A feedback regulating mechanism for constant tension in an aluminum foil winding process

Abstract

This invention discloses a feedback adjustment mechanism for maintaining constant tension during the aluminum foil winding process, belonging to the field of film product winding technology. It includes a frame, with an inlet roller for introducing aluminum foil at one end and an outlet roller group at the other end. A tension adjustment mechanism is located between the outlet roller group and the inlet roller. The tension adjustment mechanism includes a first transition roller and a second transition roller spaced apart, arranged sequentially along the aluminum foil traction direction. The aluminum foil passes through the top surfaces of the inlet roller, the first transition roller, and the second transition roller. Tension adjustment unit one and tension adjustment unit two are respectively located on both sides of the first transition roller. This invention balances the lateral force on the aluminum foil through simultaneous adjustment on both sides, avoiding deviation and wrinkling caused by unilateral force application. The counterweight roller has its own basic tension application capability, which, combined with the dynamic adjustment of the drive mechanism, balances static tension stability and dynamic working condition adaptability.

Description

Technical Field

[0001] This invention relates to the field of film winding technology, and in particular to a feedback adjustment mechanism for maintaining constant tension during the aluminum foil winding process. Background Technology

[0002] Aluminum foil, as a core material in packaging, electronics, and new energy fields, directly determines the yield rate of downstream processing stages through the quality of its winding process. During the winding process after aluminum foil rolling and slitting, tension stability is a key indicator affecting the quality of the coil: insufficient tension easily leads to interlayer misalignment and loose winding, resulting in wrinkles and scratches during subsequent unwinding; excessive tension may cause the aluminum foil to stretch and thin, break, or even overload and damage the winding equipment. Especially in the production of thin-gauge aluminum foil (thickness ≤ 0.05mm), even small fluctuations in tension are amplified, significantly impacting the flatness and interlayer tightness of the final product.

[0003] Existing tension adjustment schemes in aluminum foil winding equipment generally suffer from significant adjustment lag. Traditional mechanisms often employ a single mechanical counterweight or passive damping adjustment, which can only respond to static tension changes and cannot adapt to the inertial fluctuations caused by the continuous increase in roll diameter during winding. The larger the roll diameter, the lower the spindle angular velocity at the same linear speed. If the drive output is not adjusted in time, the tension will decrease exponentially with the increase in roll diameter, leading to loosening of the outer roll material. Furthermore, most schemes only have adjustment structures on one side of the aluminum foil. Applying force on one side easily causes uneven lateral force on the aluminum foil, which can easily lead to defects such as deviation and local wrinkles. Summary of the Invention

[0004] This invention provides a feedback adjustment mechanism for maintaining constant tension during the aluminum foil winding process, which can solve the problem of uneven lateral force on the aluminum foil caused by unilateral force application in the prior art.

[0005] A feedback adjustment mechanism for maintaining constant tension during aluminum foil winding includes a frame. One end of the frame has an inlet roller for introducing aluminum foil, and the other end has an outlet roller group. A tension adjustment mechanism is positioned between the outlet roller group and the inlet roller. The tension adjustment mechanism includes a first transition roller and a second transition roller spaced apart. The inlet roller, the first transition roller, and the second transition roller are arranged sequentially along the aluminum foil traction direction. The aluminum foil passes through the top surfaces of the inlet roller, the first transition roller, and the second transition roller. Tension adjustment unit one and tension adjustment unit two are respectively located on both sides of the first transition roller. Tension adjustment unit one and tension adjustment unit two have identical structures, each including a counterweight roller that rests against the upper surface of the aluminum foil and a drive mechanism that drives its up-and-down movement. The mechanism also includes a sensing end for real-time acquisition of winding status information, the sensing end being connected to a control end, and the control end being connected to the drive mechanism.

[0006] Furthermore, the sensing end includes an encoder pulse counting unit installed at the end of the winding spindle and coaxially connected to the spindle via a flexible coupling for real-time acquisition of rotational speed information; a laser roll diameter recognition unit composed of a laser displacement sensor and a mounting bracket, arranged below the winding roller, for real-time measurement of the outer diameter of the aluminum foil roll and dynamic estimation of the roll diameter; and a tension sensing unit composed of multiple linearly arranged pressure sensors installed on the counterweight roller.

[0007] Furthermore, the control terminal includes a controller, which employs a multi-core industrial control processor and is equipped with a high-speed counting module and an analog input module. A tension-velocity-acceleration decoupled control structure is constructed within the controller to decouple the roll diameter change, inertia fluctuation, and frictional nonlinearity into independent control channels. Based on the decoupling, an adaptive sliding mode control layer is introduced to adjust the control law online according to the tension deviation and suppress disturbances caused by start-stop.

[0008] Furthermore, the controller also has a built-in tension feedforward compensation module, which pre-stores tension-linear velocity mapping tables for aluminum foils of different thicknesses and grades; when the sensing end detects that the aluminum foil is being rolled or its specifications are being changed, it outputs a compensation amount to the drive mechanism in advance to offset the tension fluctuations caused by changes in material parameters.

[0009] Furthermore, the two ends of the counterweight roller are respectively mounted on a movable seat, and guide grooves are respectively opened on both sides of the movable seat in the vertical direction; it also includes columns welded to both sides of the movable seat, one side of the column is inserted into the guide groove and slides with the guide groove, the top of the two columns is connected to a crossbeam, the bottom side of the crossbeam is fixed with a telescopic component, and the other end of the telescopic component is connected to the upper surface of the movable seat; the telescopic component is connected to a control end.

[0010] Furthermore, the telescopic component includes an inner sleeve and an outer sleeve that are nested together, the outer sleeve and the inner sleeve being respectively mounted on the beam and the movable seat; an electric telescopic cylinder is installed on the inner bottom side of the outer sleeve, the output end of the electric telescopic cylinder is connected to a traction rope, and the end of the traction rope is fixed to the inner bottom side of the inner sleeve.

[0011] Furthermore, the lead-out roller group includes a first roller, a second roller, a third roller, a fourth roller, a fifth roller, and a sixth roller arranged sequentially along the aluminum foil traction direction; the first roller is located below the second roller and the third roller; the horizontal and vertical positions of the sixth roller are both located between the fourth roller and the fifth roller; the installation height of the fifth roller is higher than the installation height of the fourth roller, and lower than the installation height of the first roller.

[0012] Furthermore, a movable winding fixture is installed below the frame; the movable winding fixture includes a support platform and a movable frame that moves along the support platform direction above the support platform. A winding spindle is installed on the movable frame, and a winding roller is mounted on the winding spindle. The laser roll diameter recognition unit is installed on the movable frame, and its emitting end faces the winding roller.

[0013] Furthermore, the mobile winding fixture includes a horizontal beam supported by support legs, with protruding support portions on both sides of the horizontal beam along its length; the movable frame includes a connecting beam, with connecting seats connected to both ends of the connecting beam, a horizontal plate installed on the bottom side of the connecting seat, vertical plates installed on both sides of the bottom side of the horizontal plate, and a pair of rollers with a gap installed on the inner side of the vertical plates, the two rollers respectively abutting against the upper and lower sides of the support portion when moving; bearing seats for fixing the winding spindle are respectively installed on the two connecting seats.

[0014] Furthermore, the drive mechanism also includes a limit switch for limiting the extension stroke of the telescopic component. The limit switch is installed on the side of the column facing the movable seat and is electrically connected to the control terminal.

[0015] This invention balances the lateral force on the aluminum foil through dual-sided synchronous adjustment, avoiding deviation and wrinkling caused by unilateral force application. The counterweight roller has its own basic tension application capability, which, together with the dynamic adjustment of the drive mechanism, takes into account both static tension stability and dynamic working condition adaptability, solving the shortcomings of traditional single counterweight schemes that cannot respond to real-time fluctuations. At the same time, the sequential top surface conveyor layout composed of roller, first transition roller and second transition roller is introduced, with sufficient tension buffer stroke reserved. Attached Figure Description

[0016] Figure 1 A schematic diagram of the aluminum foil winding device is provided for this invention; Figure 2 Provided by the present invention Figure 1 Enlarged view of a portion of point A in the middle; Figure 3 Provided by the present invention Figure 1 Enlarged view of a section at point B in the middle; Figure 4 This is a front view of the aluminum foil winding device provided by the present invention; Figure 5 This is a schematic diagram of the telescopic component structure of the present invention; Figure 6 This is a schematic diagram of the movable winding fixture structure of the present invention.

[0017] Explanation of reference numerals in the attached figures: 1-Frame, 2-Mobile winding fixture, 11-Introduction roller, 12-First transition roller, 13-Second transition roller, 14-First roller, 15-Second roller, 16-Third roller, 17-Fourth roller, 18-Fifth roller, 19-Sixth roller, 20-Horizontal beam, 21-Support section, 22-Support leg, 23-Horizontal plate, 24-Vertical plate, 241-Roller, 25-Connecting seat, 26-Bearing seat, 27-Take-up roller, 28-Connecting beam, 281-Laser displacement sensor, 30-Tension adjustment unit one, 3-Tension adjustment unit two, 31-Movable seat, 32-Guide groove, 33-Column, 34-Horizontal beam, 35-Telescopic component, 350-Inner sleeve, 351-Outer sleeve, 36-Counterweight roller, 100-Aluminum foil. Detailed Implementation

[0018] The specific embodiments of the present invention will be described in detail below, but it should be understood that the scope of protection of the present invention is not limited to the specific embodiments.

[0019] like Figures 1 to 4 As shown, to achieve stable aluminum foil introduction and initial tension buffering, this embodiment of the invention provides a feedback adjustment mechanism for constant tension during the aluminum foil winding process. The mechanism includes a frame 1, which serves as the supporting base for the entire machine. One end of the frame is equipped with an inlet roller 11 for smoothly introducing the aluminum foil 100 from the upstream production line into the mechanism; the other end is equipped with an outlet roller group for outputting the adjusted, tension-stable aluminum foil 100 to the winding end. A tension adjustment mechanism is located between the inlet roller 11 and the outlet roller group. This mechanism employs a combination design of double transition rollers and double-sided counterweight adjustment.

[0020] The tension adjustment mechanism includes a first transition roller 12 and a second transition roller 13 spaced apart, arranged sequentially along the traction direction of the aluminum foil 100. The aluminum foil 100 passes sequentially around the top surface of the inlet roller 11, the first transition roller 12, and the second transition roller 13 before entering the outlet roller group. This routing path allows for sufficient tension adjustment stroke, avoiding surface damage caused by sharp bends in the aluminum foil.

[0021] Tension adjustment unit 1 30 and tension adjustment unit 2 3 are symmetrically arranged on both sides of the first transition roller 12. Tension adjustment unit 1 30 and tension adjustment unit 2 3 have the same structure, both including a counterweight roller 36 that rests against the upper surface of the aluminum foil 100 and a drive mechanism that drives it to move up and down. In actual operation, the weight of the counterweight roller 36 can apply basic tension to the aluminum foil. The drive mechanism then dynamically adjusts the height of the counterweight roller according to real-time feedback. By changing the wrap angle and sag of the aluminum foil, the tension can be precisely adjusted, avoiding the defect that a single mechanical counterweight cannot adapt to dynamic working conditions.

[0022] To achieve closed-loop feedback control of tension, this invention includes a sensing end and a control end, with the sensing end connected to the control end and the control end connected to the drive mechanism.

[0023] The sensing end consists of an encoder pulse counting unit, a laser roll diameter recognition unit, and a tension sensing unit.

[0024] The encoder pulse counting unit is installed at the end of the winding spindle 29 and is coaxially connected to the spindle via a flexible coupling. It acquires the spindle's rotational speed information in real time to calculate the current winding linear speed and provides speed reference data for tension decoupling control.

[0025] The laser roll diameter recognition unit consists of a laser displacement sensor 281 and a matching mounting bracket, positioned below the take-up roller 27. It measures the outer diameter of the aluminum foil roll in real time and dynamically estimates the real-time roll diameter. This design can directly capture the roll diameter change trend, avoiding the errors caused by relying solely on empirical formulas to estimate the roll diameter in traditional solutions, and providing accurate input parameters for subsequent tension compensation.

[0026] The tension sensing unit consists of multiple linearly arranged pressure sensors mounted on the counterweight roller 36, which directly collect the current actual tension value of the aluminum foil as a reference signal for tension deviation calculation.

[0027] All signals collected by the sensing end are transmitted to the control end, which is connected to the drive mechanism to achieve closed-loop regulation. The specific control logic is as follows: The core of the control unit adopts a multi-core industrial control processor, and is equipped with a high-speed counting module and an analog input module, which is compatible with the high-speed pulse signal of the encoder and the analog signal of the pressure sensor.

[0028] The processor first constructs a tension-velocity-acceleration decoupled control structure, which separates the three types of coupled disturbances—roll diameter change, inertia fluctuation, and friction nonlinearity—into independent control channels, avoiding overshoot or lag caused by multivariable coupling. Based on the decoupling, an adaptive sliding mode control layer is introduced, which adjusts the control law online according to the real-time collected tension deviation. This can quickly suppress speed impacts during start-up and shutdown, as well as disturbances caused by variant aluminum foil, and prevent excessive tension changes.

[0029] The processor also has a built-in tension feedforward compensation module, which pre-stores tension-linear velocity mapping tables for aluminum foils of different thicknesses and grades. When the sensing end detects that the aluminum foil is being rolled or its specifications are being changed, there is no need to wait for the tension to deviate before adjusting. Instead, the compensation amount is output to the drive mechanism in advance to offset the tension fluctuations caused by changes in material parameters from the source, reducing the adjustment response delay from more than 500ms to less than 50ms.

[0030] To achieve precise lifting and lowering of the counterweight roller 36, both ends of the counterweight roller 36 are fixedly mounted on two movable seats 31. Guide grooves 32 are vertically formed on both sides of the movable seats 31. Columns 33 are welded onto the frame 1. One side of each column 33 is inserted into the guide groove 32 and slides smoothly with it, ensuring no swaying during the lifting and lowering of the counterweight roller. The tops of the two columns 33 are connected to a crossbeam 34. A telescopic component 35 is fixed to the bottom side of the crossbeam 34. The other end of the telescopic component 35 is fixedly connected to the upper surface of the movable seat 31. The adjustment signal output from the control terminal directly drives the telescopic component 35 to extend or retract, causing the movable seat 31 to slide up and down along the guide groove 32, thus achieving height adjustment of the counterweight roller 36. Figure 5 The telescopic component 35 adopts an interlocking structure of an inner sleeve 350 and an outer sleeve 351. The outer sleeve 351 is fixed to the crossbeam 34, and the inner sleeve 350 is fixed to the movable seat 31. An electric telescopic cylinder 352 is installed on the inner bottom side. The output end of the electric telescopic cylinder 352 is connected to the traction rope 353. The end of the traction rope 353 is fixed to the inner bottom side of the inner sleeve 350. The interlocking structure can further improve the rigidity of the lifting process and avoid swaying under high-frequency adjustment.

[0031] To further stabilize the output posture of the aluminum foil, the lead-out roller group adopts a six-roll detour arrangement: the first roller 14, the second roller 15, the third roller 16, the fourth roller 17, the fifth roller 18, and the sixth roller 19 are arranged sequentially along the aluminum foil traction direction. The first roller 14 is located below the second roller 15 and the third roller 16. The sixth roller 19 is positioned both horizontally and vertically between the fourth roller 17 and the fifth roller 18. The installation height of the fifth roller 18 is higher than that of the fourth roller 17 but lower than that of the first roller 14. This detour path can flatten the aluminum foil and avoid interlayer wrinkles during winding.

[0032] To facilitate the control of the arrangement and disassembly / installation of the winding drum at the winding end, this application provides a movable winding fixture 2 at the winding end, such as... Figure 3 and Figure 6The mobile winding fixture 2 includes a support platform and a movable frame that moves along the support platform direction above it. A winding spindle 29 is mounted on the movable frame, and a winding roller 27 is mounted on the winding spindle 29. A laser roll diameter recognition unit is mounted on the movable frame, with its emitting end facing the winding roller 27. The support platform includes a horizontal beam 20 supported by support legs 22. Protruding support parts 21 are provided on both sides of the horizontal beam 20 along its length direction, and the support parts 21 serve as moving guide rails. The movable part uses a connecting beam 28 as the main load-bearing body, and the two ends are connected to connecting seats 25. A horizontal plate 23 is installed on the bottom side of the connecting seat 25, and vertical plates 24 are fixed on both sides of the bottom side of the horizontal plate 23. A pair of rollers 241 with gaps are installed on the inner side of the vertical plate 24. When the rollers 241 move, they abut against the upper and lower sides of the support part 21 respectively, so as to realize the smooth movement of the movable frame along the mobile winding fixture and adapt to the winding position adjustment of aluminum foil of different widths. Bearing seats 26 are installed on two connecting seats 25 to fix the winding spindle 29, which carries the winding roller 27. The laser winding diameter recognition unit is synchronously installed on the movable frame, with the emitting end of the laser winding diameter recognition unit 28 facing the winding roller 27 to ensure that the relative position of the winding diameter measurement is constant. A locking mechanism is provided on at least one connecting seat 25, the horizontal plate 23, or the vertical plate 24. When the winding position is adjusted to the correct position, the movable frame can be locked to prevent displacement during the winding process that could cause sudden tension changes.

[0033] The drive mechanism also includes a limit switch for limiting the extension stroke of the telescopic member 35. The limit switch is installed on the side of the column 33 facing the movable seat 31 and is electrically connected to the control terminal.

[0034] The above-disclosed embodiments are merely a few specific examples of the present invention. However, the embodiments of the present invention are not limited thereto, and any variations that can be conceived by those skilled in the art should fall within the protection scope of the present invention.

Claims

1. A feedback adjustment mechanism for maintaining constant tension during the aluminum foil winding process, characterized in that, Includes a frame (1), one end of which is provided with an introductory roller (11) for introducing aluminum foil (100), and the other end of which is provided with an outtroductory roller group. A tension adjustment mechanism is provided between the outtroductory roller group and the introductory roller (11). The tension adjustment mechanism includes a first transition roller (12) and a second transition roller (13) with a gap. The inlet roller (11), the first transition roller (12) and the second transition roller (13) are arranged sequentially along the traction direction of the aluminum foil (100). The aluminum foil (100) passes through the top surface of the inlet roller (11), the first transition roller (12) and the second transition roller (13). Tension adjustment unit one (30) and tension adjustment unit two (3) are respectively provided on both sides of the first transition roller (12). The tension adjustment unit one (30) and tension adjustment unit two (3) have the same structure, both including a counterweight roller (36) that rests against the upper surface of the aluminum foil (100) and a drive mechanism that drives it to move up and down. It also includes a sensing end for real-time acquisition of winding status information, the sensing end being connected to a control end, and the control end being connected to a drive mechanism.

2. The feedback adjustment mechanism for constant tension during aluminum foil winding as described in claim 1, characterized in that, The sensing end includes an encoder pulse counting unit, a laser roll diameter recognition unit, and a tension sensing unit; The encoder pulse counting unit is installed at the end of the winding spindle (29) and is coaxially connected to the spindle via a flexible coupling, and is used to obtain speed information in real time; The laser roll diameter recognition unit consists of a laser displacement sensor (281) and a mounting bracket, and is arranged below the winding roller (27) to measure the outer diameter of the aluminum foil roll in real time and dynamically estimate the roll diameter. The tension sensing unit consists of multiple pressure sensors arranged linearly on the counterweight roller (36).

3. The feedback adjustment mechanism for constant tension during aluminum foil winding as described in claim 2, characterized in that, The control terminal includes a controller, which uses a multi-core industrial control processor and is equipped with a high-speed counting module and an analog input module. A tension-velocity-acceleration decoupled control structure is constructed within the controller to decouple the roll diameter change, inertia fluctuation, and frictional nonlinearity into independent control channels. An adaptive sliding mode control layer is introduced based on the decoupling, which adjusts the control law online according to the tension deviation to suppress disturbances caused by start-stop.

4. The feedback adjustment mechanism for constant tension during aluminum foil winding as described in claim 3, characterized in that, The controller also has a built-in tension feedforward compensation module, which pre-stores tension-linear velocity mapping tables for aluminum foils of different thicknesses and grades.

5. The feedback adjustment mechanism for constant tension during aluminum foil winding as described in claim 2, characterized in that, The counterweight roller (36) is mounted on a movable seat (31) at both ends. Guide grooves (32) are opened on both sides of the movable seat (31) in the vertical direction. It also includes columns (33) welded on both sides of the movable seat (31). One side of the column (33) is inserted into the guide groove (32) and slides with the guide groove (32). The top of the two columns (33) is connected to a crossbeam (34). A drive mechanism is fixed on the bottom side of the crossbeam (34). The drive mechanism is a telescopic component (35). The other end of the telescopic component (35) is connected to the upper surface of the movable seat (31). The telescopic component (35) is connected to the control end.

6. The feedback adjustment mechanism for constant tension during aluminum foil winding as described in claim 5, characterized in that, The telescopic component (35) includes an inner sleeve (350) and an outer sleeve (351) that are nested together. The outer sleeve (351) and the inner sleeve (350) are respectively installed on the beam (34) and the movable seat (31). An electric telescopic cylinder (352) is installed on the inner bottom side of the outer sleeve (351). The output end of the electric telescopic cylinder (352) is connected to a traction rope (353), and the end of the traction rope (353) is fixed to the inner bottom side of the inner sleeve (350).

7. The feedback adjustment mechanism for constant tension during aluminum foil winding as described in claim 2, characterized in that, The lead-out roller group includes a first roller (14), a second roller (15), a third roller (16), a fourth roller (17), a fifth roller (18), and a sixth roller (19) arranged sequentially along the traction direction of the aluminum foil (100). The first roller (14) is located below the second roller (15) and the third roller (16); the sixth roller (19) is located both horizontally and vertically between the fourth roller (17) and the fifth roller (18); The fifth roller (18) is installed at a height higher than the fourth roller (17) but lower than the first roller (14).

8. The feedback adjustment mechanism for constant tension during aluminum foil winding as described in claim 7, characterized in that, A movable winding fixture (2) is installed below the frame (1); The mobile winding fixture (2) includes a support platform and a movable frame that moves along the support platform direction above the support platform. A winding spindle (29) is installed on the movable frame, and a winding roller (27) is mounted on the winding spindle (29). The laser roll diameter recognition unit is installed on the movable frame, and its emitting end faces the winding roller (27).

9. The feedback adjustment mechanism for constant tension during aluminum foil winding as described in claim 8, characterized in that, The support platform includes a horizontal beam (20) supported by a support leg (22), and protruding support parts (21) are provided on both sides of the horizontal beam (20) along its length direction. The movable frame includes a connecting beam (28), with connecting seats (25) connected to both ends of the connecting beam (28). A horizontal plate (23) is installed on the bottom side of the connecting seat (25), and vertical plates (24) are installed on both sides of the bottom side of the horizontal plate (23). A pair of rollers (241) with gaps are installed on the inner side of the vertical plate (24). When the two rollers (241) move, they abut against the upper and lower sides of the support part (21) respectively. Each of the two connecting seats (25) is equipped with a bearing seat (26) for fixing the winding spindle (29).

10. The feedback adjustment mechanism for constant tension during aluminum foil winding as described in claim 5, characterized in that, The drive mechanism also includes a limit switch for limiting the extension stroke of the telescopic member (35), the limit switch being installed on the side of the column (33) facing the movable seat (31) and electrically connected to the control terminal.

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