A temperature-pressing synergic control system and method for a PI film laminating roller

Abstract

The application discloses a temperature-pressure synergic control system and method of a PI film laminating roller pressing type rubber roller, and belongs to the technical field of industrial production process control.The application realizes millisecond-level fast response and high-precision steady-state control of the roller surface temperature of the rubber roller by integrating a distributed temperature sensor network and an intelligent PID / self-adaptive control algorithm.Meanwhile, the application introduces a hydraulic pressure self-balancing mechanism to actively compensate for the deflection deformation of the roller, so that the uniformity of the axial pressure distribution is improved.Further, by means of three-layer strategies of "time scale separation, control law feedforward decoupling and physical structure isolation", the temperature and pressure control systems which have traditionally interfered with each other are converted into an organic whole working in cooperation, so that the target of prolonging the service life of the rubber roller, reducing energy consumption and improving the product film laminating and attaching yield is finally achieved.

Description

Technical Field

[0001] This invention belongs to the field of industrial production process control technology, specifically relating to a temperature-pressure coordinated control system and method for PI film coating rollers, which is particularly suitable for high-precision and high-efficiency bonding of PI films on the surface of flat products such as power battery liquid cooling plates and flexible circuit boards. Background Technology

[0002] Polyimide (PI) film, also known as polyimide film, is a type of high-performance polymer film with imide rings as repeating units. It possesses exceptionally good overall performance and is widely recognized as one of the best-performing polymer film materials. Its key characteristics in the industrial application of new energy vehicle battery packs are as follows: 1. Excellent high / low temperature resistance: The long-term operating temperature range is -269℃ to +400℃, providing basic material support for the working environment in this patent where the rubber roller needs to be pressurized at a high temperature of 120℃ for a long time. At this temperature, the PI film will not undergo thermal deformation or decomposition, ensuring the stability functions such as safety and protection.

[0003] 2. Excellent mechanical and electrical insulation properties: It has high tensile strength and high modulus, and is tear-resistant and bend-resistant; at the same time, it has high insulation resistance and low dielectric constant, making it a key insulating encapsulation material in fields such as power batteries (e.g., cooling plates for new energy vehicle batteries) and flexible printed circuit boards (FPC).

[0004] 3. Stable chemical inertness: Except under extreme conditions such as concentrated alkalis and high-temperature steam, PI films are resistant to almost all organic solvents and acids, are not easily corroded, and have extremely stable chemical properties, ensuring their long-term reliability under complex working conditions. Due to these characteristics, PI films are widely used in fields such as aerospace cable insulation, semiconductor microelectronics packaging, flexible circuit boards, and power battery pack packaging.

[0005] This is particularly relevant to the surface bonding operation of the power battery liquid cooling plate blank. In the lamination process of PI film and product flat panels, the roller press is a key piece of equipment. It applies specific temperature and pressure to the PI film using heated rollers, ensuring a tight bond between the film and the product surface, achieving the required bubble-free and highly flat finish. The PI film (polyimide film) roller press is a crucial process equipment in the electronics and new energy manufacturing fields, used to bond PI film to the surface of product flat panels (such as power battery cooling plates, flexible circuit boards, etc.) under heated and pressurized conditions. As the core actuator of the roller press, the performance of the roller directly determines the bonding quality and production efficiency.

[0006] In existing technologies, the rubber rollers of commonly used PI film roller presses mainly employ two heating methods: one is external radiation or hot air heating, where heat is transferred from the surface of the roller inwards; the other is circulating heating inside the roller through heat conduction (such as electric heating through a metal tube or the introduction of heat transfer oil). However, existing technologies still have the following significant shortcomings under long-term high-temperature continuous operating conditions: 1. Poor heating uniformity and easy aging and failure of the adhesive layer: Both external heating and heat transfer oil methods have thermal hysteresis and temperature gradients, resulting in local overheating and cracking of the adhesive layer. The key issue is that the existing solutions lack real-time closed-loop control and precise management of the roller surface temperature, making it impossible to maintain the optimal process temperature stably during dynamic production (such as start-up, shutdown, speed changes, and environmental disturbances), further exacerbating uneven thermal stress and lifespan reduction.

[0007] II. Insufficient pressure adaptability and unstable bonding quality: Existing rubber rollers have a vague definition of the working pressure range and lack the ability to adaptively adjust the axial pressure distribution. In actual rolling, due to the slight warping of the product flat plate itself, roller deflection deformation, and installation parallelism errors, the pressure distribution along the roller surface is severely uneven, resulting in high pressure in the middle and low pressure at both ends. This directly causes quality problems such as incomplete venting of the PI film, poor edge bonding, or damage in the middle.

[0008] 3. Slow thermal response and high energy consumption: Traditional heating methods have a large heat capacity, slow heating, and cannot make intelligent power adjustments based on real-time temperature feedback of the adhesive layer, resulting in a large amount of ineffective energy consumption and process waiting time.

[0009] Therefore, optimizing the thermal response and structural design of the rubber roller to fundamentally improve the uniformity of heating and heat conduction efficiency, and enhance its material performance under specific high temperature and high pressure conditions, is the key to extending its service life, ensuring bonding quality, and reducing overall costs. Summary of the Invention

[0010] To address the aforementioned shortcomings in the prior art, the present invention provides a temperature-pressure coordinated control system and method for a PI film coating roller, which solves the problems of existing methods lacking real-time and precise closed-loop control of roller surface temperature, being unable to adaptively adjust the axial pressure distribution of the roller structure, and ignoring the coupling effect between temperature control and pressure equalization during the PI film coating process.

[0011] To achieve the above-mentioned objectives, the technical solution adopted by the present invention is as follows: a temperature-pressure coordinated control system for a PI film coating roller, comprising a roller, a heating and temperature self-compensation control module, a pressure self-balancing module, and an intelligent control module. The roller has a built-in spiral copper tube, and is divided into three independent electromagnetic heating zones. A distributed temperature sensor network is also arranged to collect the temperature at multiple measurement points. In addition, the built-in axial pressure self-balancing adjustment chamber includes several independent sealed chambers, and each sealed chamber is connected to the outside through an independent electromagnetic proportional valve. Each of the sealed chambers is equipped with a corresponding pressure sensor. The heating and temperature self-compensation control module, based on the set electromagnetic heating zone and the collected temperature, uses an adaptive PID control algorithm based on error integral weighting and dynamic attenuation factor to perform heating and temperature self-compensation control during the roller coating process. The pressure self-balancing module, based on the axial pressure self-balancing adjustment cavity, uses a distributed pressure closed-loop control algorithm of weight allocation and balance correction to perform pressure self-balancing control during the roller coating process. The intelligent control module is used to perform temperature-pressure coordinated control during the roller coating process based on the bidirectional coupling relationship between temperature and pressure, through time scale separation, control law decoupling, and physical structure isolation, in the process of heating, temperature self-compensation, and pressure self-balancing control.

[0012] On the other hand, the present invention also provides a temperature-pressure coordinated control method for a PI film coating roller, comprising the following steps: S100, Preheating and Initialization: The three electromagnetic heating zones are activated, the temperatures at the measuring points are collected, and the independent power required for each electromagnetic heating zone to reach the target temperature is calculated; in addition, each sealed chamber is pre-pressurized to 50% of the target pressure. S200, Contact and Pre-compression: Read the measured pressure values ​​of each sealed chamber, start the pressure self-balancing module to perform distributed pressure closed-loop control, adjust the opening of the electromagnetic proportional valve of each sealed chamber, and combine with the mechanical auxiliary pressure equalization structure to make the average pressure of each sealed chamber approach the target pressure. The heating and temperature self-compensation control module is kept running independently to ensure that each electromagnetic heating zone reaches the target temperature and the real-time temperature of each sealed chamber is fed back to the distributed pressure closed-loop control process. S300, steady-state roll pressing: The heating and temperature self-compensation control module and the pressure self-balancing module are kept running at a set cycle, and temperature-pressure coordinated control is performed when there is abnormal disturbance, so that the average temperature of the roller is within the target temperature and the axial pressure difference is within the preset range. Additionally, when the temperature at all measuring points reaches the target temperature and remains at it for a preset time, and the pressure fluctuation at all measuring points is less than a preset fluctuation threshold, the system enters a low-power mode. S400, Shutdown and Cooling: After the rolling process is completed, the heating power is turned off, the external auxiliary equipment is forced to cool the roller, and the pressure is released to zero after the temperature drops to the preset temperature.

[0013] The beneficial effects of this invention are as follows: (1) Fundamental improvement in roller surface temperature control accuracy and response speed This invention solves the problems of large thermal hysteresis and lack of real-time precise control in traditional heating methods by using a closed-loop system consisting of "three-segment independent electromagnetic heating + distributed PT1000 sensor network + adaptive PID algorithm".

[0014] This invention enables the roller surface temperature to remain stable within a target range of 120℃ ± 1.5℃, significantly shortens the heating time from room temperature to operating temperature, and provides millisecond-level rapid response to speed changes and environmental disturbances. This fundamentally avoids problems such as localized overheating, cracking, and thermal aging of the rubber layer caused by large temperature fluctuations, significantly extending the service life of the rubber roller.

[0015] (2) Self-balancing control of axial pressure distribution uniformity This invention utilizes a "multi-chamber independent hydraulic support structure + distributed pressure closed-loop control algorithm" to actively compensate for uneven pressure caused by roller deflection, installation parallelism error and product warping, thereby overcoming the shortcomings of the prior art where the pressure distribution is general and cannot be adaptively adjusted.

[0016] This invention can control the axial pressure unevenness rate to within 5% (existing technologies typically exceed 15-20%), effectively solving the common problem of "high pressure in the middle and low pressure at both ends" in traditional roller pressing, thereby completely eliminating bonding quality defects such as incomplete PI film degassing, edge delamination, or middle pressure damage caused by uneven pressure, and significantly improving product yield.

[0017] (3) Effective decoupling and coordinated control of temperature-pressure coupling effect were achieved. This invention transforms traditionally interfering temperature and pressure control systems into a collaborative organic whole through a three-layer strategy of "time scale separation, control law feedforward decoupling, and physical structure isolation".

[0018] This invention successfully suppresses the positive feedback oscillation where "temperature unevenness induces pressure distortion, and pressure distortion further aggravates temperature fluctuations" by explicitly incorporating temperature deviation into the pressure weighting coefficient calculation and introducing a pressure feedforward term into the temperature control algorithm. Verification shows that under typical temperature deviations (≤2℃), the resulting pressure range increment can be controlled within 0.03MPa; when the pressure changes abruptly by 30%, the temperature recovery time does not exceed 2 seconds, ensuring the stability of process parameters under complex operating conditions.

[0019] In summary, this invention, through its innovative integrated design of heat, force, and control, simultaneously achieves the goals of extending the life of the adhesive roller, reducing energy consumption, and improving production yield while ensuring high-precision bonding quality of the PI film. Attached Figure Description

[0020] Figure 1This is a diagram of the roller structure provided by the present invention.

[0021] Figure 2 The flowchart shows the temperature-pressure coordinated control method of the PI film coating roller press roller provided by the present invention.

[0022] Figure 3 The real-time temperature trend graph provided for this invention.

[0023] Figure 4 The pressure trend diagram and weight change diagram provided for this invention.

[0024] Figure 5 This is a schematic diagram of the integrated temperature and pressure monitoring interface provided by the present invention.

[0025] The components include: 1. Central iron core; 2. Central heating tube; 3. Thermally conductive and temperature-equalizing layer; 4. Temperature sensor probe; 5. Axial pressure self-balancing adjustment cavity; 6. Thermal insulation buffer layer; 7. Outer coating. Detailed Implementation

[0026] The specific embodiments of the present invention are described below to enable those skilled in the art to understand the present invention. However, it should be understood that the present invention is not limited to the scope of the specific embodiments. For those skilled in the art, various changes are obvious as long as they are within the spirit and scope of the present invention as defined and determined by the appended claims. All inventions utilizing the concept of the present invention are protected.

[0027] Example 1:

[0028] This invention provides a temperature-pressure coordinated control system for a PI film coating roller. By integrating a distributed temperature sensor network and an intelligent PID / adaptive control algorithm, it achieves millisecond-level rapid response and high-precision steady-state control of the roller surface temperature (taking a target temperature of 120℃±2℃ as an example). At the same time, by introducing a hydraulic pressure self-balancing mechanism, it actively compensates for roller deflection deformation, thereby improving the uniformity of axial pressure distribution. Ultimately, this achieves the goals of extending the roller's lifespan, reducing energy consumption, and improving the product coating and bonding yield.

[0029] The present invention provides a temperature-pressure coordinated control system for a PI film coating roller, comprising a roller, a heating and temperature self-compensation control module, a pressure self-balancing module, and an intelligent control module; The roller has a built-in spiral copper tube, and is divided into three independent electromagnetic heating zones. A distributed temperature sensor network is also arranged to collect the temperature at multiple measurement points. In addition, the built-in axial pressure self-balancing adjustment chamber includes several independent sealed chambers, and each sealed chamber is connected to the outside through an independent electromagnetic proportional valve. Each of the sealed chambers is equipped with a corresponding pressure sensor. The heating and temperature self-compensation control module, based on the set electromagnetic heating zone and the collected temperature, adopts an adaptive PID control algorithm based on error integral weighting and dynamic attenuation factor to perform heating and temperature self-compensation control during the roller coating process. The pressure self-balancing module, based on the axial pressure self-balancing adjustment chamber, adopts a distributed pressure closed-loop control algorithm with weight allocation and balance correction to perform pressure self-balancing control during the roller coating process. The intelligent control module is used to perform temperature-pressure coordinated control during the roller coating process based on the bidirectional coupling relationship between temperature and pressure, through time scale separation, control law decoupling, and physical structure isolation, in the process of heating, temperature self-compensation, and pressure self-balancing control.

[0030] In embodiments of the present invention, such as Figure 1 As shown, the main body of the roller includes, from the inside out, a central iron core 1, a central heating tube 2, a heat-conducting and temperature-equalizing layer 3, a heat-insulating buffer layer 6, and an outer rubber coating 7; wherein, the outer rubber coating 7 is made of silica-based vulcanized rubber with a Shore A hardness of 55-60A, a tensile strength of 5-5.5MPa, and a resilience of 55%-60%, in order to match the specific working conditions of PI film rolling (pressure 0.45MPa, temperature 120℃).

[0031] In this embodiment of the invention, in order to achieve heating and temperature self-compensation control, a segmented electromagnetic heating method with built-in spiral copper tubes is adopted. The outer circumference of the central heating tube 2 is divided into three independent electromagnetic heating zones along the axial direction: left, middle, and right. Each electromagnetic heating zone corresponds to a set of independently wound spiral copper tube electromagnetic induction coils. A 4mm electromagnetic isolation gap is reserved between the spiral copper tube electromagnetic induction coils of each zone, and a magnetic shielding layer is set in between to prevent electromagnetic interference between adjacent zones.

[0032] When electromagnetic heating is performed using the spiral copper tube electromagnetic induction coils described above, each set of spiral copper tube coils is connected to an independently controlled high-frequency alternating current (the operating frequency can be set from 10 to 30 kHz), generating an alternating magnetic field. This causes eddy currents and hysteresis losses to form on the surface of each section of the central heating tube 2 (magnetic material) that runs through the central alloy steel core shaft, resulting in self-heating. Heat is efficiently transferred along a radial gradient path: "central heating tube → central iron core → thermally conductive homogenizing layer → outer coating". Simultaneously, the heating power of each section can be independently adjusted, thereby achieving precise control of the axial temperature distribution.

[0033] The advantages of segmented electromagnetic heating in this invention include: thermal efficiency of up to 92%~96%, significantly higher than that of traditional resistance heating tubes; fast heating speed, with a shorter time to rise from room temperature to 120°C (at full power); low thermal inertia, enabling millisecond-level zoned power adjustment in conjunction with real-time temperature feedback; non-contact heating, resulting in a long lifespan for the heating element and eliminating the risk of localized overheating and burnout; and independent zoned control, dynamically adjusting the heating power of the left, middle, and right zones based on differences in axial temperature distribution, actively compensating for the axial temperature difference caused by faster heat dissipation at both ends and slower heat dissipation in the middle.

[0034] In this embodiment of the invention, for the distributed temperature sensor network arranged on the roller, in Figure 1 In the heat-conducting and temperature-equalizing layer 3, five high-precision PT1000 thin-film platinum resistance temperature sensor probes 4, numbered S1~S5, are embedded equidistantly along the axial direction, corresponding to temperature monitoring of the left zone (S1), the left-middle boundary zone (S2), the middle zone (S3), the right-middle boundary zone (S4), and the right zone (S5), respectively. Simultaneously, three sets of redundant sensors are arranged circumferentially at 120° intervals on the inner surface of the outer coating 7 (or close to the outer circumferential surface of the heat-conducting and temperature-equalizing layer 3). All sensors are connected to an external intelligent control module via a high-temperature resistant flexible circuit to collect axial multi-point temperature and circumferential temperature distribution in real time. The sampling frequency is set to 50Hz (20ms period) to ensure rapid capture of temperature changes.

[0035] In this embodiment of the invention, based on the above roller structure, the heating and temperature self-compensation control module is equipped with an adaptive PID control algorithm based on error integral weighting and dynamic attenuation factor. It does not require a fuzzy rule base, is purely analytical, and is suitable for embedded implementation. It adopts a common main loop (overall temperature PID) + three independent secondary loops (zone temperature PI control + zone feedforward compensation) to achieve heating and temperature self-compensation.

[0036] In the temperature control process of the common main circuit, a dynamic attenuation factor is introduced to adaptively update the gain; in the temperature control process of the three independent secondary circuits, a fuzzy feedforward compensator is introduced for each independent electromagnetic heating zone (left, middle, and right), and the feedforward compensation coefficient is calibrated according to the characteristics of the PI film material to determine the final temperature control quantity.

[0037] In this embodiment of the invention, to achieve pressure self-balancing control, a multi-chamber independent hydraulic support structure is provided on the roller. For example... Figure 1As shown, specifically, between the central iron core 1 and the outer rubber coating 7, in addition to the heat-conducting and temperature-equalizing layer 3, an additional axial pressure self-balancing chamber 5 is provided. This chamber is sealed with a high-elasticity, heat-resistant polyurethane membrane (1.5mm thick) and filled with high-temperature resistant silicone oil (operating temperature range -20℃~200℃). The axial pressure self-balancing chamber 5 is divided into 8 independent sealed chambers, each connected to the outside (compressed air source or hydraulic station) via an independent micro electromagnetic proportional valve. A thin-film pressure sensor is attached to the inner wall of the outer rubber coating layer corresponding to each chamber to measure the actual rolling pressure of that section in real time. (Unit: bar)

[0038] During the rolling process, the contact pressure distribution between the rubber roller and the product plate is mainly affected by three factors: the roller's own weight and bending deformation (deflection), the flatness error of the product plate, and the installation parallelism error of the bearing seats at both ends of the roller. These factors can cause the pressure distribution along the roller axis to present a typical parabolic shape with "high in the middle and low at both ends".

[0039] The axial pressure self-balancing regulating chamber proposed in this embodiment of the invention is essentially a hydraulic support system with independent pressure control along the axial direction, which can solve the above problems. Its working process is as follows: when the measured pressure value of a certain chamber deviates from the target pressure (set to 3.5 bar, corresponding to 0.45 MPa), the intelligent control module controls the injection or discharge of silicone oil in the sealed chamber through a micro electromagnetic proportional valve. When the pressure value is detected to be too high, the pressure relief valve is opened to release some silicone oil, reducing the force of the chamber on the coating layer, thereby reducing the contact pressure of that section; conversely, when the pressure is detected to be too low, the pressure boosting valve is opened to inject silicone oil, thereby increasing the contact pressure of that section.

[0040] In this embodiment of the invention, to further enhance the passive adaptability of the roller pressing system to large-scale geometric deviations such as frame installation errors and roller deflection, an auxiliary pressure equalization structure is also provided in the rollers. This structure includes a spherical adjusting bearing and an axial floating spring seat located between the roller's central spindle and the bearing seats at both ends. The maximum stroke of the floating spring seat is limited (±1.5mm) by mechanical limit screws at both ends of the roller. When the pressure in a certain chamber abnormally increases due to a malfunction or extreme operating conditions in the active pressure equalization system, the limit screws can prevent excessive axial or radial displacement of the roller, avoiding equipment damage and providing a physical safety boundary for the control system.

[0041] The aforementioned auxiliary pressure equalization structure allows the roller to automatically deflect within a ±1° range and also allows for slight axial floating to compensate for frame parallelism errors and length changes caused by thermal expansion. However, this axial floating spring seat can interfere with the control accuracy of the active hydraulic pressure self-balancing system, thus affecting the stability of the axial pressure distribution. To address this, this invention employs a layered coordinated design to achieve decoupling and synergy between mechanical passive compensation and active hydraulic regulation, rather than mutual interference.

[0042] Specifically, the main function of the auxiliary pressure equalization structure is to eliminate large-scale, low-frequency, static geometric deviations (such as non-parallel frame installation, bending deformation of rollers after long-term use, and axial length changes caused by thermal expansion). Its response speed is slow (above the second level) and the adjustment range is small (±1° deflection, ±1mm axial float). It is mainly used to prevent hard interference and overload protection, and to avoid rigid jamming.

[0043] The main function of the active pressure equalization system (multi-chamber independent hydraulic support structure) is to compensate for dynamic, high-frequency, and local pressure fluctuations in real time (such as uneven product thickness, instantaneous deflection changes during the rolling process, and local expansion differences caused by temperature field). It has a fast response speed, high adjustment resolution, and can achieve fine pressure adjustment of 8 independent sealed chambers in the axial direction.

[0044] In this embodiment, the auxiliary pressure equalization structure can alleviate the adjustment burden on the active hydraulic system caused by the extreme difference in axial pressure (the difference between the maximum and minimum values) due to frame parallelism errors. After overcoming the excessive adjustment burden, the active hydraulic system further reduces the remaining unevenness. The two form a series synergistic relationship of "coarse adjustment + fine adjustment," and through hierarchical functional division, control strategy decoupling, and physical limit protection, they organically complement the active hydraulic system to improve the overall system's adaptability and robustness to complex working conditions.

[0045] In this embodiment of the invention, during the operation of the rubber roller, the temperature control and pressure equalization subsystems do not operate independently, but are coupled to each other through the physical state of the controlled object (roller and rubber layer). The temperature control and pressure equalization do not interfere with each other, but have a bidirectional coupling relationship.

[0046] The effect of temperature on pressure is as follows: The elasticity and hardness of the outer coating 7 decrease with increasing temperature. When the roller surface temperature rises from room temperature to 120°C, the Shore A hardness may decrease by 3-5 degrees. This means that under the same hydraulic chamber pressure, the actual contact pressure in the high-temperature zone will be lower than that in the low-temperature zone, i.e., uneven temperature will induce uneven pressure.

[0047] Thermal expansion of the roller's metal components can cause minute changes (at the micrometer level) in the roller's diameter, which in turn alters the interference fit with the product plate and affects the overall contact pressure level.

[0048] The effect of pressure on temperature is as follows: Pressure affects heat transfer efficiency by altering the contact thermal resistance between the adhesive layer and the product plate. Increased pressure increases the microscopic contact area, decreases thermal resistance, and accelerates heat dissipation in that area; conversely, decreased pressure increases thermal resistance, causing heat to accumulate. Therefore, uneven pressure distribution can lead to localized "secondary temperature distortion."

[0049] The high-temperature resistant silicone oil in the hydraulic chamber (pressure equalization oil chamber) will generate a small amount of viscous heat loss when under pressure. Although the amount is very small (usually <0.1℃), it still needs to be considered in high-precision control.

[0050] In summary, if the above-mentioned coupling effects are not specifically addressed, the temperature control and pressure equalization system may form a "positive feedback oscillation," where temperature unevenness leads to pressure distortion, and pressure distortion further exacerbates temperature unevenness, ultimately making both systems unstable.

[0051] Therefore, this invention sets up an intelligent control module, which uses time-scale separation control, control law decoupling (feedforward compensation), and physical structure decoupling (thermal insulation buffer layer) to achieve temperature-pressure coordinated control.

[0052] Among them, the time scale separation control is as follows: The temperature system adopts a slow-speed-dominant approach: it has a large temperature inertia (thermal time constant of about 10~30 seconds), a control cycle of 50ms, but the rate of change of power regulation amplitude is limited to ≤10% / s.

[0053] The pressure system adopts rapid following: the pressure response is fast (hydraulic time constant is about 0.2~0.5 seconds), the control cycle is also 50ms, but rapid adjustment is allowed (valve opening change rate can reach 100% / s).

[0054] Coordination logic: The pressure system completes pressure equalization adjustment under the current temperature field within 50ms; the temperature system slowly adjusts the power according to the average temperature within a few seconds, without substantially interfering with the rapid adjustment of the pressure system.

[0055] In control law decoupling, during the pressure self-balancing control process, real-time temperature deviation is incorporated into the load balancing weight calculation of each sealed chamber, and the temperature deviation is used to directly calculate the first... The target pressure weight of each sealed chamber means that when a certain area is detected to be too low, the pressure self-balancing module automatically reduces the target pressure in that area to compensate for the artificially high pressure caused by the hardening of the adhesive layer, thereby avoiding "temperature-pressure positive feedback". Conversely, in the temperature control algorithm, the average value of the measured pressure distribution is used as a feedforward term to introduce PID calculation. When the overall pressure increases, the target temperature is slightly increased to compensate for the enhanced heat dissipation caused by the decrease in contact thermal resistance, which can be implemented in the control system.

[0056] Physical structural isolation refers to isolation through the heat insulation buffer layer 6, which uses a low thermal conductivity material (≤0.2W / (m·K)) to effectively block the direct conduction of heat from the heat-conducting uniform temperature layer to the hydraulic chamber, ensuring that the working temperature of the high-temperature resistant silicone oil is always below 120℃, and avoiding pressure control instability caused by drastic changes in silicone oil viscosity.

[0057] This invention transforms the physical coupling between temperature control and pressure balancing into a predictable and compensable engineering problem through the temperature-pressure coordinated control of the above-mentioned intelligent control modules.

[0058] Example 2:

[0059] The present invention provides a further limitation based on Example 1, and provides a temperature-pressure coordinated control method for a PI film coating roller, which is applied to the temperature-pressure coordinated control system in Example 1. Other contents not mentioned refer to Example 1 or the description of the prior art.

[0060] like Figure 2 As shown, a method for temperature-pressure coordinated control of a PI film coating roller includes the following steps: S100, Preheating and Initialization: The three electromagnetic heating zones are activated, the temperatures at the measuring points are collected, and the independent power required for each electromagnetic heating zone to reach the target temperature is calculated; in addition, each sealed chamber is pre-pressurized to 50% of the target pressure. S200, Contact and Pre-compression: Read the measured pressure values ​​of each sealed chamber, start the pressure self-balancing module to perform distributed pressure closed-loop control, adjust the opening of the electromagnetic proportional valve of each sealed chamber, and combine with the mechanical auxiliary pressure equalization structure to make the average pressure of each sealed chamber approach the target pressure. The heating and temperature self-compensation control module is kept running independently to ensure that each electromagnetic heating zone reaches the target temperature and the real-time temperature of each sealed chamber is fed back to the distributed pressure closed-loop control process. S300, steady-state roll pressing: The heating and temperature self-compensation control module and the pressure self-balancing module are kept running at a set cycle, and temperature-pressure coordinated control is performed when there is abnormal disturbance, so that the average temperature of the roller is within the target temperature and the axial pressure difference is within the preset range. Additionally, when the temperature at all measuring points reaches the target temperature and remains at it for a preset time, and the pressure fluctuation at all measuring points is less than a preset fluctuation threshold, the system enters a low-power mode. S400, Shutdown and Cooling: After the rolling process is completed, the heating power is turned off, the external auxiliary equipment is forced to cool the roller, and the pressure is released to zero after the temperature drops to the preset temperature.

[0061] In S100 of this embodiment of the invention, the process of preheating and initialization to equipment startup → roller surface temperature reaching 120°C includes: The three-stage electromagnetic heating zone is activated to rapidly heat up at full power. Distributed temperature sensors provide feedback on the temperature of measuring points S1 to S5 at a frequency of 50Hz. An adaptive PID algorithm calculates the independent power of each zone, with a target value of 120℃.

[0062] The pressure self-balancing module is in "standby mode". Each sealed chamber is pre-pressurized to 50% of the target pressure (3.5 bar) (approximately 1.75 bar), maintaining only the seal and basic contact, without actively adjusting. At this time, the micro electromagnetic proportional valve remains normally closed.

[0063] At this stage, since the rubber roller has not yet come into contact with the product plate (idling), the pressure sensor reading is close to zero, and the heating and temperature self-compensation control module is not affected by pressure feedback, thus achieving rapid and pure heating.

[0064] In S200 of this embodiment of the invention, the contact and pre-pressing process, which involves the roller descending to contact the product plate and the pressure stabilizing to the target value, includes: Pressure build-up: The roller clamping cylinder (external actuator) is activated, causing the rubber roller to contact the product plate. The measured values ​​of the diaphragm pressure sensors in the 8 chambers are read, and the distributed pressure closed-loop control is started. The opening of the proportional valve in each chamber is adjusted according to the average pressure deviation, so that the average pressure approaches the target pressure of 500N (corresponding to 0.45MPa).

[0065] Temperature Maintenance: Due to increased contact load and adhesive layer compression, the heat conduction path changes, and the roller surface temperature may fluctuate briefly (approximately ±2℃). The temperature control system continues to operate independently, and its dynamic attenuation factor... It will automatically identify disturbances and adjust the PID gain, restoring stability within 1 to 2 seconds.

[0066] Initial Coupling Compensation: In the pressure self-balancing control algorithm, the load balancing weight is calculated. The current temperature of each chamber is introduced in real time during the process. For example, if the temperature in the left zone of the roller surface is too low... If the temperature is 2℃, the target pressure in this area will automatically decrease by about 5% to 8% to avoid excessive pressure due to hardening of the adhesive layer. This is the explicit realization of "temperature-pressure decoupling".

[0067] In S200 of this embodiment, when the heating and temperature self-compensation control module operates independently, the process of heating and temperature self-compensation control for each electromagnetic heating zone in each set cycle is as follows: SA201, Preset process parameters, including target temperature =120℃, initial PID gain =2.5、 =0.15、 =0.05, sampling period =0.05s (20Hz), output limiting 0~100%, smoothing coefficient 0.7, adaptive rate factor =0.5、 =0.3、 =0.4 and dynamic attenuation factor coefficient =0.05、 =0.01, and simultaneously reset the integral term and the error history queue; SA202. During the sampling period, the temperature of multiple measuring points is collected through a distributed temperature sensor network, and then the average temperature of each electromagnetic heating zone and the roller surface as a whole is calculated. Specifically, temperature values ​​at five axial points are acquired using a distributed sensor (PT1000) network (S1~S5) at a sampling frequency of 50Hz. , , , , The temperature data is transmitted to the intelligent control unit ⑩ via a high-temperature resistant flexible circuit. The controller reads the current temperature of all measuring points every 20ms and calculates the average temperature of the left zone, middle zone, right zone, and overall temperature. SA203. Based on the average temperature of each electromagnetic heating zone, calculate the current error and error rate of change between the current temperature and the target temperature. For each electromagnetic heating zone (left, center, and right), the current error and the rate of change of error are calculated as follows:

[0068]

[0069] In the formula, The sampling period is This represents the real-time average temperature of the currently being calculated independent heating zone. Its purpose is to allow each zone to independently calculate its deviation from the target value based on its own real-time temperature. The digital control cycle of the temperature control system is the time interval between two consecutive PID operations. When the current error is greater than 0, it means that the current temperature is lower than the target and the system needs to heat up; when the current error is less than 0, it means that the current temperature is higher than the target and the system needs to reduce power or stop heating. This is the most basic input of PID control, which determines the "main direction" of control. SA204. Based on the current error and the rate of change of error, calculate the dynamic attenuation factor, then update the proportional, integral and derivative gains, and limit the gain. in, Dynamic decay factor at time The calculation formula is:

[0070] In the formula, and These are the first dynamic attenuation factor coefficient and the second dynamic attenuation factor coefficient, respectively. and These are the current error and the rate of change of error, respectively; for example, , When the error or rate of change increases, The adaptive amplitude is reduced, and the constraint is applied to prevent sudden parameter changes from causing system oscillations. thus, Proportion of moments ,integral and differential gain The calculation formula is:

[0071] In the formula, , and They are proportions ,integral and differential gain The corresponding initial gain, , and They are proportions ,integral and differential gain The adaptive rate factor; for example, , and The values ​​are 2.5, 0.15, and 0.05 respectively. , and The values ​​are 0.5, 0.3, and 0.4 respectively. Furthermore, the gain is limited as follows: , , ; Among them, the proportional gain increases when the error and the rate of change of error have the same sign (error trend is expanding) and decreases when they have opposite signs, thus enhancing the dynamic response capability; the integral gain decreases as the absolute value of the error increases, thus suppressing integral saturation; it recovers when the error approaches zero, thus eliminating steady-state error; the differential gain increases as the absolute value of the rate of change of error increases, thus improving the ability to predict rapid disturbances. SA205 uses an incremental PID algorithm based on calculated proportional, integral, and derivative gains to output the current control increment. It is represented as:

[0072] Among them, error increment The integral term is accumulated independently and limited (the limit is 50% of the output limit) to avoid integral saturation; SA206. Calculate the current feedforward compensation amount based on the current roller linear speed and PI film thickness; in, Feedforward compensation at time for:

[0073] In the formula, This is the empirical compensation coefficient. The linear speed of the roller is 210 m / min. For PI film thickness, For PI film density, For the heat capacity of the PI film, This is the rated maximum heating power of the heating system, used to normalize the theoretical heating power requirement into a control percentage dimension.

[0074] SA207: The current control increment, the current feedforward compensation amount and the control amount of the previous moment are accumulated, and the output is limited and exponentially smoothed to obtain the current heating control amount. It is then converted into the PWM duty cycle signal of each heating zone to drive the corresponding electromagnetic induction coil for heating and temperature self-compensation. The sum of the current control increment, the current feedforward compensation, and the control quantity from the previous moment is obtained as follows:

[0075] Then, output limiting is performed, represented as:

[0076] Furthermore, to reduce the jitter of the execution structure (PWM drive), an exponential smoothing filter is applied to obtain the current heating control quantity, which is expressed as:

[0077] SA208. Repeat steps SA202~S207 until the temperature of all measuring points is within the preset range of the target temperature and continues for a set time. The heating and temperature self-compensation control module then enters low-power maintenance mode.

[0078] All the above calculations and output updates are performed at a fixed cycle of 20Hz (once every 50ms). The intelligent control module ensures that the control cycle is strictly synchronized through the built-in real-time operating system timer, avoiding jitter from affecting temperature stability.

[0079] In this invention, the three independent electromagnetic heating zones (left, center, and right) operate the above temperature control steps independently, and each electromagnetic heating zone has its own PID state variables (error history, integral accumulation, etc.). Cross-interference is avoided between the zones through electromagnetic isolation gaps. When the temperature of a certain zone deviates from the overall average temperature by more than 2°C, the controller automatically increases the feedforward compensation coefficient for that zone to actively suppress axial temperature differences.

[0080] In this embodiment of the invention, in order to intuitively demonstrate and verify the dynamic response characteristics of the temperature control algorithm provided by the present invention, a human-computer interface (HMI) based on the PyQt5 framework is provided as the host computer monitoring module of the temperature control system. The device interface integrates the core logic of the above algorithm, real-time data acquisition, control command issuance and visualization feedback functions, and can effectively evaluate the temperature control performance in actual equipment debugging or simulation environment.

[0081] The modular temperature control adaptive interface is developed using the PyQt5 library and mainly includes the following functional modules: Parameter setting module: Users can set the target temperature (e.g., 120℃) through the numeric input box, and the controller can update the setting value immediately; Real-time data display module: Displays the current measured temperature, instantaneous heating power (in the form of progress bars and percentages), and the real-time gain of the adaptive PID controller. , and gain ; Control operation module: Provides three buttons: "Start Control", "Stop Control", and "Reset PID", which are used to activate the temperature control closed loop, stop the control output, and reset the integral term and error history, respectively. Real-time trend chart module: Based on matplotlib and embedded FigureCanvas, it dynamically plots the measured temperature curve and the set temperature curve. The horizontal axis is time (seconds) and the vertical axis is temperature (°C). It supports toolbar zooming and panning. Status indicator module: The bottom status bar displays the current system status (standby / running / stopped) and system time.

[0082] The backend interface adopts a dual-timer collaborative architecture, including: Control Timer: Period =50ms (20Hz), perform the following steps within each cycle: Obtain the latest measured temperature (from the sensor simulation thread or actual hardware acquisition); Call the update() method of the adaptive PID controller to calculate the heating power output; The output power value is passed to the progress bar and the power recording buffer.

[0083] Display refresh timer: period 100ms (10Hz), used to update the digital display, PID gain label, and refresh the temperature curve on the interface to avoid interface lag caused by high-frequency redrawing.

[0084] Temperature data simulation: When used for simulation verification, a first-order hysteresis plus white noise model is used to simulate the roller surface temperature response. The transfer characteristics between the measured temperature and heating power are close to the actual thermal inertia (time constant approximately 10~30 seconds). In actual equipment, this module can be replaced by reading real temperature sensor data via industrial protocols such as Modbus / OPC UA.

[0085] Through the interface described above, users can directly observe the following technical results: Rapid heating: The time to heat from room temperature (25°C) to the target 120°C is significantly shortened (full power heating stage); Steady-state high precision: The measured temperature is stable within the range of 120℃±1.5℃, with no steady-state error; Adaptive disturbance rejection: When the simulated temperature is disturbed (such as by changes in ambient heat dissipation conditions), the PID gain is automatically adjusted, and the temperature recovery time is less than 3 seconds; Parameter visualization: , and gain The effectiveness of the gain update law was verified by the dynamic changes in error and error rate.

[0086] Following the above workflow, an adaptive PID algorithm was designed and run using a PyCharm user interface combined with PyQt5. (See [link to documentation]). Figure 3 This invention realizes a complete closed loop from sensor sampling, adaptive gain adjustment, incremental PID calculation, feedforward compensation to output limiting and filtering. It can respond to temperature disturbances in milliseconds and accurately control the roller surface temperature within the range of 120℃±1.5℃, and has no steady-state error during long-term operation.

[0087] In S200 of this embodiment, the process of distributed pressure closed-loop control performed by the pressure self-balancing module in each set period is as follows: SB201. Collect the pressure values ​​of each sealed chamber, as well as the corresponding temperature and thickness data; SB202. Based on the temperature deviation and material thickness deviation of each sealing chamber, calculate the load balancing weight of each sealing chamber. for:

[0088] In the formula, For the first The temperature of the sealed chamber As the reference temperature, For temperature tolerance, For the first The thickness of the PI film at the corresponding location in each sealed chamber. The average thickness of all sealed chambers, For thickness tolerance; This invention sets load balancing weights. This allows for a smaller target pressure distribution in zones with lower temperatures or thinner thicknesses, achieving "temperature-pressure decoupling." SB203, considering the inherent parameter characteristics of PI film roller presses, introduces linear velocity feedforward compensation and a roller gap position loop to perform dual closed-loop cascade control, calculating and correcting the target total pressure. for:

[0089]

[0090] In the formula, Pressure on basic objectives The linear velocity of the roller, For velocity feedforward coefficient, For the target roll gap, For the current roll gap, For roll gap deviation gain, This is the integral compensation term for pressure error. The total pressure difference (the difference between the baseline target pressure and the current actual average pressure of all chambers). , These are the proportional gain and integral gain in the pressure self-balancing control process, respectively. The average pressure of all sealed chambers; where, , The values ​​are 0.6 and 0.1 respectively, and the integral term is limited to [-200, 200]N to prevent integral saturation. Ultimately, [the result will be...]. Limit to [200, 1500]N; where the basic target pressure is... It is the fixed reference pressure set by the process target, and it is the starting point for all calculations. The corrections caused by disturbances such as speed changes and roll gap fluctuations are all calculated by superimposing them on this basis. SB204. Based on the corrected target total pressure and the load balancing weight of each sealing chamber, calculate the target pressure of each sealing chamber; No. Target pressure in each sealed chamber for:

[0091] In the formula, For the first Load balancing weights for each sealed chamber For the balance correction coefficient, To control the cycle, For the first The measured pressure values ​​of each sealed chamber. This represents the average measured pressure values ​​for all sealed chambers, with subscripts indicating the average value. For the index of sealed chambers, This represents the total number of sealed chambers; The first item achieves weighted allocation of total pressure demand; the second item is local balance correction: chambers with low pressure receive positive compensation, and chambers with high pressure are automatically depressurized, thereby achieving axial pressure self-balancing. SB205 performs low-pass filtering and amplitude limiting on the target pressure of each seal to determine the corresponding pressure regulation command, and converts it into a PWM signal to drive the electromagnetic proportional valve of each sealing chamber to regulate the silicone oil injection / discharge. Specifically, to reduce the jitter of the actuator (miniature electromagnetic proportional valve), a first-order low-pass filter is applied to the target pressure in each chamber to reduce the proportional valve jitter, thus obtaining the... A sealed chamber in Constant pressure to achieve goals:

[0092] In the formula, These are the filter coefficients. =0.5s; Furthermore, it is further limited to [200, 1500]N, and finally converted into a pressure regulation command for the corresponding chamber electromagnetic proportional valve.

[0093] In step S200 of this embodiment of the invention, based on the distributed pressure closed-loop control performed by the pressure self-balancing module, pressure balancing is performed in conjunction with a mechanically assisted pressure equalization structure. Specifically: When the pressure self-balancing module is running, the overall positional change of the rollers caused by the mechanical floating structure is treated as a known, slowly changing external disturbance. The pressure value measured by the pressure sensor already includes the change in contact force caused by the mechanical floating. Therefore, the active control system automatically compensates for the pressure deviation caused by the floating, thus preventing it from being misinterpreted as an erroneous signal requiring reverse adjustment.

[0094] This invention incorporates a pressure change rate threshold: when the pressure change rate in a chamber is below 0.5 bar / s (corresponding to slow changes caused by mechanical float), the active control system does not perform rapid response adjustments to avoid "competitive adjustment" with the mechanical structure; only when the pressure change rate exceeds 1.5 bar / s (corresponding to local pressure difference or instantaneous disturbances) does the active hydraulic system intervene for rapid adjustment. This mechanism is implemented through software filtering, effectively suppressing mutual oscillations between the two systems.

[0095] In this embodiment of the invention, to intuitively verify the dynamic response and axial pressure distribution uniformity of the pressure self-balancing mechanism described in this invention, a human-machine interface (HMI) based on the PyQt5 framework is provided as the host computer monitoring module for pressure self-balancing. This interface fully encapsulates the aforementioned distributed pressure balancing control algorithm, visually displays the real-time pressure values, pressure unevenness rate, weight allocation, and historical trends of each zone, and supports online tuning of closed-loop control parameters.

[0096] The pressure self-balancing human-computer interaction interface is developed based on PyQt5 and mainly includes the following functional modules: Parameter setting module: Users can set the target total pressure (e.g., 500N) through the numeric input box, and the controller will immediately update the setting value; Real-time data display module: Displays the measured total pressure (average of 8 zones) and the current pressure unevenness rate; 8 vertical progress bars display the real-time pressure value of each zone (range 200~1500N), and the color changes dynamically with the pressure level; Control operation module: Provides three buttons: "Start Equalization Control", "Stop Control", and "Reset Controller", which are used to activate the pressure closed loop, stop the control output, and reset the integral term and filter status, respectively. Pressure Trend Graph Module: Based on matplotlib and embedded FigureCanvas, it dynamically draws the total pressure curve, the set pressure curve, and the pressure curves of typical partitions (such as partition 1 and partition 4). The horizontal axis is time (seconds) and the vertical axis is pressure (N). It supports scaling and panning. Weighted Table Module: Displays the current weight coefficients of the 8 partitions in real time in tabular form. This facilitates observation of the impact of temperature / thickness on pressure distribution; Status indicator module: The bottom status bar displays the current system status (standby / running / stopped) and system time.

[0097] The backend interface uses a dual-timer collaborative architecture, similar to the temperature control interface, including: Control Timer: Period =50ms (20Hz), executed within each cycle: Obtain the current total pressure (from the pressure simulation thread or the actual sensor). Obtain the current thickness and temperature of each partition (simulated data or measured values); Call SelfBalancingPressureController.update() to calculate the target pressure for the 8 partitions; Send the target pressure to the pressure actuator model (simulated thread or actual proportional valve drive).

[0098] Display refresh timer: 100ms period (10Hz) to update the digital display, progress bar, weight table and pressure curve to ensure smooth interface.

[0099] Pressure simulation thread: When used for simulation verification, a first-order inertial plus white noise model is used to simulate the pressure response of each zone, and the transmission characteristics are close to those of an actual hydraulic system (time constant 0.2 seconds). In actual equipment, this module can be replaced by reading data from a diaphragm pressure sensor via an industrial bus and outputting a proportional valve control signal.

[0100] Based on the above interface settings, the following technical effects can be observed intuitively: Self-balancing convergence is fast: After the control is started, the initial pressure unevenness rate (e.g., 15%~20%) drops to less than 5% within 5~10 seconds, and the pressure in each zone approaches the target value (500N). Dynamic disturbance rejection capability: When the simulated thickness is disturbed (such as a sudden increase of 0.02 mm in film thickness in a certain section) or the temperature is disturbed (such as a drop of 5℃ in temperature in a certain section), the weighting coefficient is automatically adjusted, the target pressure of the corresponding section changes accordingly, and the measured pressure is adjusted accordingly, with the unevenness fluctuation not exceeding ±2%; Effective roll gap / speed feedforward: When the simulated linear speed jumps from 1m / min to 5m / min, the total pressure setpoint automatically increases (feedforward term), and the measured pressure follows quickly without significant overshoot; The balancing correction effect is significant: observing the pressure curves of zone 1 and zone 4, the two initially differed greatly, but gradually converged after the balancing correction, verifying the local negative feedback term. Its function.

[0101] The above process embodies the integrated design concept of "algorithm modeling + closed-loop simulation + real-time monitoring" in this invention. The interface code fully conforms to the above control logic and can be directly deployed on the device's host computer or embedded industrial control system for parameter tuning and effect evaluation (see [link]). Figure 4 (Pressure trend chart and weight change chart). This interactive interface not only provides an intuitive tool for visualizing pressure distribution during engineering commissioning, but also forms an integral part of the pressure self-balancing system.

[0102] In S300 of this embodiment, the heating and temperature self-compensation control module executes at a 20Hz cycle: sampling the temperature at 5 points → calculating the average temperature and temperature difference → updating the adaptive PID gain → outputting the three-segment heating zone PWM → low-pass filtering. The focus is on the overall average temperature. Maintain within the range of 120℃±1.5℃.

[0103] The pressure self-balancing module executes at a 20Hz cycle: sampling the pressure of 8 chambers → calculating the load balancing weights. →Update total pressure integral term→Allocate target pressure to each chamber→Filter the output proportional valve opening to control the axial pressure range to meet the requirements. .

[0104] In S300 of this embodiment, abnormal disturbances include local increases / decreases in the thickness of the incoming material and local increases / decreases in heat dissipation on the roller surface; When the thickness of the incoming material increases or decreases locally, temperature-pressure coordinated control includes: Determine the sealing chamber corresponding to the area where the thickness locally increases / decreases, and open / close the corresponding electromagnetic proportional valve to relieve pressure within a set time; Meanwhile, based on the decrease / increase in contact thermal resistance of the corresponding area due to local increase / decrease in thickness, the heating and temperature self-compensation control module increases / decreases the heating power of the corresponding area in the next cycle.

[0105] For example, the above temperature-pressure coordinated control process is as follows: a sudden increase in the thickness of the incoming material (e.g., the PI film thickness jumps from 0.5mm to 0.55mm) → the pressure sensor detects a surge in pressure in the corresponding chamber → the pressure system opens the pressure relief valve within 50ms to reduce the pressure in the chamber → at the same time, the temperature control system detects a temperature drop trend in the area due to the decrease in contact thermal resistance → the temperature control system increases the heating power in the area in the next cycle (after 50ms) → the two form a staggered response of "fast pressure and slow temperature" without conflicting with each other.

[0106] When local heat dissipation on the roller surface increases / decreases, temperature-pressure coordinated control includes: Determine the electromagnetic heating zone corresponding to the local heat dissipation enhancement / weakening area on the roller surface, and at the same time reduce the load balancing weight of the corresponding electromagnetic heating zone in the pressure self-balancing module; For example, the above temperature-pressure coordinated control process is as follows: the ambient airflow causes local heat dissipation on the roller surface to increase (such as the temperature of the left zone drops) → the temperature control system responds first and increases the heating power of the left zone → at the same time, the weighting coefficient in the pressure system automatically reduces the target pressure of the left zone due to the low temperature → the pressure system will not mistakenly judge that "the pressure in this zone is too high and needs to be released", thus avoiding reverse adjustment.

[0107] Furthermore, when all measuring points If the pressure fluctuation is less than 0.1 bar / s for 30 seconds, the heating and temperature self-compensation control module switches to low power mode (PWM duty cycle 15%~25%); the pressure self-balancing module maintains normal adjustment, but no longer performs fast response (pressure change rate threshold is raised to 2.0 bar / s).

[0108] In S400 of this embodiment of the invention, the temperature control system shuts off the heating power supply and forces external auxiliary equipment (such as a fan) to perform controlled cooling of the roller (cooling rate ≤ 5℃ / min to prevent thermal stress cracking); after the temperature drops below 80℃, the pressure system is completely depressurized to zero to facilitate maintenance and the next start-up.

[0109] In this embodiment of the invention, the above-mentioned temperature-pressure coordinated control process is also designed to handle abnormal operating conditions (such as emergency stop, sudden speed change, material interruption, etc.), specifically: Emergency Stop: The intelligent control unit ⑩ detects an emergency stop signal → immediately cuts off the power supply to all electromagnetic heating zones (safety first) → the pressure system switches all chamber proportional valves to the "pressure relief" state to quickly release the silicone oil pressure and prevent the rubber roller from being crushed and deformed due to prolonged static contact with the product.

[0110] A sudden drop in speed (e.g., from 10 m / min to 2 m / min) → the temperature control feedforward compensation automatically decreases (because the linear velocity v decreases, the heat carried away by the film layer decreases) → the heating power is adjusted accordingly to prevent overheating → the speed feedforward coefficient of the pressure system also decreases to reduce the target total pressure (lower pressure is required at low speeds) → both are adjusted synchronously without coupling conflict.

[0111] Material supply interruption (product plate gap) → Pressure sensor detects a sudden drop in pressure in multiple chambers → Pressure system quickly depressurizes to standby pressure → Temperature control system maintains low power mode, waiting for re-contact.

[0112] Through the aforementioned collaborative control strategy, this invention achieves the following quantitative indicators to demonstrate that "mutual influence" has been effectively suppressed:

[0113] In summary, this invention does not simply treat temperature control and pressure equalization as two independent loops, but rather transforms the physical coupling between the two into a predictable and compensable engineering problem through a three-layer mechanism of "time scale separation, control law decoupling, and physical isolation".

[0114] In this embodiment of the invention, to further verify the collaborative performance of the temperature control and pressure self-balancing system and to facilitate engineering debugging and production monitoring, the invention integrates the above-mentioned temperature-pressure collaborative control process into a unified human-machine interaction platform. This integrated interface is developed based on the PyQt5 framework and implements the following core functions: Dual-system parallel monitoring: The main window simultaneously displays the temperature control area (target / measured temperature, three-stage heating power, PID real-time gain) and the pressure control area (target / measured total pressure, 8-zone pressure bars, pressure unevenness rate, weighting coefficient table), making the status clear at a glance.

[0115] Collaborative parameter configuration: Supports online modification of temperature and pressure system setpoints (120℃ / 500N), PID initial parameters, feedforward coefficients, and balance correction coefficients, and can link start / stop and reset operations.

[0116] Multi-dimensional trend fusion display: Temperature curves (actual / set) and pressure curves (total pressure / zone pressure / unevenness rate) are displayed in the same chart area or split screen, with the time axis synchronized, which facilitates the analysis of temperature-pressure coupling response relationship.

[0117] Operating condition simulation and fault testing: Built-in temperature disturbance (environmental heat dissipation change) and pressure disturbance (sudden change in incoming material thickness) injection functions, which can intuitively observe the staggered response of "fast pressure and slow temperature" and the effect of weight adaptive adjustment.

[0118] The aforementioned integrated interface not only fully replicates the three-layer collaborative strategy of "time scale separation + control law decoupling + physical isolation" proposed in this invention, but also provides an operation platform that allows direct modification of the engineering code deployed on the host computer of the device, providing a powerful visualization tool for system parameter tuning, fault diagnosis, and process optimization (see...). Figure 5 (Schematic diagram of integrated temperature and pressure monitoring interface).

[0119] In the description of this invention, it should be understood that the terms "center," "thickness," "upper," "lower," "horizontal," "top," "bottom," "inner," "outer," and "radial," etc., indicating orientation or positional relationships based on the orientation or positional relationships shown in the accompanying drawings, are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying the relative importance or the number of technical features implicitly specified. Therefore, a feature defined by "first," "second," and "third" may explicitly or implicitly include one or more of that feature.

[0120] Specific embodiments have been used to illustrate the principles and implementation methods of this invention. The descriptions of the embodiments above are only for the purpose of helping to understand the method and core ideas of this invention. At the same time, for those skilled in the art, there will be changes in the specific implementation methods and application scope based on the ideas of this invention. Therefore, the content of this specification should not be construed as a limitation of this invention.

[0121] Those skilled in the art will recognize that the embodiments described herein are intended to help the reader understand the principles of the invention, and should be understood that the scope of protection of the invention is not limited to such specific statements and embodiments. Those skilled in the art can make various other specific modifications and combinations based on the technical teachings disclosed in this invention without departing from the spirit of the invention, and these modifications and combinations are still within the scope of protection of this invention.

Claims

1. A temperature-pressure coordinated control system for a PI film coating roller, characterized in that, Includes rollers, heating and temperature self-compensation control module, pressure self-balancing module and intelligent control module; The roller has a built-in spiral copper tube, and is divided into three independent electromagnetic heating zones. A distributed temperature sensor network is also arranged to collect the temperature at multiple measurement points. In addition, the built-in axial pressure self-balancing adjustment chamber (5) includes several independent sealed chambers, and each sealed chamber is connected to the outside through an independent electromagnetic proportional valve. Each of the sealed chambers is equipped with a corresponding pressure sensor. The heating and temperature self-compensation control module, based on the set electromagnetic heating zone and the collected temperature, uses an adaptive PID control algorithm based on error integral weighting and dynamic attenuation factor to perform heating and temperature self-compensation control during the roller coating process. The pressure self-balancing module, based on the axial pressure self-balancing adjustment cavity (5), adopts a distributed pressure closed-loop control algorithm of weight allocation and balance correction to perform pressure self-balancing control during the roller coating process. The intelligent control module is used to perform temperature-pressure coordinated control during the roller coating process based on the bidirectional coupling relationship between temperature and pressure, through time scale separation, control law decoupling and physical structure isolation, in the process of heating, temperature self-compensation and pressure self-balancing control. When the heating and temperature self-compensation control module operates independently, the process of heating and temperature self-compensation control for each electromagnetic heating zone within each set cycle is as follows: SA201, preset process parameters, including target temperature, initial PID gain, sampling period, smoothing coefficient, adaptive rate factor and dynamic attenuation factor coefficient; SA202. During the sampling period, the temperature of multiple measuring points is collected through a distributed temperature sensor network, and then the average temperature of each electromagnetic heating zone and the roller surface as a whole is calculated. SA203. Based on the average temperature of each electromagnetic heating zone, calculate the current error and error rate of change between the current temperature and the target temperature. SA204. Based on the current error and the rate of change of error, calculate the dynamic attenuation factor, then update the proportional, integral and derivative gains, and limit the gain. SA205 uses an incremental PID algorithm to output the current control increment based on calculated proportional, integral, and derivative gains. SA206. Calculate the current feedforward compensation amount based on the current roller linear speed and PI film thickness; SA207: The current control increment, the current feedforward compensation amount and the control amount of the previous moment are accumulated, and the output is limited and exponentially smoothed to obtain the current heating control amount. It is then converted into the PWM duty cycle signal of each heating zone to drive the corresponding electromagnetic induction coil for heating and temperature self-compensation. SA208. Repeat steps SA202~S207 until the temperature of all measuring points is within the preset range of the target temperature and continues for a set time. The heating and temperature self-compensation control module then enters a low-power maintenance mode. Within each set period, the process of distributed pressure closed-loop control performed by the pressure self-balancing module is as follows: SB201. Collect the pressure values ​​of each sealed chamber, as well as the corresponding temperature and thickness data; SB202. Calculate the load balancing weight of each sealing chamber based on the temperature deviation and material thickness deviation of each sealing chamber. SB203. Based on the inherent parameter characteristics of the PI film roller press, linear velocity feedforward compensation and roller gap position loop are introduced to calculate and correct the target total pressure. SB204. Based on the corrected target total pressure and the load balancing weight of each sealing chamber, calculate the target pressure of each sealing chamber; SB205 performs low-pass filtering and amplitude limiting on the target pressure of each sealed chamber, determines the corresponding pressure regulation command, and converts it into a PWM signal to drive the electromagnetic proportional valve of each sealed chamber to regulate the silicone oil injection / discharge volume.

2. The temperature-pressure coordinated control system for the PI film coating roller according to claim 1, characterized in that, The roller is also equipped with an auxiliary pressure equalization structure, including a spherical adjusting bearing and an axial floating spring seat between the central spindle of the roller and the bearing seats at both ends, and the maximum stroke of the floating spring seat is limited by mechanical limit screws at both ends of the roller.

3. The temperature-pressure coordinated control system for the PI film coating roller according to claim 1, characterized in that, The roller is provided with a heat insulation buffer layer (6) to block the direct conduction of heat to each sealed chamber.

4. A temperature-pressure coordinated control method for a PI film coating roller, applied in the temperature-pressure coordinated control system of the PI film coating roller as described in any one of claims 1 to 3, characterized in that, Includes the following steps: S100, Preheating and Initialization: The three electromagnetic heating zones are activated, the temperatures at the measuring points are collected, and the independent power required for each electromagnetic heating zone to reach the target temperature is calculated; in addition, each sealed chamber is pre-pressurized to 50% of the target pressure. S200, Contact and Pre-compression: Read the measured pressure values ​​of each sealed chamber, start the pressure self-balancing module to perform distributed pressure closed-loop control, adjust the opening of the electromagnetic proportional valve of each sealed chamber, and combine with the mechanical auxiliary pressure equalization structure to make the average pressure of each sealed chamber approach the target pressure. The heating and temperature self-compensation control module is kept running independently to ensure that each electromagnetic heating zone reaches the target temperature and the real-time temperature of each sealed chamber is fed back to the distributed pressure closed-loop control process. S300, steady-state roll pressing: The heating and temperature self-compensation control module and the pressure self-balancing module are kept running at a set cycle, and temperature-pressure coordinated control is performed when there is abnormal disturbance, so that the average temperature of the roller is within the target temperature and the axial pressure difference is within the preset range. Additionally, when the temperature at all measuring points reaches the target temperature and remains at it for a preset time, and the pressure fluctuation at all measuring points is less than a preset fluctuation threshold, the system enters a low-power mode. S400, Shutdown and Cooling: After the rolling process is completed, the heating power is turned off, the external auxiliary equipment is forced to cool the roller, and the pressure is released to zero after the temperature drops to the preset temperature.

5. The temperature-pressure coordinated control method for PI film coating rollers according to claim 4, characterized in that, In S200, when the heating and temperature self-compensation control module operates independently, the process of heating and temperature self-compensation control for each electromagnetic heating zone within each set cycle is as follows: SA201, preset process parameters, including target temperature, initial PID gain, sampling period, smoothing coefficient, adaptive rate factor and dynamic attenuation factor coefficient; SA202. During the sampling period, the temperature of multiple measuring points is collected through a distributed temperature sensor network, and then the average temperature of each electromagnetic heating zone and the roller surface as a whole is calculated. SA203. Based on the average temperature of each electromagnetic heating zone, calculate the current error and error rate of change between the current temperature and the target temperature. SA204. Based on the current error and the rate of change of error, calculate the dynamic attenuation factor, then update the proportional, integral and derivative gains, and limit the gain. SA205 uses an incremental PID algorithm to output the current control increment based on calculated proportional, integral, and derivative gains. SA206. Calculate the current feedforward compensation amount based on the current roller linear speed and PI film thickness; SA207: The current control increment, the current feedforward compensation amount and the control amount of the previous moment are accumulated, and the output is limited and exponentially smoothed to obtain the current heating control amount. It is then converted into the PWM duty cycle signal of each heating zone to drive the corresponding electromagnetic induction coil for heating and temperature self-compensation. SA208. Repeat steps SA202~S207 until the temperature of all measuring points is within the preset range of the target temperature and continues for a set time. Then the heating and temperature self-compensation control module enters the low power consumption maintenance mode.

6. The temperature-pressure coordinated control method for PI film coating rollers according to claim 5, characterized in that, In the SA204, Dynamic decay factor at time The calculation formula is: In the formula, and These are the first dynamic attenuation factor coefficient and the second dynamic attenuation factor coefficient, respectively. and These are the current error and the rate of change of error, respectively. In the SA204, Proportion of moments ,integral and differential gain The calculation formula is: In the formula, , and They are proportions ,integral and differential gain The corresponding initial gain, , and They are proportions ,integral and differential gain Adaptive rate factor; In the SA206, Feedforward compensation at time for: In the formula, This is the empirical compensation coefficient. The linear velocity of the roller, For PI film thickness, For PI film density, For the heat capacity of the PI film, This is the rated maximum heating power of the heating system.

7. The temperature-pressure coordinated control method for PI film coating rollers according to claim 4, characterized in that, In S200, the process of distributed pressure closed-loop control performed by the pressure self-balancing module within each set period is as follows: SB201. Collect the pressure values ​​of each sealed chamber, as well as the corresponding temperature and thickness data; SB202. Calculate the load balancing weight of each sealing chamber based on the temperature deviation and material thickness deviation of each sealing chamber. SB203. Based on the inherent parameter characteristics of the PI film roller press, linear velocity feedforward compensation and roller gap position loop are introduced to calculate and correct the target total pressure. SB204. Based on the corrected target total pressure and the load balancing weight of each sealing chamber, calculate the target pressure of each sealing chamber; SB205 performs low-pass filtering and amplitude limiting on the target pressure of each sealed chamber, determines the corresponding pressure regulation command, and converts it into a PWM signal to drive the electromagnetic proportional valve of each sealed chamber to regulate the silicone oil injection / discharge volume.

8. The temperature-pressure coordinated control method for PI film coating rollers according to claim 7, characterized in that, In SB202, the first Load balancing weight of each sealed chamber for: In the formula, For the first The temperature of the sealed chamber As the reference temperature, For temperature tolerance, For the first The thickness of the PI film at the corresponding location in each sealed chamber. The average thickness of all sealed chambers, For thickness tolerance; In the SB203, the target total pressure is corrected. for: In the formula, Pressure on basic objectives The linear velocity of the roller, For velocity feedforward coefficient, For the target roll gap, For the current roll gap, For roll gap deviation gain, This is the integral compensation term for pressure error. For the total pressure difference, , These are the proportional gain and integral gain in the pressure self-balancing control process, respectively. The average pressure of all sealed chambers; In SB204, the first Target pressure in each sealed chamber for: In the formula, For the first Load balancing weights for each sealed chamber For the balance correction coefficient, To control the cycle, For the first The measured pressure values ​​of each sealed chamber. This represents the average measured pressure values ​​for all sealed chambers, with subscripts indicating the average value. For the index of sealed chambers, This represents the total number of sealed chambers.

9. The temperature-pressure coordinated control method for PI film coating rollers according to claim 4, characterized in that, In S300, the abnormal disturbances include local increases / decreases in the thickness of the incoming material and local increases / decreases in heat dissipation on the roller surface; When the thickness of the incoming material increases or decreases locally, temperature-pressure coordinated control includes: Determine the sealing chamber corresponding to the area where the thickness locally increases / decreases, and open / close the corresponding electromagnetic proportional valve to relieve pressure within a set time; Meanwhile, based on the decrease / increase in contact thermal resistance of the corresponding area due to local increase / decrease in thickness, the heating and temperature self-compensation control module increases / decreases the heating power of the corresponding area in the next cycle; When local heat dissipation on the roller surface increases / decreases, temperature-pressure coordinated control includes: Identify the electromagnetic heating zone corresponding to the area of ​​enhanced / weakened local heat dissipation on the roller surface, and at the same time reduce the load balancing weight of the corresponding electromagnetic heating zone in the pressure self-balancing module.

10. The temperature-pressure coordinated control method for the PI film coating roller according to claim 4, characterized in that, In the aforementioned temperature-pressure coordinated control process: In case of emergency stop, immediately cut off the power supply to the electromagnetic heating zone and switch the electromagnetic proportional valves of all sealed chambers to the pressure relief state; When the speed drops sharply, the feedforward compensation in the heating and temperature self-compensation control module is reduced, and the heating power is lowered; the target pressure of the pressure self-balancing module is reduced simultaneously. When material supply is interrupted, the electromagnetic proportional valves of all sealed chambers are switched to the depressurization state until the pressure is reduced to the standby pressure. The heating and temperature self-compensation control modules are then switched to low power mode to wait for re-connection.

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