A method for segmented compensation of RTP cutting depth

Abstract

This invention discloses a segmented compensation method for RTP cutting depth, belonging to the technical field of polarizer manufacturing equipment. The method includes: measuring the levelness difference of each segment of the cutting platform; converting the levelness difference into a cutting depth compensation value; writing the compensation value and its corresponding position interval into a PLC program; and during the RTP half-cutting process, the PLC controller calls the compensation value of the corresponding interval based on the current position of the cutting blade and controls the cutting blade lifting mechanism to adjust the downward pressure depth. This invention achieves segmented automatic compensation of cutting depth by pre-measuring the levelness difference of each segment of the platform and writing the compensation value into the PLC program. It eliminates the need for additional sensing devices, tool replacement, or cutting platform replacement, solving the problem of inconsistent blade depth caused by cutting platform wear. The compensation adjustment is flexible and rapid, reducing material loss due to poor cutting and improving production yield.

Description

Technical Field

[0001] This invention relates to the field of polarizer manufacturing technology, and in particular to an RTP cutting depth segmentation compensation method. Background Technology

[0002] RTP (Release Towel) bonding is a key process in polarizer manufacturing, where polarizers are bonded to glass substrates. This process employs a semi-cutting method, where the polarizer film layer is cut using a semi-cutting blade while preserving the integrity of the underlying release film. The semi-cutting blade requires extremely high precision in cutting depth, with the levelness of the cut surface controlled within 0.05%. In actual production, the blade mark position of the semi-cutting blade remains fixed, and prolonged cutting at the same location leads to wear on the cutting platform surface. The cutting platform has a large span, resulting in uneven wear across different sections and differences in levelness between the starting and ending points, thus causing inconsistent cutting depths and affecting the quality of the cut edges and product yield. Existing technologies primarily address the inconsistent cutting depth problem in two ways: one is by adding a pressure sensor to monitor changes in cutting pressure in real time and dynamically compensate for the cut depth through feedback control; however, this solution relies on the accuracy and response speed of the sensor, making the system complex and costly. The other solution is to address the wear problem through physical repair methods such as replacing the blade or cutting platform, but this requires downtime for replacement, impacting production efficiency and increasing equipment maintenance costs.

[0003] Therefore, how to quickly and effectively compensate for the difference in cutting depth caused by platform wear without stopping the machine, installing additional sensing devices, or replacing the cutting tools has become a technical problem that urgently needs to be solved in this field. Summary of the Invention

[0004] The purpose of this invention is to provide an RTP cutting depth segment compensation method, comprising the following steps: measuring the levelness difference of each segment of the cutting platform; determining the compensation value for each segment based on the measurement data, wherein the levelness difference of each segment is converted into a cutting depth compensation value, the absolute value of the compensation value is equal to the absolute value of the levelness difference of that segment, and the positive and negative directions of the compensation value are the same as the positive and negative directions of the levelness difference. When the levelness difference is positive, the compensation value is positive, and the cutting depth is compensated downward based on the reference depth, so that the actual cutting depth of that segment is equal to the reference depth plus the absolute value of the compensation value; when the levelness difference is negative, the compensation value is negative, and the cutting depth is compensated upward based on the reference depth, so that the actual cutting depth of that segment is equal to the reference depth minus the absolute value of the compensation value. The reference depth is determined by the RTP half-cutting process requirements; writing the compensation value of each segment into the PLC program; and the cutting blade performing segmented cutting according to the compensation value.

[0005] Furthermore, the measurement of the levelness difference of each segment of the cutting platform specifically includes: dividing the cutting line travel path into several measurement segments of equal length, the length of each measurement segment being determined according to the span of the cutting platform, which can reach 1.7 meters; using a micrometer to measure the surface height of the cutting platform at each measurement point and recording the height data of each measurement point; calculating the height difference between each adjacent measurement point, which is the levelness difference of each segment.

[0006] Furthermore, a positive level difference indicates that the surface of the platform segment bulges upward relative to the previous segment, while a negative level difference indicates that the surface of the platform segment is concave downward relative to the previous segment.

[0007] Furthermore, writing the compensation values ​​of each segment into the PLC program specifically includes: writing the compensation values ​​of each segment and their corresponding position intervals into the data table of the PLC program. The position intervals are defined by the start and end positions in the direction of the cutter travel. The PLC program data structure includes the coordinates of the start point of the position interval, the coordinates of the end point of the position interval, and the compensation value corresponding to the interval. The PLC controller is electrically connected to the cutter lifting mechanism. The PLC controller sends corresponding displacement commands to the cutter lifting mechanism according to the positive or negative direction of the compensation value. The displacement amount is equal to the absolute value of the compensation value.

[0008] Furthermore, the compensation data for all intervals is written into the PLC program and then subjected to simulation testing.

[0009] Furthermore, the segmented cutting according to the compensation value specifically includes: the cutter moves horizontally along the cutting line of the cutting platform, and the PLC controller reads the current position coordinates of the cutter in real time; when the current position coordinates of the cutter enter a certain position interval, the PLC controller calls the corresponding compensation value of the interval from the data table and sends a compensation command to the cutter lifting mechanism. The cutter lifting mechanism adjusts the cutting depth so that the cutting depth of the cutter in that interval is the sum of the reference depth and the compensation value.

[0010] Furthermore, when the current position coordinates of the cutter leave the interval, the PLC controller cancels the compensation instruction for that segment, and the cutter returns to the reference depth, or performs the corresponding depth adjustment according to the compensation value of the next position interval.

[0011] Furthermore, the cutter performs a compensation action only once within each segment, and the cutting depth transitions smoothly between segments.

[0012] Furthermore, when the wear condition of the platform changes, the level difference of each segment is remeasured and the compensation value in the PLC program is updated.

[0013] Compared with the prior art, the present invention has the following beneficial effects:

[0014] (1) By setting up a storage roller group on the conveyor path, the present invention constructs an extended path between the cutting process and the bonding process, which can temporarily store whole or multiple films. This allows the cut films to enter the bonding station immediately without needing to be immediately cut. The cutting action and the bonding action are decoupled in time, eliminating the equipment idle time caused by the waiting between cutting and bonding, and significantly improving the bonding output per unit time.

[0015] (2) The present invention changes the triggering condition for attachment start from the traditional “the whole film is in place and vacuum adsorption is confirmed” to “the front end of the film reaches the attachment preparation position”. The attachment pressure roller can start the bonding action before the tail of the film leaves the cutting area or storage path, thereby greatly shortening the waiting time of the attachment mechanism caused by long-distance transportation of large-size films and effectively compressing the overall cycle time of the equipment.

[0016] (3) This invention divides the entire film conveying path into multiple tension-independent sections by setting pinch roller groups at multiple key nodes of the conveyor belt. The isolation effect of each pinch roller group ensures that the tension fluctuation of the half-cut section does not affect the storage section, and the tension fluctuation of the storage section does not affect the bonding section, thus providing a stable tension environment for the parallel operation of the cutting and bonding processes, and ensuring the film conveying accuracy and bonding quality.

[0017] (4) By setting multiple adjustable tension adjustment rollers upstream of the bonding station, the present invention can absorb the instantaneous tension fluctuations caused by the bonding start and the reverse pulling of the supporting base film in real time during the bonding process, prevent the film from being stretched or peeled off due to sudden tension changes, and ensure the consistency and reliability of bonding quality.

[0018] (5) The present invention requires minimal modification to existing polarizer attachment equipment. It does not require redesigning the main structure of the equipment. Only the addition of a storage roller group, tension adjustment roller and corresponding clamping roller group to the original conveyor path is needed to achieve parallel operation of cutting and attachment. The modification cost is low, the implementation cycle is short, and it has good industrial applicability and promotion prospects.

[0019] The present invention will now be further described with reference to the accompanying drawings. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the workflow of the present invention. Detailed Implementation

[0021] Reference Figure 1 , Figure 1 This is a flowchart illustrating an RTP cutting depth segmentation compensation method according to the present invention. The method includes the following steps:

[0022] Step S100: Measure the levelness difference of each segment of the cutting platform. Specifically, this includes:

[0023] S101 divides the tool path into several equal measurement segments. The length of each measurement segment is determined according to the span of the cutting platform, and the distance between two adjacent measurement points is the length of the measurement segment. The span of the cutting platform can reach 1.7 meters. After long-term cutting operations at the same tool mark position, the wear degree of each segment on the platform surface is uneven, and there may be obvious differences in levelness between the starting end and the ending end.

[0024] S102 uses a micrometer to measure the height of the cutting platform surface at each measurement point. The micrometer probe is brought into contact with the cutting platform surface, the height value at that point is read, and the height data for each measurement point is recorded. The micrometer is a non-contact measuring tool, allowing for rapid measurements during equipment downtime without requiring disassembly or modification of the cutting platform.

[0025] S103, after completing the measurement of all measurement points in sequence, calculate the height difference between each adjacent measurement point, which is the levelness difference of each segment. The sign of the levelness difference indicates the direction of the elevation of the platform surface of that segment: a positive value indicates that the platform surface of that segment convexes upward relative to the previous segment, and the actual cutting depth of the cutter in that segment is deeper than the reference depth, so the cutting force needs to be reduced to decrease the cutting depth; a negative value indicates that the platform surface of that segment is concave relative to the previous segment, and the actual cutting depth of the cutter in that segment is shallower than the reference depth, so the cutting force needs to be increased to increase the cutting depth.

[0026] Step S200: Determine the compensation value for each segment based on the measurement data. Specifically, this includes:

[0027] S201, the levelness difference values ​​of each segment measured in step S100 are converted into cutting depth compensation values. The absolute value of the compensation value is equal to the absolute value of the levelness difference of that segment, and the positive and negative directions of the compensation value are the same as those of the levelness difference. This method determines the depth compensation scheme for each segment of the entire line before cutting begins by pre-measuring the levelness difference of each segment of the platform and converting it into compensation values. This differs from the existing technology that relies on real-time feedback from pressure sensing devices for dynamic compensation. It eliminates the need for additional sensing devices, making the system simple and cost-effective.

[0028] S202, when the levelness difference of this segment is positive, the compensation value is positive, and the cutting depth is compensated downward based on the reference depth, so that the actual cutting depth of this segment is equal to the reference depth plus the absolute value of the compensation value.

[0029] S203, when the levelness difference of this segment is negative, the compensation value is negative, and the cutting depth is compensated upward based on the reference depth, so that the actual cutting depth of this segment is equal to the reference depth minus the absolute value of the compensation value. The reference depth is the downward pressure depth of the cutter when it makes normal cutting in the unworn area of ​​the platform, which is determined by the requirements of the RTP half-cut process to ensure that the polarizer film layer is completely cut off while the bottom release film remains intact.

[0030] Step S300: Write the compensation values ​​for each segment into the PLC program. Specifically, this includes:

[0031] S301, the compensation values ​​and corresponding position intervals determined in step S200 are written into the data table of the PLC program one by one. The position interval is defined by the start and end positions in the cutting line travel direction. The PLC program data structure includes the coordinates of the start point of the position interval, the coordinates of the end point of the position interval, and the compensation value corresponding to the interval. The PLC controller is electrically connected to the cutter lifting mechanism, which is used to drive the cutter to move in the vertical direction to adjust the pressing depth.

[0032] S302, when the compensation value is positive, the PLC controller sends a downward displacement command to the cutter lifting mechanism, and the displacement is equal to the absolute value of the compensation value.

[0033] S303, when the compensation value is negative, the PLC controller sends an upward displacement command to the cutter lifting mechanism, and the displacement is equal to the absolute value of the compensation value.

[0034] In step S304, after writing the compensation data for all intervals into the PLC program, a simulation test is performed to confirm that the execution sequence and displacement direction of each compensation instruction are consistent with expectations. After the test passes, proceed to step S400. This method achieves segmented compensation by writing the compensation values ​​into the PLC program via software. When wear occurs on the cutting platform, there is no need to replace the cutting tools or the cutting platform itself, nor is there a need to stop the machine for mechanical repair. This differs from existing technologies that solve platform wear problems through physical repair, reducing equipment maintenance costs and production downtime.

[0035] Step S400: The cutter performs cutting in segments according to the compensation value. Specifically, this includes:

[0036] S401, during the RTP half-cutting process, the cutter moves horizontally along the cutting platform's blade line, and the PLC controller reads the cutter's current position coordinates in real time.

[0037] S402, when the current position coordinate of the cutter enters a certain position range, the PLC controller retrieves the corresponding compensation value from the data table and sends a compensation command to the cutter lifting mechanism. The cutter lifting mechanism adjusts the cutting depth so that the cutting depth of the cutter in that range is the sum of the reference depth and the compensation value.

[0038] S403: When the current position coordinate of the cutter leaves the interval, the PLC controller cancels the compensation instruction for that segment, and the cutter returns to the reference depth, or performs the corresponding depth adjustment according to the compensation value of the next position interval.

[0039] S404: The cutter sequentially passes through each segment's position range, completing the cut of the entire segment while maintaining a uniform depth along the entire cutting line. This achieves segmented compensation for differences in cutting depth caused by platform wear. During the cutting process, the cutter does not need to repeatedly adjust the depth at the same position; each segment only performs a compensation action once, resulting in a smooth transition in cutting depth between segments. This ensures the continuity of the cutting line and the quality of the cutting edge.

[0040] Using the above method, without stopping the machine, installing additional sensing devices, or replacing the cutting tools, the segmented automatic compensation of the cutting depth can be achieved simply by pre-measuring the difference in the levelness of each segment of the platform and writing the compensation value into the PLC program. This quickly and effectively solves the problem of inconsistent cutting line depth caused by wear of the cutting platform, reduces the loss of raw materials due to poor cutting, and improves the production yield.

Claims

1. A method for segmented compensation of RTP cutting depth, characterized in that, Includes the following steps: Step S100: Measure the difference in levelness between different sections of the cutting platform; Step S200, determining the compensation value for each segment based on the measurement data, includes: S201, convert the levelness difference values ​​of each segment measured in step S100 into cutter depth compensation values. The absolute value of the compensation value is equal to the absolute value of the levelness difference of that segment, and the positive and negative directions of the compensation value are the same as the positive and negative directions of the levelness difference. S202, when the levelness difference of this segment is positive, the compensation value is positive, and the cutting depth is compensated downward based on the reference depth, so that the actual cutting depth of this segment is equal to the reference depth plus the absolute value of the compensation value; S203, when the levelness difference of this section is negative, the compensation value is negative, and the cutting depth is compensated upward based on the reference depth, so that the actual cutting depth of this section is equal to the reference depth minus the absolute value of the compensation value. The reference depth is determined by the RTP half-cutting process requirements. Step S300: Write the compensation values ​​for each segment into the PLC program; Step S400: The cutter performs cutting in segments according to the compensation value.

2. The RTP cutter depth segmentation compensation method according to claim 1, characterized in that, Step S100 specifically includes: S101 divides the tool path into several measurement segments of equal length. The length of each measurement segment is determined according to the span of the cutting platform, which can reach 1.7 meters. S102, Use a micrometer to measure the height of the cutting platform surface at each measuring point and record the height data of each measuring point; S103, calculate the height difference between each adjacent measurement point, which is the levelness difference of each segment.

3. The RTP cutter depth segmentation compensation method according to claim 2, characterized in that, In step S103, a positive level difference indicates that the surface of the platform segment is convex upward relative to the previous segment, while a negative level difference indicates that the surface of the platform segment is concave downward relative to the previous segment.

4. The RTP cutter depth segmentation compensation method according to claim 1, characterized in that, Step S300 specifically includes: S301, write the compensation values ​​of each segment and the corresponding position intervals into the data table of the PLC program. The position interval is defined by the start and end positions in the direction of the cutter travel. The PLC program data structure includes the coordinates of the start point of the position interval, the coordinates of the end point of the position interval, and the compensation value corresponding to the interval. The PLC controller is electrically connected to the cutter lifting mechanism. S302, the PLC controller sends the corresponding displacement command to the cutter lifting mechanism according to the positive or negative direction of the compensation value, and the displacement is equal to the absolute value of the compensation value.

5. The RTP cutter depth segmentation compensation method according to claim 4, characterized in that, Step S300 also includes: S304: After the compensation data for all intervals is written into the PLC program, a simulation test is performed.

6. The RTP cutter depth segmentation compensation method according to claim 1, characterized in that, Step S400 specifically includes: S401, the cutter moves horizontally along the cutting platform's blade line, and the PLC controller reads the cutter's current position coordinates in real time; S402, when the current position coordinate of the cutter enters a certain position range, the PLC controller retrieves the corresponding compensation value from the data table and sends a compensation command to the cutter lifting mechanism. The cutter lifting mechanism adjusts the cutting depth so that the cutting depth of the cutter in that range is the sum of the reference depth and the compensation value.

7. The RTP cutter depth segmentation compensation method according to claim 6, characterized in that, Step S400 also includes: S403: When the current position coordinate of the cutter leaves the interval, the PLC controller cancels the compensation instruction for that segment, and the cutter returns to the reference depth, or performs the corresponding depth adjustment according to the compensation value of the next position interval.

8. The RTP cutter depth segmentation compensation method according to claim 1, characterized in that, In step S400, the cutter performs a compensation action only once in each segment interval, and the cutting depth transitions smoothly between each segment.

9. The RTP cutter depth segmentation compensation method according to claim 1, characterized in that, When the wear condition of the platform changes, the level difference of each section is remeasured and the compensation value in the PLC program is updated.

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