened edge material away from the take-up shaft in case of an anomaly; The sensing and detection subsystem monitors the arrival status of copper foil edge material in real time and triggers alarm and reset signals. The communication and interface module enables signal interaction with the foil-making machine's early warning system. The human-machine interface and remote monitoring module are used for status display, parameter setting, and fault diagnosis.

[0006] Furthermore, the pneumatic actuation subsystem includes a mounting plate, an air shaft located at the edge material winding station behind the slitting machine, an external inflation / deflation system, an electronic air valve, and a cylinder push rod mechanism. The drive shaft of the air shaft extends through to the other side of the mounting plate and is connected to a drive motor. The inflation / deflation system is used to inflate and deflate the air shaft. The electronic air valve is mounted on the air circuit control board, near the pneumatic interface between the cylinder and the winding shaft, and is connected to the PLC output port via a cable. The cylinder push rod mechanism includes a cylinder with its drive end penetrating through the mounting plate. The drive end of the cylinder is connected to a push plate, and a circular hole is opened at the center of the push plate. The air expansion shaft passes through the circular hole, and the diameter of the circular hole is larger than the diameter of the air expansion shaft in the inflated state.

[0007] Furthermore, the sensing and detection subsystem includes an alarm light sensing module and a rotary switch installed at the slitting outlet or next to the edge guide roller, with the rotary switch and the alarm light sensing module installed in conjunction.

[0008] Furthermore, the human-machine interface and remote monitoring module are installed on the operating console and communicate with the PLC via Ethernet or serial port for status display, parameter setting, and alarm recording.

[0009] Furthermore, the sensing and detection subsystem also includes a vision detection unit, which includes an industrial camera and a high-brightness ring LED coaxial light source, and is installed at a lateral position directly above the copper foil running path. The vision detection unit is connected to the PLC central control unit via the native Profinet protocol.

[0010] Compared with the prior art, the beneficial effects of the present invention are: the present invention realizes automatic rejection and rewinding of edge material when the alarm is triggered by pneumatic and electronic induction linkage, without the need for manual intervention, thus ensuring the continuity and stability of the production of raw foil; at the same time, it reduces the risk of edge material entanglement and equipment damage, reduces copper foil loss, improves material utilization, is compatible with existing raw foil production lines, has low modification costs, and strong compatibility. Attached Figure Description

[0011] Figure 1 This is a flowchart illustrating the system of the present invention; Figure 2 This is a schematic diagram of the actuator in this invention.

[0012] Attached diagram descriptions: 1. Air shaft; 2. Push plate; 3. Cylinder; 4. Rotary switch; 5. Mounting plate. Detailed Implementation

[0013] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings and are used only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. In the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0014] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art will understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0015] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0016] An automatic edge material loading and unloading device control system, which uses a five-dimensional closed-loop logic of "perception-decision-execution-feedback-optimization" as its core operating logic, constructs an adaptive, predictable, and zero-contact intelligent edge material processing unit, specifically including: The PLC central control unit is responsible for logic operations, instruction issuance and status monitoring. It is installed in the workshop electrical control cabinet and connected to the pneumatic actuation subsystem and sensing detection subsystem via cables. The pneumatic actuator subsystem is responsible for pushing the loosened edge material away from the take-up shaft in case of an anomaly; The sensing and detection subsystem monitors the arrival status of copper foil edge material in real time and triggers alarm and reset signals. The communication and interface module enables signal interaction with the foil-making machine's early warning system. The human-machine interface and remote monitoring module are used for status display, parameter setting, and fault diagnosis.

[0017] The process described above is as follows: S1, Air Release and Shaft Loosening: When the cutting of edge material causes abnormalities in thickness / tension, the alarm light flashes → the PLC receives the alarm signal → controls the edge material take-up shaft to automatically release air, so that the roll is loosened and the edge material is prevented from being further damaged by tension.

[0018] S2. Remove edge material: The PLC drives the electronic air valve to control the cylinder push rod to move quickly (response ≤ 0.5 seconds) to push the loosened edge material out of the shaft surface.

[0019] S3, Re-clamp: The edge material take-up shaft is automatically inflated to restore the clamping force on the drum.

[0020] S4. Resume winding: The winding shaft starts negative pressure adsorption to re-adsorb the detached copper foil edge material back onto the shaft surface.

[0021] S5, Automatic Rewinding: The alarm light sensor module detects that the copper foil is in place → automatically triggers the rotary switch → the PLC resumes the edge material winding operation of the foil production machine → the system returns to normal.

[0022] Specifically, the pneumatic actuation subsystem includes a mounting plate 5, an air shaft 1 located at the edge material winding station behind the slitting machine, an external inflation / deflation system, an electronic air valve, and a cylinder push rod mechanism. The drive shaft of the air shaft 1 extends through to the other side of the mounting plate 5 and is connected to a drive motor. The inflation / deflation system is used to inflate and deflate the air shaft 1. The electronic air valve is mounted on the air circuit control board, near the pneumatic interface between the cylinder and the winding shaft, and is connected to the PLC output port via a cable. Among them, the electronic air valve replaces the original mechanical air valve, and the PLC precisely controls the opening and closing of the air circuit between the cylinder and the winding shaft. The air expansion shaft 1 is coaxially installed with the original edge material winding mechanism.

[0023] The cylinder push rod mechanism includes a cylinder 3 whose drive end passes through the mounting plate 5. The drive end of the cylinder 3 is connected to a push plate 2. A circular hole is opened at the center of the push plate 2. The air expansion shaft 1 passes through the circular hole, and the diameter of the circular hole is larger than the diameter of the air expansion shaft 1 in the inflation and expansion state.

[0024] The sensing and detection subsystem includes an alarm light sensing module and a rotary switch 4 installed at the slitting outlet or next to the edge guide roller. The rotary switch 4 and the alarm light sensing module are installed in conjunction, and the sensing module and the rotary switch 4 form a closed-loop detection. During installation, it should be ensured that it can accurately capture the position / displacement status of the copper foil edge material. The alarm light sensing module is a photoelectric sensor or proximity switch. It outputs NPN / PNP signals to align with the edge material's travel path and connects the signal to the PLC input point.

[0025] The human-machine interface and remote monitoring module is installed on the control panel and communicates with the PLC via Ethernet or serial port for status display, parameter setting, and alarm recording.

[0026] In the above, the system workflow strictly follows the automated sequence of "alarm → loosening the shaft → rejection → tightening → adsorption → rewinding": S1. Anomaly Detection and Alarm Triggering When the alarm light flashes due to thickness deviation, abnormal tension, or other reasons, the alarm light sensing module transmits the signal to the PLC.

[0027] After receiving the signal, the PLC immediately enters the exception handling procedure.

[0028] S2, Release air and loosen shaft The PLC-controlled pneumatic inflation and deflation mechanism of the edge material take-up shaft releases pneumatic pressure, allowing the edge material roll to relax and preventing damage caused by continued tension on the edge material.

[0029] S3, Remove edge material The PLC drives the electronic air valve, which controls the cylinder push rod mechanism to move rapidly within ≤0.5 seconds, pushing the loosened edge material off the surface of the take-up shaft.

[0030] S4, Hug again The edge material take-up shaft automatically inflates to restore clamping force, securing the roll and preparing for subsequent winding.

[0031] S5. Resume winding. The rewinding shaft activates the negative pressure adsorption function to recapture the detached copper foil edges.

[0032] S6, Automatic Continue After the alarm light sensor module detects that the copper foil edge material has been repositioned, it automatically triggers the rotary switch.

[0033] The PLC controls the foil production machine to resume edge material winding, and the system returns to normal production status.

[0034] Key points of software and control program design PLC Program Structure The main program continuously scans the status of each sensor.

[0035] Establish an exception handling interrupt routine to ensure that alarm signals are responded to first.

[0036] Design a pneumatic timing control subroutine to precisely control the time intervals between inflation / deflation, push rod action, and adsorption start / stop.

[0037] Signal Interaction Design The PLC communicates with the foil-making machine early warning system via digital I / O or industrial Ethernet (such as Profinet, EtherNet / IP) to receive alarm signals and provide feedback on the system status.

[0038] The sensing module and the rotary switch form a closed-loop detection logic to ensure that the edge material is reset before rewinding resumes.

[0039] Security and fault tolerance mechanisms Set timeout detection: If the rejection or adsorption process times out, the system will automatically stop and issue an alarm.

[0040] Fault self-diagnosis: The PLC monitors the air circuit pressure, sensor status, and actuator feedback in real time. When an abnormality occurs, it records the fault code and displays it on the HMI.

[0041] Manual / Automatic Switching: Retain the manual operation mode for easy debugging and emergency handling.

[0042] In addition, the sensing and detection subsystem also includes a vision detection unit, which includes an industrial camera and a high-brightness ring LED coaxial light source, and is installed at the side position directly above the copper foil running path. The vision detection unit is connected to the PLC central control unit through the native Profinet protocol. Installation height: 250-350 mm from the copper foil surface, ensuring that the field of vision covers the width of the edge material (10-50 mm) and both sides; Installation angle: Vertical downward view (0° tilt angle) to avoid image distortion caused by oblique view and ensure the accuracy of width measurement; Light source configuration: A high-brightness ring LED coaxial light source with a wavelength of white light (550-650 nm) is used to uniformly illuminate the copper foil surface, enhance the grayscale contrast between the edge of the material and the background, and effectively suppress the reflection interference of the copper foil.

[0043] The vision inspection unit and the PLC control logic work together in a deep collaboration: Triggering phase The PLC sends an external trigger command (Trigger signal set to 1) to the vision system via encoder pulses or photoelectric sensor signals. The vision system automatically starts image acquisition when the copper foil moves to the preset detection point.

[0044] Image processing stage After the camera acquires images, the built-in CV-X controller performs parallel processing using multiple tools: Edge detection: Identify the left and right boundaries of the edge material and calculate the actual width; Blob analysis: detects tears (≥0.5mm) and foreign objects (metal / fiber); Grayscale threshold segmentation: to identify oxidation points and stains; All detection results are encapsulated using a self-developed algorithm (FB_VisionDefectDetect) and output as structured data.

[0045] Results output and PLC interaction The vision system continuously outputs key signals to the PLC through the Profinet I / O data block and executes responses.

[0046] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, 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 equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0047] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A control system for an automatic loading and unloading edge material device, characterized in that: The system includes: The PLC central control unit is responsible for logic operations, instruction issuance and status monitoring. It is installed in the workshop electrical control cabinet and connected to the pneumatic actuation subsystem and sensing detection subsystem via cables. The pneumatic actuator subsystem is responsible for pushing the loosened edge material away from the take-up shaft in case of an anomaly; The sensing and detection subsystem monitors the arrival status of copper foil edge material in real time and triggers alarm and reset signals. The communication and interface module enables signal interaction with the foil-making machine's early warning system. The human-machine interface and remote monitoring module are used for status display, parameter setting, and fault diagnosis.

2. The automatic loading and unloading edge material control system according to claim 1, characterized in that: The pneumatic actuation subsystem includes a mounting plate (5), an air shaft (1) located at the edge material winding station behind the slitting machine, an external inflation / deflation system, an electronic air valve, and a cylinder push rod mechanism. The drive shaft of the air shaft (1) extends through to the other side of the mounting plate (5) and is connected to a drive motor. The inflation / deflation system is used to inflate and deflate the air shaft (1). The electronic air valve is installed on the air circuit control board, near the pneumatic interface between the cylinder and the winding shaft, and is connected to the PLC output port via a cable. The cylinder push rod mechanism includes a cylinder (3) whose drive end passes through the mounting plate (5). The drive end of the cylinder (3) is connected to a push plate (2). A circular hole is opened at the center of the push plate (2). The air expansion shaft (1) passes through the circular hole, and the diameter of the circular hole is larger than the diameter of the air expansion shaft (1) in the inflation state.

3. The automatic loading and unloading edge material control system according to claim 1, characterized in that: The sensing and detection subsystem includes an alarm light sensing module and a rotary switch (4) installed at the slitting outlet or next to the edge guide roller. The rotary switch (4) is installed in conjunction with the alarm light sensing module.

4. The automatic loading and unloading edge material control system according to claim 1, characterized in that: The human-machine interface and remote monitoring module are installed on the control panel and communicate with the PLC via Ethernet or serial port for status display, parameter setting and alarm recording.

5. The automatic loading and unloading edge material control system according to claim 1, characterized in that: The sensing and detection subsystem also includes a vision detection unit, which includes an industrial camera and a high-brightness ring LED coaxial light source. It is installed at a lateral position directly above the copper foil running path. The vision detection unit is connected to the PLC central control unit via the native Profinet protocol.

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