A method for improving the control of web creasing by using the gravimetric method and a winding device

Abstract

The application discloses a control method and a winding device for improving roll wrinkles by using a weighing method, relates to the general control or regulation field, and the method comprises the following steps: determining a theoretical weight prediction value corresponding to each time node and a target pressure interval; outputting a basic feedforward displacement instruction to a hydraulic cylinder based on the theoretical weight prediction value corresponding to the current time node; obtaining a real-time pressure signal by collecting a contact normal pressure applied by a roll to a conveying belt through a metering scale, and calculating an actual normal pressure effective value; recording a deviation duration when the actual normal pressure effective value deviates from the target pressure interval corresponding to the current time node; calculating a compensation displacement amount when the deviation duration exceeds a preset anti-jitter time threshold; and outputting the compensation displacement amount to the hydraulic cylinder, so as to adjust the actual contact normal pressure between the roll and the conveying belt to be within the target pressure interval. By implementing the application, the roll can be accurately lifted in a friction type winding process, and the yield of finished products can be ensured.

Description

Technical Field

[0001] This application relates to the general field of control or regulation, and more particularly to a control method and winding device for improving the wrinkling of rolled materials using a weighing method. Background Technology

[0002] In the production of flexible roll materials such as rubber conveyor belts and sealing sheets, friction winding technology is widely used due to its simple structure and convenient operation. It relies on the static friction generated between the horizontally running conveyor belt at the bottom and the upper winding roller and the surface of the surrounding roll to continuously drive the winding roller to rotate and wind the material. As more material is wound into the winding roller, the geometric outer diameter of the roll continuously increases, leading to a simultaneous increase in the contact area and contact pressure between the bottom of the roll and the conveyor belt, and a rise in the rotational resistance torque of the winding roller. When the resistance exceeds the effective friction of the conveyor belt, the rotational linear velocity of the winding roller becomes asynchronous with the conveyor belt's conveying linear velocity, causing the rubber material to accumulate and bend before entering the roll, forming irreversible wrinkles or creases.

[0003] In related technologies, a control scheme based on roll diameter displacement tracking is adopted to ensure yield. This scheme involves installing ultrasonic sensors or laser rangefinders above or to the side of the winding roller. During winding, these sensors emit detection signals to the outer surface of the roll in real time and receive reflected signals to calculate the actual outer diameter of the roll, i.e., the roll diameter. Based on this roll diameter, the required lifting height is determined, which then drives a hydraulic cylinder or servo motor to lift the winding roller, matching the increase in the roll diameter.

[0004] However, the relevant technologies cannot effectively avoid errors caused by factors such as roll bulkiness, strip thickness fluctuations, and rubber compression deformation. In these cases, the roll diameter and the actual contact positive pressure are not linearly related, which makes it difficult to effectively and accurately control the roll pressure, and wrinkles often occur. Summary of the Invention

[0005] This application provides a method and a winding device for controlling the wrinkles of rolled materials by using a weighing method, which is used to achieve precise lifting of the rolled material in the friction winding process and ensure the yield of finished products.

[0006] In a first aspect, this application provides a control method for improving the wrinkling of rolled material using a weighing method, applied to a winding device. The winding device includes a conveyor belt for conveying rubber strip material and providing frictional driving force, a winding roller, a winding roller mounting bracket for mounting the winding roller, a hydraulic cylinder for driving the lifting and lowering of the winding roller mounting bracket, a weighing scale for real-time pressure detection, and a controller electrically connected to the weighing scale and the hydraulic cylinder. The method includes: under the condition of receiving the physical parameters and attenuation coefficient of the rolled material, calculating the cumulative weight sequence and target pressure range sequence of the rolled material as a function of winding time, determining the theoretical weight prediction value and target pressure range corresponding to each time node; and outputting the theoretical weight prediction value corresponding to the current time node to the hydraulic cylinder. The basic feedforward displacement command causes the take-up roll mounting bracket to lift the take-up roll to the predicted spatial height. The contact normal pressure applied by the material roll to the conveyor belt is collected by a metering scale to obtain a real-time pressure signal. The real-time pressure signal is filtered by a sliding time window to obtain the effective value of the actual normal pressure after removing high-frequency noise. When the effective value of the actual normal pressure deviates from the target pressure range corresponding to the current time node, a timing operation is started to record the duration of the deviation. When the duration of the deviation exceeds the preset anti-shake time threshold, the compensation displacement is calculated based on the difference between the effective value of the actual normal pressure and the target pressure range. The compensation displacement is output to the hydraulic cylinder to adjust the actual contact normal pressure between the material roll and the conveyor belt to within the target pressure range.

[0007] In the above embodiments, the winding device acquires the physical parameters and attenuation coefficient of the roll material, and executes a basic feedforward displacement command based on the theoretical weight prediction value. This allows the winding roller mounting bracket to be pre-lifted as the theoretical roll diameter increases, reducing hysteresis errors. Furthermore, by using the contact positive pressure signal collected in real time by the weighing scale to compensate for the displacement calculation and output, the winding device can accurately adjust the position of the hydraulic cylinder when the actual pressure deviates from the target range, maintaining the actual contact positive pressure between the roll material and the conveyor belt within the target pressure range. This effectively solves the problem of material belt wrinkling caused by the continuous increase of winding resistance, while ensuring sufficient frictional driving force, avoiding slippage, and improving the yield of flexible roll materials.

[0008] In conjunction with some embodiments of the first aspect, in some embodiments, the step of calculating the cumulative weight sequence and target pressure range sequence of the roll material as it changes with winding time, and determining the theoretical weight prediction value and target pressure range corresponding to each time node, under the condition of receiving the physical parameters and attenuation coefficient of the roll material, specifically includes: obtaining the physical parameters of the roll material; the physical parameters include the strip width, strip thickness, material density, and conveyor belt speed; calculating the theoretical volume of the strip material wound into the winding roller at the current time node based on the physical parameters and the current winding time, and calculating the theoretical weight prediction value in combination with the material density; determining the benchmark target pressure value based on the attenuation coefficient and the theoretical weight prediction value; the attenuation coefficient is used to characterize the optimal weight ratio required to maintain synchronous friction without causing compression deformation of the roll material; and expanding a preset tolerance range upward and downward from the benchmark target pressure value to generate the target pressure range corresponding to the current time node.

[0009] In the above embodiments, the introduction of the attenuation coefficient allows the setting of the benchmark target pressure value to match the optimal weight ratio that does not cause compression deformation of the roll, preventing material damage caused by excessive positive pressure. Expanding the preset tolerance range upwards and downwards from the benchmark target pressure value provides a reasonable buffer zone for the actual control process, improving the stability of the entire winding process and the mechanical life of the equipment, and ensuring that the friction driving force is in optimal working condition.

[0010] In conjunction with some embodiments of the first aspect, in some embodiments, the step of outputting a basic feedforward displacement command to the hydraulic cylinder based on the theoretical weight prediction value corresponding to the current time node, so that the take-up roll mounting bracket drives the take-up roll to be raised to the predicted spatial height, specifically includes: calculating the theoretical outer diameter of the unloaded roll at the current time node in reverse based on the theoretical weight prediction value, the strip width and the material density; calculating the difference between the theoretical outer diameter and the initial outer diameter of the take-up roll as the theoretical radius increment; using the theoretical radius increment as the predicted spatial height, generating a basic feedforward displacement command and outputting it to the hydraulic cylinder to drive the take-up roll mounting bracket to perform feedforward lifting.

[0011] In the above embodiment, the difference between the theoretical outer diameter and the initial outer diameter of the take-up roll constitutes the theoretical radius increment, which truly reflects the radial dimension increase of the roll. This theoretical radius increment is converted into a predicted spatial height and a basic feedforward displacement command is generated and output to the hydraulic cylinder, enabling the take-up roll mounting bracket to actively perform feedforward lifting. By pre-compensating for the spatial compression caused by the increase in the roll radius, the burden of the bottom closed-loop pressure regulation is reduced, ensuring that the actual contact positive pressure is always maintained near the target range. This reduces the risk of instantaneous overpressure or underpressure due to untimely adjustment and ensures the winding quality.

[0012] In conjunction with some embodiments of the first aspect, in some embodiments, the step of performing sliding time window filtering on the real-time pressure signal to obtain the effective value of actual positive pressure after removing high-frequency noise specifically includes: obtaining the installation spacing of the bottom support rollers of the conveyor belt and the conveying line speed of the conveyor belt; calculating the periodic mechanical vibration frequency generated by the conveyor belt during operation based on the installation spacing and the conveying line speed, and deriving the corresponding mechanical vibration period; setting the time length of the sliding time window to an integer multiple of the mechanical vibration period to construct an adaptive sliding window; and performing moving average filtering on the real-time pressure signal based on the adaptive sliding window to cancel the alternating interference caused by the periodic mechanical vibration and obtain the effective value of actual positive pressure.

[0013] In the above embodiments, the winding device obtains the installation spacing of the bottom support rollers of the conveyor belt and the conveying line speed, and sets the time length of the sliding time window to an integer multiple of the mechanical vibration cycle to construct an adaptive sliding window. This adaptive sliding window can accurately cover the complete vibration cycle. When performing moving average filtering, positive and negative vibration interference cancel each other out within the window, improving the accuracy and robustness of the pressure closed-loop control and ensuring the stability of the winding process.

[0014] In conjunction with some embodiments of the first aspect, in some embodiments, the step of calculating the compensation displacement based on the difference between the actual effective value of the normal pressure and the target pressure range specifically includes: calculating a first pressure difference between the actual effective value of the normal pressure and the upper limit of the target pressure range when the actual effective value of the normal pressure is greater than the upper limit of the target pressure range; or, calculating a second pressure difference between the actual effective value of the normal pressure and the lower limit of the target pressure range when the actual effective value of the normal pressure is less than the lower limit of the target pressure range; determining the radial stiffness coefficient of the roll at the current time node based on the roll stiffness model; the radial stiffness coefficient is used to characterize the pressure change corresponding to the unit radial deformation of the roll at the current roll diameter; calculating the compensation displacement based on the first pressure difference or the second pressure difference, combined with the radial stiffness coefficient, so that the compensation displacement is used to match the physical elastic properties of the current roll.

[0015] In the above embodiments, the winding device quantifies the severity of the current pressure deviation from the target by calculating the first pressure difference value that exceeds the upper limit value or the second pressure difference value that is lower than the lower limit value of the actual positive pressure effective value. The radial stiffness coefficient determined by the material roll stiffness model is introduced to convert the pressure difference value into a spatial displacement, so that the calculated compensation displacement can accurately match the actual deformation requirements of the material roll, avoiding the overshoot or under-adjustment problems that may occur when using a fixed proportional coefficient for adjustment.

[0016] In conjunction with some embodiments of the first aspect, in some embodiments, after the step of calculating the compensation displacement based on a first pressure difference or a second pressure difference and in combination with a radial stiffness coefficient, so that the compensation displacement is used to match the physical elastic properties of the current coil, the method further includes: after the hydraulic cylinder executes the compensation displacement, acquiring the effective value of the actual normal pressure at the next time node; calculating the actual pressure change before and after executing the compensation displacement, and using the ratio of the actual pressure change to the compensation displacement as the actual stiffness feedback value; using the actual stiffness feedback value to update the radial stiffness coefficient in the coil stiffness model using Kalman filtering to obtain a corrected radial stiffness coefficient, which is used to improve the accuracy of the next calculation of the compensation displacement to overcome the nonlinear error caused by the random fluctuation of the coil's bulkiness.

[0017] In the above embodiments, after the hydraulic cylinder performs the compensation displacement, the winding device calculates the actual pressure change before and after the action by collecting the actual effective value of the normal pressure at the next time node. This achieves dynamic adaptive correction of the stiffness coefficient, ensuring that the model parameters always fit the actual physical state. This gives the system the ability to learn and evolve on its own, resulting in more stable and reliable control performance over long-term operation.

[0018] In conjunction with some embodiments of the first aspect, in some embodiments, the step of adjusting the actual contact positive pressure between the material roll and the conveyor belt to within the target pressure range specifically includes: superimposing the compensation displacement amount and the basic feedforward displacement command corresponding to the current time node to generate a comprehensive displacement control command; determining whether the absolute value of the compensation displacement amount exceeds a preset safety limit threshold; if it does not exceed the threshold, outputting the comprehensive displacement control command to the hydraulic cylinder to smoothly pull the actual contact positive pressure back to the target pressure range; if it exceeds the threshold, determining that an equipment abnormality has occurred during the winding process, including material belt breakage or sensor failure, intercepting the comprehensive displacement control command and triggering a shutdown alarm signal.

[0019] In the above embodiment, the winding device superimposes the compensation displacement amount and the basic feedforward displacement command to generate a comprehensive displacement control command, which smoothly pulls the actual contact positive pressure back to the target pressure range. By judging whether the absolute value of the compensation displacement amount exceeds the preset safety limit threshold, when the absolute value does not exceed the threshold, the system performs the adjustment action normally; when the absolute value exceeds the threshold, the system determines that there is an equipment abnormality such as material belt breakage or sensor failure, and promptly intercepts the command and triggers a shutdown alarm signal, avoiding equipment damage and safety accidents, and improving the operational safety and reliability of the entire winding device.

[0020] In a second aspect, embodiments of this application provide a winding device, which includes: one or more processors and a memory; the memory is coupled to the one or more processors, and the memory is used to store computer program code, the computer program code including computer instructions, and the one or more processors call the computer instructions to cause the winding device to perform the method described in the first aspect and any possible implementation thereof.

[0021] Thirdly, embodiments of this application provide a computer-readable storage medium including instructions that, when executed on a winding device, cause the winding device to perform the method described in the first aspect and any possible implementation thereof.

[0022] Fourthly, embodiments of this application provide a computer program product containing instructions that, when the computer program product is run on a winding device, cause the winding device to perform the method described in the first aspect and any possible implementation thereof.

[0023] Understandably, the winding device provided in the second aspect, the computer storage medium provided in the third aspect, and the computer program product provided in the fourth aspect are all used to execute the methods provided in the embodiments of this application. Therefore, the beneficial effects they can achieve can be referred to the beneficial effects in the corresponding methods, and will not be repeated here.

[0024] One or more technical solutions provided in the embodiments of this application have at least the following technical effects or advantages:

[0025] 1. By using the technical characteristics of calculating the cumulative weight sequence and target pressure range sequence of the roll material as it changes with winding time under the conditions of the received physical parameters and attenuation coefficient, and determining the theoretical weight prediction value and target pressure range corresponding to each time node, a weight and pressure prediction model that changes with time is constructed. This effectively solves the problem of not being able to dynamically set the pressure benchmark in related technologies, and thus realizes the accurate quantification and adaptive matching of the pressure control target throughout the winding process.

[0026] 2. By adopting the technical feature of outputting a basic feedforward displacement command to the hydraulic cylinder based on the theoretical weight prediction value corresponding to the current time node, the winding roll mounting bracket drives the winding roll to lift to the predicted spatial height. Therefore, the winding roll can perform pre-space compensation in accordance with the increase of the theoretical roll diameter, which effectively solves the serious lag problem of pure feedback control in related technologies, and thus achieves high synchronization between the lifting action of the winding roll and the increase of the roll volume.

[0027] 3. By employing a sliding time window filtering process on the real-time pressure signal to obtain the effective value of the actual positive pressure after eliminating high-frequency noise, the high-frequency mechanical noise during the conveyor belt operation is filtered out. This effectively solves the problem of pressure sensors being susceptible to mechanical vibration interference and causing misjudgment in related technologies, thereby achieving high-precision extraction and stable closed-loop control of the actual contact positive pressure. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the physical structure of a winding device according to an embodiment of this application;

[0029] Figure 2 This is a flowchart illustrating a method for controlling roll wrinkles using a weighing method in an embodiment of this application.

[0030] Figure 3 This is another flowchart illustrating the method for controlling roll wrinkles using the weighing method in the embodiments of this application;

[0031] Figure 4 This is a schematic diagram of the circuit structure of a winding device in an embodiment of this application. Detailed Implementation

[0032] The terminology used in the following embodiments of this application is for the purpose of describing particular embodiments only and is not intended to be limiting of this application. As used in the specification of this application, the singular expressions “a,” “an,” “the,” “the,” and “this” are intended to include the plural expressions as well, unless the context clearly indicates otherwise. It should also be understood that the term “and / or” as used in this application refers to any or all possible combinations including one or more of the listed items.

[0033] Hereinafter, the terms "first" and "second" are used for descriptive purposes only and should not be construed as implying or suggesting relative importance or implicitly indicating the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature, and in the description of the embodiments of this application, unless otherwise stated, "multiple" means two or more.

[0034] In the manufacturing of flexible roll materials, such as the continuous roll winding process after calendering or extrusion molding of products like rubber conveyor belts and sealing films, friction winding is commonly used. This process relies on the static friction between the conveyor belt surface and the outer surface of the winding roller to drive the roller's rotation. As the winding process progresses, the diameter and weight of the roll continuously increase, causing the contact pressure between the bottom of the roll and the conveyor belt to increase synchronously, and the rotational resistance torque of the winding roller to rise. When the resistance exceeds the effective friction force of the conveyor belt, the rotational speed of the winding roller and the linear speed of the conveyor belt become asynchronous, causing the rubber strip material to accumulate, bend, and form irreversible wrinkles or creases. Related technologies typically use tension control or roll diameter following control methods, but these cannot effectively avoid errors caused by nonlinear factors such as roll bulkiness and material compression deformation, and cannot fundamentally solve the contradiction between wrinkles and slippage caused by changes in contact pressure.

[0035] Based on the above scenario, this application provides a winding device. Please refer to... Figure 1 This is a schematic diagram of the physical structure of a winding device in an embodiment of this application; Figure 1 The winding device includes a conveyor belt, a winding roller, a winding roller mounting bracket, a hydraulic cylinder, a weighing scale, and a controller. The conveyor belt is horizontally arranged to transport the rubber strip and provide frictional driving force at the bottom. The winding roller is mounted on the winding roller mounting bracket above the conveyor belt and is used to wind the rubber strip into a roll. The piston rod of the hydraulic cylinder is connected to the winding roller mounting bracket and is used to drive the winding roller mounting bracket to move up and down, adjusting the spatial height of the winding roller. The weighing scale is installed below the carrying section of the conveyor belt, directly opposite the pressing area between the winding roller and the conveyor belt, and includes support rollers to detect the contact pressure applied by the roll to the conveyor belt in real time. The controller is electrically connected to both the weighing scale and the hydraulic cylinder, receiving pressure signals from the weighing scale and outputting displacement control commands to the hydraulic cylinder to achieve closed-loop pressure regulation.

[0036] The following describes the process of the method provided in this implementation. Please refer to [link / reference]. Figure 2 This is a flowchart illustrating a method for controlling roll wrinkles using a weighing method in an embodiment of this application.

[0037] To achieve initial planning for the winding process, the system first needs to establish control benchmarks, namely:

[0038] S201. Under the condition of receiving the physical parameters and attenuation coefficient of the coil, calculate the cumulative weight sequence and target pressure range sequence of the coil as the winding time changes, and determine the theoretical weight prediction value and target pressure range corresponding to each time node.

[0039] Among them, the physical parameters of the roll material represent a set of values ​​describing the inherent properties of the rubber strip material; the attenuation coefficient represents an empirical value used to adjust the proportional relationship between the theoretical weight and the actual required pressure; the theoretical weight prediction value represents the theoretical mass of the roll material at a specific time point; and the target pressure range represents a reasonable range of values ​​that allows for fluctuations in the actual contact positive pressure.

[0040] Specifically, before the winding process begins, the controller of the winding device receives externally input physical parameters and attenuation coefficients. The controller's internal calculation module, based on the set winding linear speed and time, integrates to calculate the current volume of material being wound, and combines this with the density to derive a theoretical weight prediction. Subsequently, the attenuation coefficient is used to correct this prediction, generating a reference pressure. This reference pressure then fluctuates within a certain range above and below the reference pressure to form the target pressure range. This step is executed periodically before and during winding, providing a dynamic reference target for the entire control process.

[0041] In some embodiments, this step can be implemented in several ways: Optionally, the controller reads the formula parameter table pre-stored in the database and extracts the corresponding physical parameters; iteratively calculates the cumulative weight at fixed time steps according to the built-in mathematical integral formula; multiplies the cumulative weight by the attenuation coefficient and adds or subtracts a fixed tolerance to generate an interval sequence. Optionally, the controller receives the real-time parameter stream sent by the host computer through the communication interface; calculates the predicted weight value of the current node in real time using the discrete-time difference equation; obtains the tolerance range corresponding to the current weight according to the dynamic lookup table method, and synthesizes the target pressure interval. It is understood that other methods can also be used to implement this step, which are not limited here. In some embodiments, there may be a slight deviation in the input physical parameters. In this regard, the winding device will perform a zero-point calibration on the theoretical weight prediction model using the initial reading of the weighing scale during the initial winding stage to correct the initial parameter deviation.

[0042] After establishing the baseline, the system needs to undergo pre-emptive spatial adjustments, namely:

[0043] S202. Based on the theoretical weight prediction value corresponding to the current time node, output the basic feedforward displacement command to the hydraulic cylinder, so that the winding roll mounting bracket drives the winding roll to be raised to the predicted space height.

[0044] Among them, the basic feedforward displacement command represents the open-loop position control signal actively issued by the controller and independent of feedback signals; the predicted spatial height represents the spatial vertical position that the take-up roll center axis should be located based on the theoretical roll diameter.

[0045] Specifically, at the beginning of each control cycle, the controller extracts the theoretical weight prediction value for the current time point. Using the conversion formula between volume and geometric dimensions, it calculates the theoretical radius of the current coil. The controller converts this change in theoretical radius into the extension / retraction displacement of the hydraulic cylinder, generating a basic feedforward displacement command. This command is output to the servo valve of the hydraulic cylinder via the digital-to-analog converter module, driving the hydraulic cylinder to move and causing the take-up roll mounting bracket to lift the take-up roll to the predicted spatial height. This step is continuously executed during the winding process, achieving macroscopic following and lifting of the take-up roll.

[0046] In some embodiments, this step can be implemented in several ways: Optionally, the controller calculates the theoretical volume based on the theoretical weight; assuming the coil is a standard cylinder, the theoretical radius is calculated backwards; the displacement command is obtained by subtracting the initial radius from the theoretical radius. Optionally, the controller uses a pre-trained neural network model, inputs the predicted theoretical weight value, and directly outputs the predicted spatial height; the predicted spatial height is converted into a pulse control signal for the hydraulic cylinder and output. It is understood that other methods can also be used to implement this step, which are not limited here. In some embodiments, there may be a mechanical delay in the response of the hydraulic cylinder. To address this, the winding device adds a time advance compensation term when generating the basic feedforward displacement command, so that the command is output one mechanical response cycle in advance.

[0047] In order to obtain the actual stress state, the system needs to perform real-time data acquisition, that is:

[0048] S203. The contact pressure applied by the material roll to the conveyor belt is collected by a weighing scale to obtain a real-time pressure signal.

[0049] Among them, the weighing scale refers to the sensor assembly installed below the conveyor belt to measure the vertical force; the contact positive pressure refers to the combined pressure of the material roll weight and the hydraulic cylinder force on the conveyor belt in the vertical direction; and the real-time pressure signal refers to the continuous electrical signal output by the weighing scale.

[0050] Specifically, during the winding process, the material roll is pressed against the conveyor belt, and the support rollers at the bottom of the conveyor belt transmit the pressure to the load cell of the weighing scale. The load cell undergoes elastic deformation under pressure, outputting a corresponding weak voltage or current signal. This signal is amplified by the front-end amplifier circuit and then converted into a digital real-time pressure signal by the analog-to-digital converter, which is then transmitted to the controller. This acquisition process is continuously performed at a high-frequency sampling rate to ensure that minute details of pressure changes are captured.

[0051] In some embodiments, this step can be implemented in several ways: Optionally, a strain gauge load cell is used, outputting a voltage signal through a Wheatstone bridge circuit; after amplification by an operational amplifier, it is converted into a digital signal by a 24-bit ADC chip; and transmitted to the controller via an RS485 bus. Optionally, a piezoelectric force sensor is used, outputting a charge signal; after conversion by a charge amplifier, it is converted into a voltage signal; and after analog-to-digital conversion by a high-speed data acquisition card, it is sent to the controller. It is understood that other methods can also be used to implement this step, and no limitation is made here. In some embodiments, changes in ambient temperature may cause zero-point drift of the sensor. To address this, the winding device will perform an automatic tare operation in an unloaded state after each unloading to recalibrate the zero-point reference of the weighing scale.

[0052] The raw data collected often contains noise and needs to be cleaned up, i.e.:

[0053] S204. Perform sliding time window filtering on the real-time pressure signal to obtain the effective value of the actual positive pressure after removing high-frequency noise.

[0054] Among them, sliding time window filtering represents an algorithm that uses data within a fixed time interval to perform statistical calculations to smooth the signal; high-frequency noise represents invalid signals that fluctuate rapidly due to mechanical vibration or electromagnetic interference; and the effective value of actual normal pressure represents a value that reflects the true stress state after smoothing.

[0055] Specifically, after receiving the real-time digital pressure signal, the controller stores it in a first-in, first-out (FIFO) data buffer queue. The length of this queue corresponds to the length of the sliding time window. In each sampling period, the controller calculates the arithmetic mean or weighted average of all data in the queue as the effective value of the actual positive pressure at the current moment. As new data is added, the oldest data is removed from the queue, and the window slides forward over time. This step effectively filters out periodic high-frequency noise caused by conveyor belt joint vibrations, eccentric rotation of idlers, etc.

[0056] In some embodiments, this step can be implemented in several ways: Optionally, the controller maintains a circular buffer of length N; each time a new sample value is stored, the oldest value is overwritten; the arithmetic mean of the N data in the buffer is calculated as the effective value. Optionally, the controller uses a weighted moving average algorithm; different weight coefficients are assigned to the data in the buffer, with newer data having a larger weight; the weighted sum is calculated as the effective value of the actual positive pressure. It is understood that other methods can also be used to implement this step, and no limitation is made here. In some embodiments, sudden pulse interference may cause distortion of the average value. To address this, the winding device will first use a median filter to remove extreme value data within the window before performing the moving average filtering.

[0057] After acquiring valid data, the system needs to determine whether the current state deviates from the target, i.e.:

[0058] S205. When the actual effective value of positive pressure deviates from the target pressure range corresponding to the current time node, start the timing operation and record the duration of the deviation.

[0059] Among them, deviation indicates that the effective value of the actual positive pressure is greater than the upper limit of the target pressure range or less than the lower limit; timing operation indicates that the timer inside the controller starts to accumulate time; deviation duration indicates the continuous length of time that the pressure is in the deviation state.

[0060] Specifically, in each control cycle, the controller compares the calculated effective value of the actual positive pressure with the target pressure range corresponding to the current time point. If the effective value of the actual positive pressure exceeds the upper or lower limit of the target pressure range, the controller's internal state machine flips, triggering a timer to start counting. In subsequent cycles, if the pressure continues to deviate, the timer continuously increments to record the duration of the deviation; if the pressure returns to the range, the timer is reset to zero. This step is used to confirm the authenticity of the pressure anomaly and eliminate instantaneous fluctuations.

[0061] In some embodiments, this step can be implemented in several ways: Optionally, the controller sets a Boolean flag; when the pressure exceeds the limit, the flag is set, and the current system timestamp is recorded; in subsequent cycles, the deviation duration is obtained by subtracting the recorded timestamp from the current time. Optionally, the controller starts a hardware timer interrupt; each time an interrupt occurs, it checks whether the pressure exceeds the limit; if it does, the number of interrupts is accumulated and multiplied by the interrupt cycle to obtain the deviation duration. It is understood that other methods can also be used to implement this step, and no limitation is made here. In some embodiments, there may be a situation where the pressure frequently crosses the boundary, causing the timer to reset frequently. To address this, the winding device sets a hysteresis comparison interval at the boundary of the target pressure range to prevent the state machine from flipping frequently.

[0062] Once the deviation is confirmed to be stable, the system needs to calculate the required correction force, i.e.:

[0063] S206. When the duration of deviation exceeds the preset anti-shake time threshold, calculate the compensation displacement based on the difference between the actual effective value of positive pressure and the target pressure range.

[0064] Among them, the preset anti-shake time threshold represents the minimum confirmation time length used to filter out brief interference; the difference represents the numerical difference between the actual pressure and the target boundary; and the compensation displacement represents the additional hydraulic cylinder stroke required to eliminate the pressure deviation.

[0065] Specifically, when the controller detects that the duration of the deviation exceeds the preset anti-shake time threshold, it confirms that a genuine pressure breach has occurred. The controller calculates the difference between the actual effective value of the positive pressure and the target boundary (upper or lower limit) on the breach side. Subsequently, it calls its internal control algorithm (such as a PID algorithm or a stiffness model-based algorithm) to convert this pressure difference into a corresponding spatial displacement, i.e., a compensation displacement. This step quantifies the pressure deviation into a specific mechanical action target.

[0066] In some embodiments, this step can be implemented in several ways: Optionally, the controller employs an incremental PID control algorithm; using the pressure difference as an error input, it calculates the compensation displacement by combining proportional, integral, and derivative coefficients; and stores the calculation result in an output register. Optionally, the controller uses a pre-calibrated pressure-displacement mapping table; it performs linear interpolation in the mapping table using the pressure difference to directly obtain the corresponding compensation displacement. It is understood that other methods can also be used to implement this step, and no limitation is made here. In some embodiments, there may be a situation where the calculated compensation displacement is too large, leading to mechanical impact. To address this, the winding device will perform amplitude limiting processing on the calculated compensation displacement, restricting the maximum step size of a single adjustment.

[0067] Finally, the system translates the corrective force into actual physical action, namely:

[0068] S207: Output compensation displacement to the hydraulic cylinder to adjust the actual contact positive pressure between the material roll and the conveyor belt to the target pressure range.

[0069] Among them, output represents the process by which the controller converts digital instructions into physical control signals; adjustment represents the process by which the hydraulic cylinder performs physical displacement to change the force state.

[0070] Specifically, the controller synthesizes the calculated compensation displacement with the basic feedforward displacement command to generate the final control signal. This control signal is amplified by the drive circuit and then applied to the proportional servo valve of the hydraulic cylinder. The servo valve controls the flow and direction of the hydraulic oil, driving the piston rod of the hydraulic cylinder to extend or retract by the corresponding displacement. The take-up roller mounting bracket then experiences slight lifting and lowering, changing the pressing depth between the roll and the conveyor belt, causing the actual contact pressure to smoothly return to the target pressure range. This step completes the final execution stage of the closed-loop control.

[0071] In some embodiments, this step can be implemented in several ways: Optionally, the controller converts the comprehensive displacement into a PWM duty cycle signal; outputs it to the servo valve drive board to control the valve core opening; the hydraulic cylinder generates physical displacement based on the flow integral. Optionally, the controller sends the displacement command to the intelligent hydraulic pump station via industrial Ethernet; the closed-loop controller inside the pump station drives the motor and pump according to the command to precisely control the stroke of the hydraulic cylinder. It is understood that other methods can also be used to implement this step, which are not limited here. In some embodiments, there may be a situation where the hydraulic system has steady-state errors that lead to incomplete adjustment. In this regard, the winding device will continuously monitor the actual effective value of the positive pressure after outputting the command. If it still has not entered the target range, it will continue to accumulate and output the compensation displacement in the next cycle.

[0072] To further enhance the precision of control, the specific details of parameter acquisition and model construction in the basic process described above are elaborated below. The method provided in this implementation is described in more detail below. Please refer to... Figure 3 This is another flowchart illustrating the method for controlling roll wrinkles using the weighing method in this application embodiment.

[0073] S301. Given the physical parameters and attenuation coefficient of the received roll material, calculate the cumulative weight sequence and target pressure range sequence of the roll material as a function of winding time, and determine the theoretical weight prediction value and target pressure range corresponding to each time node. Refer to step S201, which will not be repeated here.

[0074] In some embodiments, the winding device performs detailed calibration of the target pressure range, that is, the winding device acquires the physical parameters of the roll material, including the strip width, strip thickness, material density, and conveyor belt speed; based on the physical parameters and the current winding time, it calculates the theoretical volume of the strip material wound into the winding roller at the current time point, and calculates the theoretical weight prediction value in combination with the material density; a reference target pressure value is determined based on the attenuation coefficient and the theoretical weight prediction value; the attenuation coefficient is used to characterize the optimal weight ratio required to maintain synchronous friction without causing compression deformation of the roll material; and a preset tolerance range is expanded upward and downward from the reference target pressure value to generate the target pressure range corresponding to the current time point.

[0075] Among them, the theoretical volume represents the space occupied by the material calculated based on geometric parameters; the benchmark target pressure value represents the optimal pressure applied by the material roll to the conveyor belt under ideal conditions; and the preset tolerance range represents the safe upper and lower limits of pressure fluctuations.

[0076] Specifically, during the initialization phase, the controller acquires physical parameters such as the width, thickness, density, and linear velocity of the material strip through a human-machine interface or communication with a host computer. During the winding process, the controller calculates the winding length by integrating the linear velocity and winding time, combines this with the width and thickness to obtain the theoretical volume, and then multiplies it by the density to obtain the theoretical weight prediction. To prevent excessive pressure from causing material deformation, the controller multiplies the theoretical weight prediction by an attenuation coefficient to obtain a baseline target pressure value. Finally, a preset tolerance range is added to or subtracted from this baseline value to generate a dynamically changing target pressure range. This process achieves adaptive dynamic setting of the control target.

[0077] In some embodiments, this step can be implemented in several ways: Optionally, the controller performs multiplication to calculate the length; performs consecutive multiplication to calculate the volume and weight; multiplies by the attenuation coefficient to obtain the baseline value; and performs addition and subtraction operations to generate the interval boundary. Optionally, the controller inputs physical parameters into a preset mathematical model matrix; and outputs the baseline target pressure value and tolerance range for the current time node in one go through matrix operations. It is understood that other methods can also be used to implement this step, which are not limited here. In some embodiments, there may be slight differences in the density of different batches of material. To address this, the winding device will measure the weight of a section of material using a weighing scale at the beginning of winding to calibrate the input material density parameters online.

[0078] After obtaining the theoretical weight prediction, the system needs to convert it into geometric dimensions, i.e.:

[0079] S302. Based on the theoretical weight prediction, strip width, and material density, the theoretical outer diameter of the roll to be cut at the current time point is calculated in reverse.

[0080] Among them, the strip width represents the physical dimension of the rubber strip in the transverse direction; the material density represents the mass of the rubber strip per unit volume; and the theoretical outer diameter represents the diameter of the cylindrical roll calculated by a mathematical model.

[0081] Specifically, the controller extracts the theoretical weight prediction value at the current time point, divides it by the material density, and obtains the total volume of the material currently being wound into the roll. Then, this total volume is divided by the strip width to obtain the theoretical cross-sectional area of ​​the roll. Assuming the roll cross-section is a standard circle, the theoretical outer diameter of the roll at the current time point is calculated using the formula for the area of ​​a circle and the initial cross-sectional area of ​​the take-up roller. This step achieves the parameter transformation from the mass domain to the spatial geometric domain.

[0082] In some embodiments, this step can be implemented in several ways: Optionally, the controller performs division to obtain the total volume; performs division to obtain the cross-sectional area; adds the initial cross-sectional area of ​​the winding roller, divides by pi and takes the square root, multiplies by 2 to obtain the theoretical outer diameter. Optionally, the controller uses a pre-generated weight-outer diameter curve; inputs the predicted theoretical weight value, and directly calculates the theoretical outer diameter using a polynomial fitting function. It is understood that other methods can also be used to implement this step, and no limitation is made here. In some embodiments, there may be a situation where the material strip experiences slight stretching during the winding process, causing a change in density. To address this, the winding device introduces a tension correction coefficient during the calculation process to dynamically compensate for the material density.

[0083] After obtaining the theoretical outer diameter, the system needs to calculate the increment relative to the initial state, i.e.:

[0084] S303. Calculate the difference between the theoretical outer diameter and the initial outer diameter of the take-up roll, and use it as the theoretical radius increment.

[0085] Wherein, the initial outer diameter of the take-up roll represents the diameter of the take-up roll itself when no material is wound in; the theoretical radius increment represents the increase in thickness of the roll on one side in the radial direction.

[0086] Specifically, the controller reads the preset initial outer diameter parameters of the take-up roll from the memory. The theoretical outer diameter calculated in step S302 is subtracted from this initial outer diameter to obtain the diameter increment. The diameter increment is then divided by 2 to obtain the theoretical radius increment. This theoretical radius increment represents the theoretical distance the bottom of the roll extends downwards relative to the center axis of the take-up roll. This step provides a direct geometric basis for subsequent displacement compensation.

[0087] In some embodiments, this step can be implemented in several ways: Optionally, the controller executes a subtraction instruction to calculate the diameter difference; performs a right shift by one bit to divide by 2, obtaining the theoretical radius increment; and stores the result in a designated register. Optionally, the controller directly calculates the theoretical radius when calculating the theoretical outer diameter; subtracts the initial radius of the take-up roll from the theoretical radius to directly obtain the theoretical radius increment. It is understood that other methods can also be used to implement this step, and no limitation is made here. In some embodiments, there may be a situation where the surface of the take-up roll has a rubber coating, causing the initial outer diameter to be inaccurate. To address this, the winding device will provide a calibration interface for the operator to input the measured initial outer diameter after each take-up roll replacement.

[0088] Based on the calculated geometric increment, the system generates feedforward control commands, namely:

[0089] S304. Using the theoretical radius increment as the predicted spatial height, generate a basic feedforward displacement command and output it to the hydraulic cylinder to drive the take-up roll mounting bracket to perform feedforward lifting. Refer to step S202, which will not be repeated here.

[0090] While performing feedforward control, the system initiates monitoring of the actual state, namely:

[0091] S305. The contact pressure applied by the material roll to the conveyor belt is collected by a weighing scale to obtain a real-time pressure signal. Refer to step S203, which will not be repeated here.

[0092] To achieve accurate filtering, the system needs to obtain the characteristic parameters of the mechanical structure, namely:

[0093] S306. Obtain the installation spacing of the bottom support rollers of the conveyor belt and the conveying line speed of the conveyor belt.

[0094] Among them, the installation spacing refers to the horizontal distance between the central axes of two adjacent support rollers; the conveyor linear speed refers to the linear displacement speed of the conveyor belt surface as it moves forward.

[0095] Specifically, the controller obtains the fixed installation spacing of the bottom support rollers of the conveyor belt by reading the system configuration parameter table. Simultaneously, the controller obtains the current actual conveyor speed by reading feedback data from the frequency converter or servo drive. These two parameters are key physical quantities that determine the mechanical vibration characteristics of the conveyor belt during operation. This step provides the necessary data foundation for subsequently constructing the adaptive filtering window.

[0096] In some embodiments, this step can be implemented in several ways: Optionally, during the initialization phase, the controller reads the installation spacing from non-volatile memory; periodically reads the rotational speed of the main drive motor via the fieldbus, and calculates the conveyor line speed based on the transmission ratio. Optionally, the controller receives the process recipe from the host computer, parses the installation spacing and conveyor line speed parameters, and stores them in memory variables for later retrieval. It is understood that other methods can also be used to implement this step, and no limitation is made here. In some embodiments, there may be situations where the conveyor line speed is dynamically adjusted during the winding process. To address this, the winding device updates the conveyor line speed variable in real time during each control cycle to ensure the real-time nature of the parameters.

[0097] Using the acquired characteristic parameters, the system derives the frequency characteristics of the interference signal, namely:

[0098] S307. Based on the installation spacing and conveyor line speed, calculate the frequency of periodic mechanical vibration generated by the conveyor belt during operation, and derive the corresponding mechanical vibration period.

[0099] Among them, the periodic mechanical vibration frequency represents the frequency at which the conveyor belt bounces up and down when it passes the idler roller; the mechanical vibration period represents the time required to complete one full vibration.

[0100] Specifically, the controller divides the acquired conveyor line speed by the installation spacing of the supporting idlers to calculate the frequency at which the conveyor belt joint or specific point passes through adjacent idlers. This frequency is the primary periodic mechanical vibration frequency. Subsequently, the controller calculates the reciprocal of this frequency to derive the corresponding mechanical vibration period. This mechanical vibration period reflects the fluctuation pattern of high-frequency noise in the pressure signal. This step transforms the mechanical kinematic characteristics into the basis for signal processing.

[0101] In some embodiments, this step can be implemented in several ways: Optionally, the controller performs a floating-point division operation to divide the linear velocity by the spacing to obtain the frequency; then performs another floating-point division operation to divide the frequency by 1 to obtain the vibration period. Optionally, the controller uses a lookup table to pre-calculate a table of vibration periods for different linear velocities; and looks up the corresponding mechanical vibration period in the table based on the current linear velocity. It is understood that other methods can also be used to implement this step, and no limitation is made here. In some embodiments, there may be a situation where the complex mechanical structure results in multiple harmonic frequencies. In this case, the winding device performs a spectral analysis of the initial pressure signal using a Fast Fourier Transform (FFT) to extract the dominant frequency with the highest energy as the basis for calculation.

[0102] Based on the derived periodic characteristics, the system constructs a dedicated filtering tool, namely:

[0103] S308. Set the length of the sliding time window to an integer multiple of the mechanical vibration period to construct an adaptive sliding window.

[0104] Among them, the time length represents the historical data time span covered by the sliding window; integer multiples indicate that the time length is 1, 2 or more times the mechanical vibration period; adaptive sliding window indicates a data processing interval whose length can be dynamically adjusted according to changes in mechanical parameters.

[0105] Specifically, the controller acquires the calculated mechanical vibration period, multiplies it by a preset integer multiple (e.g., 1 or 2), and determines the length of the sliding time window. Based on this time length and the system's sampling frequency, the controller calculates the number of data points that need to be included in the window and dynamically allocates a data queue of the corresponding length in memory to construct an adaptive sliding window. This step ensures that the filtering window can completely cover one or more vibration periods, so that the integral of periodic disturbances within the window is zero.

[0106] In some embodiments, this step can be implemented in several ways: Optionally, the controller multiplies the vibration period by a factor to obtain the time length; divides the time length by the sampling period to obtain the number of data points N; and allocates a circular array of length N in RAM as a sliding window. Optionally, the controller constructs the sliding window using a linked list structure; based on the calculated time length, nodes are dynamically added or deleted from the linked list to maintain the time span of the window. It is understood that other methods can also be used to implement this step, and no limitation is made here. In some embodiments, there may be cases where the calculated number of data points is not an integer. In this case, the winding device rounds the calculation result to the nearest integer and compensates for the rounding error by fine-tuning the sampling frequency.

[0107] Using pre-built tools, the system cleanses the raw data, namely:

[0108] S309. Apply a moving average filter to the real-time pressure signal using an adaptive sliding window to cancel out the alternating interference caused by periodic mechanical vibration, thus obtaining the effective value of the actual positive pressure. Refer to step S204; details are omitted here.

[0109] The purified data is used for status monitoring, and the system records the duration of abnormal states, i.e.:

[0110] S310. When the actual effective value of the positive pressure deviates from the target pressure range corresponding to the current time node, start the timing operation and record the duration of the deviation. Refer to step S205, which will not be repeated here.

[0111] Once the abnormal state is confirmed, the system calculates the specific correction parameters, namely:

[0112] S311. When the deviation duration exceeds the preset anti-shake time threshold, calculate the compensation displacement based on the difference between the actual effective value of the positive pressure and the target pressure range. Refer to step S206, which will not be repeated here.

[0113] In calculating the compensation displacement, to match the elastic properties of the material, in some embodiments, the winding device introduces a stiffness model for calculation. That is, when the effective value of the actual normal pressure is greater than the upper limit of the target pressure range, the winding device calculates a first pressure difference between the effective value of the actual normal pressure and the upper limit; or, when the effective value of the actual normal pressure is less than the lower limit of the target pressure range, it calculates a second pressure difference between the effective value of the actual normal pressure and the lower limit. Based on the material roll stiffness model, the radial stiffness coefficient of the material roll at the current time node is determined. This radial stiffness coefficient is used to characterize the pressure change corresponding to the unit radial deformation of the material roll at the current roll diameter. Based on the first pressure difference or the second pressure difference, combined with the radial stiffness coefficient, the compensation displacement is calculated so that the compensation displacement is used to match the physical elastic properties of the current material roll.

[0114] Wherein, the first pressure difference represents the deviation under overpressure; the second pressure difference represents the deviation under underpressure; the coil stiffness model represents the mathematical equation describing the relationship between the force and deformation of the coil; and the radial stiffness coefficient represents the proportional parameter in the model.

[0115] Specifically, once the pressure exceeds the limit, the controller calculates the difference between the actual pressure and the corresponding boundary (the first or second pressure difference). Since the coil is a flexible material, its deformation under pressure is non-linearly related to the pressure change. The controller calls the coil stiffness model and calculates the corresponding radial stiffness coefficient based on the current theoretical coil diameter. Subsequently, the controller divides the pressure difference by this radial stiffness coefficient to calculate the required compensation displacement. This process transforms the abstract pressure deviation into a specific mechanical displacement that conforms to the material's physical properties.

[0116] In some embodiments, this step can be implemented in several ways: Optionally, the controller determines the direction of the out-of-bounds movement, performs subtraction to calculate the difference, calls the stiffness function, inputs the current roll diameter to obtain the stiffness coefficient, and performs division to obtain the compensation displacement. Optionally, the controller uses a preset three-dimensional lookup table matrix (input is the pressure difference and roll diameter, output is the displacement); and directly obtains the compensation displacement by looking up the table using a bilinear interpolation algorithm. It is understood that other methods can also be used to implement this step, and no limitation is made here. In some embodiments, the roll stiffness model may be inaccurate at extreme roll diameters. To address this, the winding device sets limit protection values ​​for the stiffness coefficient at both ends of the model to prevent the calculation of excessively large compensation displacements.

[0117] To cope with the random fluctuations in material properties, the system has self-learning capabilities. In some embodiments, the winding device dynamically updates the stiffness model. That is, after the hydraulic cylinder performs the compensation displacement, the winding device collects the effective value of the actual normal pressure at the next time node; calculates the actual pressure change before and after the compensation displacement, and uses the ratio of the actual pressure change to the compensation displacement as the actual stiffness feedback value; and uses the actual stiffness feedback value to update the radial stiffness coefficient in the material roll stiffness model using Kalman filtering to obtain the corrected radial stiffness coefficient. This corrected radial stiffness coefficient is used to improve the accuracy of the next calculation of the compensation displacement, so as to overcome the nonlinear error caused by the random fluctuation of the material roll's bulkiness.

[0118] Among them, the actual pressure change represents the true change in pressure after displacement adjustment; the actual stiffness feedback value represents the current true stiffness calculated based on measured data; and the Kalman filter update represents an optimal estimation algorithm that uses observed data to correct the model state.

[0119] Specifically, after outputting the compensation displacement and waiting for the mechanical response, the controller reads the new effective value of the actual normal pressure. The controller calculates the pressure difference before and after adjustment, divides it by the output compensation displacement, and obtains the actual stiffness feedback value. Subsequently, the controller uses this feedback value as an observation input and iteratively updates the radial stiffness coefficient in the coil stiffness model using a Kalman filter algorithm. This process achieves online adaptive correction of model parameters, effectively overcoming the nonlinear error caused by changes in coil bulkiness.

[0120] In some embodiments, this step can be implemented in several ways: Optionally, the controller records the pressure value before adjustment; reads the pressure value after adjustment and calculates the difference; performs division to obtain the feedback value; and calls the Kalman filter function to update the stiffness coefficient variable. Optionally, the controller uses recursive least squares instead of Kalman filtering; and uses historical displacement and pressure change data sequences to identify and update the radial stiffness coefficient online. It is understood that other methods can also be used to implement this step, and no limitation is made here. In some embodiments, sensor noise may cause abnormal jumps in the actual stiffness feedback value. To address this, the winding device will perform a threshold check on the actual stiffness feedback value before updating the Kalman filter to eliminate unreasonable outliers.

[0121] Finally, the system executes corrective actions to restore the normal force state, that is:

[0122] S312. Output the compensation displacement to the hydraulic cylinder to adjust the actual contact pressure between the material roll and the conveyor belt to the target pressure range. Refer to step S207, which will not be repeated here.

[0123] Before the final output command, the system must ensure the safety of the operation. In some embodiments, the winding device will execute a safety interception mechanism, that is, the winding device will superimpose the compensation displacement amount and the basic feedforward displacement command corresponding to the current time node to generate a comprehensive displacement control command; determine whether the absolute value of the compensation displacement amount exceeds the preset safety limit threshold; if it does not exceed the threshold, the comprehensive displacement control command will be output to the hydraulic cylinder to smoothly pull the actual contact positive pressure back to the target pressure range; if it exceeds the threshold, it will be determined that there is an equipment abnormality in the winding process, including material belt breakage or sensor failure, and the comprehensive displacement control command will be intercepted and a shutdown alarm signal will be triggered.

[0124] Among them, the comprehensive displacement control command represents the final execution signal that includes feedforward following and closed-loop compensation; the safety limit threshold represents the maximum displacement limit that is allowed for a single adjustment; and the equipment abnormality represents an abnormal operating condition that causes a sudden change in the force on the system.

[0125] Specifically, the controller adds the calculated compensated displacement to the basic feedforward displacement command to synthesize a comprehensive displacement control command. Before outputting, the controller extracts the absolute value of the compensated displacement and compares it with a preset safety limit threshold. If the limit is not exceeded, it indicates that the system is within the normal adjustment range, and the command is output normally to drive the hydraulic cylinder. If the limit is exceeded, it indicates that the system may have experienced a sudden pressure drop due to a broken conveyor belt, or that a sensor malfunction has caused abnormal readings. The controller immediately intercepts the command, stops the hydraulic cylinder's movement, and sends a shutdown alarm signal to the main control system. This process ensures the safety of equipment and personnel.

[0126] In some embodiments, this step can be implemented in several ways: Optionally, the controller executes an addition operation to synthesize instructions; calls an absolute value function to process the compensation displacement; executes a conditional judgment statement to compare thresholds; and executes an output or alarm branch based on the judgment result. Optionally, the controller uses a hardware comparator circuit to monitor the output signal; when the signal amplitude exceeds a set threshold, the hardware circuit directly cuts off the enable signal of the servo valve and triggers an interrupt to notify the controller of an alarm. It is understood that other methods can also be used to implement this step, which are not limited here. In some embodiments, there may be a situation where a large pressure fluctuation at the moment of startup leads to a false alarm. In this regard, the winding device will temporarily increase the safety limit threshold during the first few control cycles of winding startup to get through the startup transition period.

[0127] In this embodiment, the closed-loop control based on actual contact positive pressure combined with feedforward displacement compensation is adopted, which enables the take-up roller to accurately follow the growth of the roll volume and dynamically maintain the optimal pressing state. This effectively solves the problems of material strip wrinkling caused by increased winding resistance and slippage caused by insufficient pressure in related technologies, thereby achieving a significant improvement in the yield of flexible roll winding products.

[0128] The winding device in the embodiments of this invention is described below from the perspective of hardware processing. Please refer to [link / reference]. Figure 4 This is a schematic diagram of the circuit structure of a winding device in an embodiment of this application.

[0129] It should be noted that, Figure 4 The structure of the winding device shown is merely an example and should not impose any limitation on the functionality and scope of use of the embodiments of the present invention.

[0130] like Figure 4As shown, the winding device includes a CPU 401, which can perform various appropriate actions and processes according to a program stored in ROM 402 or a program loaded into RAM 403 from storage section 408, such as executing the methods described in the above embodiments. RAM 403 also stores various programs and data required for system operation. CPU 401, ROM 402, and RAM 403 are interconnected via bus 404. I / O interface 405 is also connected to bus 404.

[0131] The following components are connected to I / O interface 405: input section 406 including audio input devices, push-button switches, etc.; output section 407 including liquid crystal display (LCD) and audio output devices, indicator lights, etc.; storage section 408 including hard disks, etc.; and communication section 409 including network interface cards such as LAN (Local Area Network) cards, modems, etc. Communication section 409 performs communication processing via a network such as the Internet. Drive 410 is also connected to I / O interface 405 as needed. Removable media 411, such as disks, optical disks, magneto-optical disks, semiconductor memories, etc., are installed on drive 410 as needed so that computer programs read from them can be installed into storage section 408 as needed.

[0132] In particular, according to embodiments of the present invention, the processes described above with reference to the flowcharts can be implemented as computer software programs. For example, embodiments of the present invention include a computer program product comprising a computer program carried on a computer-readable medium, the computer program containing computer programs for performing the methods shown in the flowcharts. In such embodiments, the computer program can be downloaded and installed from a network via communication section 409, and / or installed from removable medium 411. When the computer program is executed by CPU 401, it performs the various functions defined in the present invention.

[0133] The flowcharts and block diagrams in the accompanying drawings illustrate the architecture, functionality, and operation of possible implementations of systems, methods, and computer program products according to various embodiments of the present invention. Each block in a flowchart or block diagram may represent a module, program segment, or portion of code, which contains one or more executable instructions for implementing a specified logical function. It should also be noted that in some alternative implementations, the functions indicated in the blocks may occur in a different order than those shown in the drawings.

[0134] Specifically, the winding device in this embodiment includes a processor and a memory. The memory stores a computer program. When the computer program is executed by the processor, it implements the control method for improving the wrinkles of the rolled material by using the weighing method provided in the above embodiment.

[0135] In another aspect, the present invention also provides a computer-readable storage medium, which may be included in the winding device described in the above embodiments, or may exist independently and not assembled into the winding device. The storage medium carries one or more computer programs that, when executed by a processor of the winding device, cause the winding device to implement the control method for improving coil wrinkles using a weighing method provided in the above embodiments.

[0136] The above-described embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit it. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this application.

[0137] As used in the above embodiments, depending on the context, the term "when..." can be interpreted as meaning "if...", "after...", "in response to determining...", or "in response to detecting...". Similarly, depending on the context, the phrase "when determining..." or "if (the stated condition or event) is interpreted as meaning "if determining...", "in response to determining...", "when (the stated condition or event) is detected", or "in response to detecting (the stated condition or event)".

Claims

1. A method for controlling wrinkles in rolled fabric using a weighing method, characterized in that, The method is applied to a winding device, which includes a conveyor belt for conveying rubber strip material and providing frictional driving force, a winding roller, a winding roller mounting bracket for mounting the winding roller, a hydraulic cylinder for driving the winding roller mounting bracket to rise and fall, a weighing scale for real-time pressure detection, and a controller electrically connected to the weighing scale and the hydraulic cylinder; the method includes: Under the condition of receiving the physical parameters and attenuation coefficient of the roll material, calculate the cumulative weight sequence and target pressure range sequence of the roll material as the winding time changes, and determine the theoretical weight prediction value and target pressure range corresponding to each time node. Based on the theoretical weight prediction value corresponding to the current time node, a basic feedforward displacement command is output to the hydraulic cylinder, so that the take-up roll mounting bracket drives the take-up roll to be raised to the predicted space height; The contact pressure applied by the material roll to the conveyor belt is collected by the weighing scale to obtain a real-time pressure signal; The real-time pressure signal is subjected to sliding time window filtering to obtain the effective value of the actual positive pressure after removing high-frequency noise; When the actual effective value of the positive pressure deviates from the target pressure range corresponding to the current time node, a timing operation is started to record the duration of the deviation. When the duration of the deviation exceeds the preset anti-shake time threshold, the compensation displacement is calculated based on the difference between the actual effective value of the positive pressure and the target pressure range. The compensation displacement is output to the hydraulic cylinder to adjust the actual contact pressure between the material roll and the conveyor belt to the target pressure range.

2. The method for controlling roll fabric wrinkles using a weighing method according to claim 1, characterized in that, The step of calculating the cumulative weight sequence and target pressure range sequence of the roll material as it changes with winding time, under the conditions of the received physical parameters and attenuation coefficient, and determining the theoretical weight prediction value and target pressure range corresponding to each time node, specifically includes: Obtain the physical parameters of the roll material; the physical parameters include the strip width, strip thickness, material density, and conveyor belt speed. Based on the physical parameters and the current winding time, calculate the theoretical volume of the strip wound into the winding roller at the current time point, and combine it with the material density to calculate the predicted theoretical weight. The baseline target pressure value is determined based on the attenuation coefficient and the theoretical weight prediction value; the attenuation coefficient is used to characterize the optimal weight ratio required to maintain synchronous friction without causing compression deformation of the coil. Centered on the benchmark target pressure value, a preset tolerance range is expanded upwards and downwards to generate the target pressure range corresponding to the current time node.

3. The method for controlling roll fabric wrinkles using a weighing method according to claim 2, characterized in that, The step of outputting a basic feedforward displacement command to the hydraulic cylinder based on the theoretical weight prediction value corresponding to the current time node, so that the take-up roll mounting bracket drives the take-up roll to lift to the predicted spatial height, specifically includes: Based on the theoretical weight prediction, the strip width, and the material density, the theoretical outer diameter of the roll at the current time point is calculated in reverse. Calculate the difference between the theoretical outer diameter and the initial outer diameter of the take-up roll, and use it as the theoretical radius increment; The theoretical radius increment is used as the predicted spatial height to generate a basic feedforward displacement command, which is then output to the hydraulic cylinder to drive the take-up roll mounting bracket to perform feedforward lifting.

4. The method for controlling roll fabric wrinkles using a weighing method according to claim 1, characterized in that, The step of performing sliding time window filtering on the real-time pressure signal to obtain the effective value of the actual positive pressure after removing high-frequency noise specifically includes: The installation spacing of the bottom support rollers of the conveyor belt and the conveying line speed of the conveyor belt are obtained. Based on the installation spacing and the conveyor line speed, the frequency of periodic mechanical vibration generated by the conveyor belt during operation is calculated, and the corresponding mechanical vibration period is derived. An adaptive sliding window is constructed by setting the length of the sliding time window to an integer multiple of the mechanical vibration period. The real-time pressure signal is filtered by moving average based on the adaptive sliding window to cancel the alternating interference caused by the periodic mechanical vibration, thereby obtaining the effective value of the actual positive pressure.

5. The method for controlling roll fabric wrinkles using a weighing method according to claim 1, characterized in that, The step of calculating the compensation displacement based on the difference between the actual effective value of the positive pressure and the target pressure range specifically includes: When the effective value of the actual positive pressure is greater than the upper limit of the target pressure range, a first pressure difference between the effective value of the actual positive pressure and the upper limit is calculated; Alternatively, when the effective value of the actual positive pressure is less than the lower limit of the target pressure range, a second pressure difference between the effective value of the actual positive pressure and the lower limit is calculated; The radial stiffness coefficient of the coil at the current time point is determined based on the coil stiffness model; the radial stiffness coefficient is used to characterize the pressure change corresponding to a unit radial deformation of the coil at the current coil diameter. Based on the first pressure difference or the second pressure difference, the compensation displacement is calculated in conjunction with the radial stiffness coefficient, so that the compensation displacement is used to match the physical elastic properties of the current coil.

6. The method for controlling roll fabric wrinkles using a weighing method according to claim 5, characterized in that, After the step of calculating the compensation displacement based on the first pressure difference or the second pressure difference, combined with the radial stiffness coefficient, such that the compensation displacement is used to match the physical elastic properties of the current coil, the method further includes: After the hydraulic cylinder performs the compensation displacement, the effective value of the actual positive pressure at the next time node is collected; Calculate the actual pressure change before and after the compensation displacement is performed, and use the ratio of the actual pressure change to the compensation displacement as the actual stiffness feedback value. The radial stiffness coefficient in the material roll stiffness model is updated by Kalman filtering using the actual stiffness feedback value to obtain the corrected radial stiffness coefficient. This corrected radial stiffness coefficient is used to improve the accuracy of the compensation displacement in the next calculation, so as to overcome the nonlinear error caused by the random fluctuation of the material roll's bulkiness.

7. The method for controlling roll fabric wrinkles using a weighing method according to any one of claims 1 to 6, characterized in that, The step of adjusting the actual contact pressure between the material roll and the conveyor belt to within the target pressure range specifically includes: The compensation displacement and the basic feedforward displacement command corresponding to the current time node are superimposed to generate a comprehensive displacement control command. Determine whether the absolute value of the compensated displacement exceeds a preset safety limit threshold; If the pressure does not exceed the target range, the integrated displacement control command is output to the hydraulic cylinder to smoothly pull the actual contact positive pressure back to the target pressure range. If the error exceeds the limit, it is determined that there is an equipment abnormality in the winding process, including tape breakage or sensor failure, and the integrated displacement control command is intercepted and a shutdown alarm signal is triggered.

8. A winding device, characterized in that, The winding device includes: one or more processors and a memory; the memory is coupled to the one or more processors, the memory being used to store computer program code, the computer program code including computer instructions, and the one or more processors invoking the computer instructions to cause the winding device to perform the method as described in any one of claims 1-7.

9. A computer-readable storage medium comprising instructions, characterized in that, When the instruction is executed on the winding device, the winding device performs the method as described in any one of claims 1-7.

10. A computer program product, characterized in that, When the computer program product is run on the winding device, it causes the winding device to perform the method as described in any one of claims 1-7.

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