High-precision self-adjusting and self-checking full-automatic intelligent closed-loop die head

Abstract

The present application relates to the technical field of coating die, and discloses a high-precision self-adjusting and self-checking full-automatic intelligent closed-loop die.The die is provided with two-stage detection mechanisms and an adjusting module to form a full-automatic closed-loop adjustment.The first-stage detection mechanism can detect the flow distribution of the slurry along the length direction in advance at the second slit, and the adjusting module can adjust the opening of the first slit at the corresponding position in advance to solve the problem of adjustment lag in the prior art.Meanwhile, the second-stage detection mechanism at the lip can perform secondary detection and calibration on the actual parameters of the slurry flowing out to further improve the adjustment accuracy, realize real-time monitoring and closed-loop adjustment of the slurry flow from feeding to discharging, ensure the discharging uniformity of the slurry along the length direction of the lip, greatly improve the coating precision and coating consistency, reduce the coating rejection rate, and better meet the coating production requirements of high-end lithium electrode sheets.

Description

Technical Field

[0001] This invention relates to the field of coating die technology, specifically to a high-precision, self-adjusting, self-testing, fully automatic, intelligent closed-loop die. Background Technology

[0002] In the development of the new energy industry, lithium batteries and other products, with their core advantages of high energy density and long cycle life, have become key carriers driving the progress of new energy technologies. The precision of lithium battery electrode coating directly determines the battery's capacity, consistency, and cycle safety performance, making it a core process affecting product quality in the lithium battery production process.

[0003] Currently, the coating process on the market mainly relies on slit coating dies. Slit coating dies can achieve high-precision and high-efficiency coating operations by precisely controlling the flow rate, pressure and gap size of the coating liquid, and have been widely used in the lithium battery field.

[0004] Traditional slit coating dies employ a rear-end thickness measurement → feedback adjustment mode, which suffers from bottlenecks such as slow response, frequent adjustments, high initial coating scrap rate, poor lateral consistency, and insufficient short-coat detection accuracy, making it difficult to meet the high-precision, high-stability, and high-consistency production requirements of high-end manufacturing. To address this technical problem, a coating die (patent number CN115780175B) has been introduced in the prior art. This die incorporates a flow meter that detects the slurry flow rate within the coating slit and uses the measured value as feedback. The coating thickness adjustment mechanism adjusts the slurry flow rate in the coating slit based on this feedback value. This closed-loop adjustment of coating thickness using a built-in flow meter as feedback signal ensures that the feedback signal is closer to the adjustment actuator during coating, eliminating the waste of long, uncontrollable coating sections and resulting in better overall lateral flatness of the coating.

[0005] As described above, although the inventor has added a detection module to the discharge lip of the existing die head, the abnormal flow can only be detected after the slurry has been output to the lip. By this time, the slurry has already filled the first slit, and the abnormal flow has already affected the coating effect. It is impossible to predict and adjust the flow distribution before the slurry enters the discharge slit, resulting in adjustment lag and accuracy deviation, and making it impossible to achieve stable high-precision coating. Therefore, how to achieve real-time detection and automatic closed-loop adjustment of the slurry flow throughout the coating process is an important technical problem that urgently needs to be solved by those skilled in the art. Based on this, the present invention provides a high-precision self-adjusting and self-testing fully automatic intelligent closed-loop die head. Summary of the Invention

[0006] This invention provides a high-precision, self-adjusting, self-testing, fully automatic, intelligent closed-loop mold head to solve the problems mentioned in the background art.

[0007] The objective of this invention is achieved through the following means: A high-precision, self-adjusting, self-testing, fully automatic intelligent closed-loop die head is provided. The die head has a first slit inside, and a lip on one side of the die head for slurry to flow out of the first slit. The end of the slit away from the lip is connected to an external feed pipe through a cavity. The die head is equipped with an adjustment module and a detection module. The detection module includes a primary detection mechanism and a secondary detection mechanism, with the secondary detection mechanism located at the lip. The primary detection mechanism includes a barrier and several primary detection units. The barrier is installed in the cavity, dividing the cavity into a feed chamber and a discharge chamber. The feed chamber is connected to the external feed pipe, and the discharge chamber is connected to the first slit. A second slit connecting the feed chamber and the discharge chamber is formed between the lower end of the barrier and the inner surface of the cavity. Several primary detection units are sequentially arranged on the second slit along its length. The adjustment module adjusts the slurry flow rate of the first slit in response to the flow detection signals from the primary and secondary detection mechanisms.

[0008] As a preferred solution for a high-precision, self-adjusting, self-testing, fully automatic, intelligent closed-loop die head, the primary detection unit is a bridge flow meter. The primary detection unit includes an electrode plate A located at the end of the barrier and an electrode plate B located on one side of the second slit. The electrode plate A and the electrode plate B are arranged facing each other. The electrode plate A is connected to the positive and negative terminals of an external power supply as the input terminal of the bridge signal, and the electrode plate B is the output terminal of the bridge signal.

[0009] As a preferred solution for a high-precision self-adjusting and self-testing fully automatic intelligent closed-loop mold head, the adjustment module includes multiple execution components, which are arranged sequentially on the lip.

[0010] As a preferred solution for a high-precision, self-adjusting, self-testing, fully automatic, intelligent closed-loop die head, the execution component includes an electric push rod and a flow-blocking block. The flow-blocking block is installed on the output end of the electric push rod, and the electric push rod is installed on the die head.

[0011] As a preferred solution for a high-precision, self-adjusting, self-testing, fully automatic, intelligent closed-loop mold head, multiple primary detection units and multiple execution components are arranged side by side along the length direction of the lip and are set in corresponding positions. The execution components adjust the slurry flow rate at the corresponding position in the first slit in response to the flow detection signal issued by the primary detection unit corresponding to the position.

[0012] As a preferred solution for a high-precision, self-adjusting, self-testing, fully automatic, intelligent closed-loop mold head, the secondary detection mechanism includes multiple secondary detection units, which are arranged sequentially along the length of the lip at the lip opening. Each secondary detection unit corresponds to one or more execution components.

[0013] As a preferred solution for a high-precision, self-adjusting, self-testing, fully automatic, intelligent closed-loop mold head, the secondary detection unit is an ultrasonic flow meter.

[0014] As a preferred solution for a high-precision, self-adjusting, self-testing, fully automatic, intelligent closed-loop mold head, the mold head includes an upper mold and a lower mold, a gasket is provided between the upper mold and the lower mold, the gasket is installed in the upper mold through a flow-retarding block, the flow-retarding block is disposed in the cavity, and the barrier is installed on the flow-retarding block.

[0015] As a preferred solution for a high-precision, self-adjusting, self-testing, fully automatic intelligent closed-loop mold head, both ends of the flow buffer block are arc-shaped convex surfaces.

[0016] This invention utilizes a two-stage detection mechanism in conjunction with an adjustment module to form a fully automatic closed-loop control. The first-stage detection mechanism can detect the flow distribution of the slurry along its length at the second slit, allowing for early prediction of flow anomalies before they enter the first slit. The adjustment module can then adjust the opening of the first slit at the corresponding position in advance, solving the problem of adjustment lag in existing technologies. Simultaneously, the second-stage detection mechanism at the lip performs secondary detection and calibration of the actual parameters of the final outflowing slurry, further improving the adjustment accuracy. This achieves real-time monitoring and closed-loop control of the slurry flow from inlet to outlet, ensuring the uniformity of slurry outflow along the length of the lip, significantly improving coating accuracy and consistency, reducing the initial coating scrap rate, and better meeting the coating production requirements of high-end lithium electrode sheets. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the structure of the high-precision self-adjusting and self-testing fully automatic intelligent closed-loop mold head of the present invention; Figure 2 This is a cross-sectional view of the high-precision self-adjusting and self-testing fully automatic intelligent closed-loop mold head of the present invention; Figure 3 This is a partial cross-sectional view of the high-precision self-adjusting and self-testing fully automatic intelligent closed-loop mold head of the present invention; Figure 4 This is a schematic diagram of the slurry flow path inside the die head in this embodiment.

[0018] The reference numerals in the figure are as follows: 1-Die head, 2-Barrier, 3-First-level detection unit, 4-Second-level detection unit, 5-Electric push rod, 6-Flow blocking block, 7-Gasket, 8-Flow retardant block, 10-Lip, 11-First slit, 12-Second slit, 13-Infeed cavity, 14-Outfeed cavity, 15-Upper die, 16-Lower die. Detailed Implementation

[0019] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and not intended to limit it. Furthermore, it should be noted that, for ease of description, the accompanying drawings show only the parts relevant to the present invention, and not all of the structures.

[0020] In the description of this invention, unless otherwise explicitly specified and limited, the terms "connected," "linked," and "fixed" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0021] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0022] In the description of this embodiment, terms such as "upper," "lower," "left," and "right" are based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of description and simplification of operation, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the present invention.

[0023] In the description of this invention, unless otherwise stated, "a plurality of" means two or more. Furthermore, the terms "first" and "second" are used merely for descriptive distinction and have no specific meaning.

[0024] In one embodiment of the present invention, such as Figure 1-4 As shown, a high-precision self-adjusting and self-testing fully automatic intelligent closed-loop mold head 1 is specifically implemented. The mold head 1 is provided with a first slit 11. One side of the mold head 1 is provided with a lip 10 for the slurry to flow out of the first slit 11. The end of the first slit 11 away from the lip 10 is connected to an external feed pipe through a cavity. The feed gear pump accurately pumps the slurry into the cavity through the feed pipe.

[0025] The mold head 1 is equipped with an adjustment module and a detection module. The detection module includes a primary detection mechanism and a secondary detection mechanism, with the secondary detection mechanism located at the lip 10.

[0026] The primary detection mechanism includes a barrier 2 and several primary detection units 3. The barrier 2 is installed in the cavity and divides the cavity into a feeding chamber 13 and a discharging chamber 14. The feeding chamber 13 is connected to an external feeding pipe, and the discharging chamber 14 is connected to the first slit 11. A second slit 12 is formed between the lower end of the barrier 2 and the inner side of the cavity to connect the feeding chamber 13 and the discharging chamber 14. Along the length of the second slit 12, several primary detection units 3 are arranged sequentially on the second slit 12.

[0027] The adjustment module adjusts the slurry flow rate of the first slit 11 in response to the flow detection signals issued by the primary and secondary detection mechanisms.

[0028] This invention utilizes a two-stage detection mechanism in conjunction with an adjustment module to form a fully automatic closed-loop control. The first-stage detection mechanism can detect the flow distribution of the slurry along its length at the second slit 12, allowing for early prediction of abnormal flow before it enters the first slit 11. The adjustment module can then adjust the opening of the first slit 11 at the corresponding position in advance, solving the problem of adjustment lag in existing technologies. Simultaneously, the second-stage detection mechanism at the lip 10 performs secondary detection and calibration of the actual parameters of the final outflowing slurry, further improving the adjustment accuracy. This achieves real-time monitoring and closed-loop control of the slurry flow from inlet to outlet, ensuring the uniformity of slurry outflow along the length of the lip 10, significantly improving coating accuracy and consistency, reducing the initial coating scrap rate, and better meeting the coating production requirements of high-end lithium electrode sheets.

[0029] The primary detection unit 3 is an electric bridge flow meter. The primary detection unit 3 includes an electrode plate A located at the end of the barrier 2 and an electrode plate B located on one side of the second slit 12. Electrode plates A and B are positioned opposite each other. Electrode plate A is connected to the positive and negative terminals of an external power supply as the input terminal of the electric bridge signal, and electrode plate B serves as the output terminal of the electric bridge signal. Compared with the existing method of measuring slurry flow using an electromagnetic flow meter, this method of measuring slurry flow using an electric bridge flow meter eliminates the need for an additional excitation device, resulting in a simpler structure. It also provides higher accuracy for measuring the flow of low-velocity slurries, has no requirements on the conductivity of the measured slurry, and has wider applicability.

[0030] Furthermore, both electrode plates A and B are covered with shielded electrodes, which are then covered with an insulating layer. The shielded electrodes effectively prevent interference from external electromagnetic signals, thus improving the accuracy of the bridge flowmeter's measurement results. The insulating layer provides insulation between the shielded electrodes and the slurry.

[0031] The primary detection mechanism also includes a signal processor electrically connected to the primary detection unit 3. The signal processor is used to filter, rectify, and amplify the flow detection signal collected by the measuring element before outputting it. Specifically, the signal processing of the electrical signal collected by the primary detection unit 3 in the signal processor is as follows: preamplifier → amplifier → rotating capacitor filter → rectification and filtering → low-pass filter → calibration circuit → low-pass filter → voltage amplification → ADC sampling → communication.

[0032] In this embodiment, the signal processor includes multiple signal conversion units, each corresponding to a primary detection unit 3 and an execution component. These signal conversion units are communicatively connected to a control unit, which is electrically connected to multiple execution components in the same group. The control unit responds to control signals issued by the signal conversion units to activate the corresponding execution components. For example, when one of the primary detection units 3 detects a large local slurry flow rate within the second slit 12, it sends a feedback signal to the control unit. The control unit adjusts the actuating end of the execution component at the corresponding local position to extend into the first slit 11 based on the feedback signal value, thereby reducing the slurry flow rate in the corresponding area. This ensures more precise uniformity of the coating thickness throughout the longitudinal direction.

[0033] In the second embodiment of this invention, the primary detection unit 3 is an ultrasonic flow meter. The measuring element includes an ultrasonic transmitter and an ultrasonic receiver located on one side or opposite sides of the coating die 1 of the second slit 12. The ultrasonic signal emitted by the ultrasonic transmitter is received by the ultrasonic receiver, converted into an electrical signal, processed by a signal processor, and then emitted outward. Using an ultrasonic flow meter to measure the slurry flow rate has the advantages of non-contact measurement, immunity to electromagnetic interference, and resistance to highly corrosive liquids such as acids and alkalis. Therefore, it has stable performance, high reliability, long service life, and is convenient for repeated testing.

[0034] In the third embodiment of this example, the primary detection unit 3 is a capacitive electromagnetic flowmeter, and the coating die head 1 is provided with an excitation device for generating a magnetic field in the coating slit; the measuring element includes a positive electrode plate located at the end of the barrier 2 and a negative electrode plate located on one side of the second slit 12.

[0035] The positive and negative plates can sense potential signals. There is a potential difference (i.e., voltage) between the potential signals sensed by the positive and negative plates. This potential difference is related to the slurry flow rate on the coating slit cross-section. Therefore, the potential difference signal value can be used as the feedback value for coating thickness adjustment. By adjusting the slurry flow rate of the coating slit corresponding to the position of the actuator, the coating thickness can be adjusted. This method of adjusting the coating thickness by setting an electromagnetic flowmeter in the coating die 1 to provide feedback electrical signals ensures that there are no areas on the substrate where the coating thickness cannot be adjusted during coating, resulting in better lateral flatness of the overall coating.

[0036] Furthermore, the excitation device is preferably a dual-frequency rectangular wave excitation device. This device creates an electromagnetic field with both high-frequency and low-frequency components within the measurement channel of the capacitive electromagnetic flowmeter. For example, a 75Hz high-frequency rectangular wave effectively suppresses medium noise and significantly reduces the polarization of the liquid on the detection electrode; a 6.25Hz low-frequency rectangular wave helps suppress zero-point drift. Electromagnetic flowmeters using dual-frequency excitation can operate under harsh conditions, exhibiting good zero-point stability and strong slurry noise suppression capabilities. Specifically, the dual-frequency rectangular wave excitation device employs a dual-frequency three-phase rectangular wave.

[0037] Compared with the method of measuring slurry flow using an electric bridge flow meter, the capacitive electromagnetic flow meter has the advantages of simple structure, fewer required electrode plates, and the electrode plates do not need to be in direct contact with the liquid. Moreover, the excitation device can use sine wave or rectangular wave excitation, which can reduce zero drift.

[0038] The adjustment module includes multiple execution components, which are arranged sequentially on the lip 10. Each execution component includes an electric push rod 5 and a flow-blocking block 6. The flow-blocking block 6 is installed on the output end of the electric push rod 5, which is installed on the die head 1. The flow-blocking block 6 can extend into or out of the first slit 11 under the drive of the electric push rod 5. By changing the length of the flow-blocking block 6 extending into the first slit 11, the effective opening of the first slit 11 at the corresponding position is adjusted, thereby changing the slurry flow rate at the corresponding position and achieving precise adjustment segment by segment.

[0039] Furthermore, the equal spacing between two adjacent electric actuators 5 ensures uniform flow regulation. To improve the wear resistance of the flow deflector 6 and extend its service life, the working surface of the flow deflector 6 is generally treated with a wear-resistant ceramic or hard alloy coating to prevent wear caused by long-term slurry erosion, which would affect the accuracy of the opening adjustment. Simultaneously, the electric actuator 5 has a self-locking function, maintaining the current opening position after adjustment without requiring continuous power, thus saving energy and preventing opening deviation during production, ensuring production stability.

[0040] In the second embodiment of this example, the actuating component can directly push the upper or lower end of the lip 10 to deform via the electric push rod 5, thereby changing the opening size of the corresponding position of the first slit 11. This structure does not require the addition of an additional barrier 2 inside the first slit 11, will not cause additional interference to the flow of the slurry, and also avoids the problem of slurry accumulating on the surface of the barrier 2.

[0041] The upper mold 15 has an installation slot corresponding to the position of each execution component. The flow blocking block 6 of the execution component passes through the installation slot. A small gap is left between the installation slot and the flow blocking block 6, which does not restrict the extension and retraction adjustment of the flow blocking block 6, and can also fill the gap by the pressure of the slurry itself, so that there will be no leakage problem.

[0042] Multiple primary detection units 3 and multiple execution components are arranged side by side along the length of the lip 10 and are set in corresponding positions. Each primary detection unit 3 corresponds to the execution component at one position. The detection and adjustment positions are in one-to-one correspondence, which can accurately locate the area corresponding to abnormal flow, avoid adjustment misalignment, and further improve adjustment accuracy and adjustment response speed.

[0043] The execution component adjusts the slurry flow rate at the corresponding position within the first slit 11 in response to the flow detection signal emitted by the first-level detection unit 3 corresponding to the position. This enables precise point-to-point adjustment of local abnormal flow rates, avoiding the drawback of adjusting one area affecting the entire area, and further improving adjustment efficiency and accuracy.

[0044] Specifically, the flow signal of the first-level detection unit 3 is converted into the estimated discharge thickness, and then compared with the actual discharge thickness detected by the second-level detection unit 4. Based on the thickness deviation value, the stroke that the corresponding execution component needs to be adjusted is calculated, and the opening correction is automatically completed without manual intervention for calibration. The entire process achieves fully automatic intelligent adjustment, truly forming a complete closed loop from detection to adjustment and then to verification and calibration.

[0045] The secondary detection mechanism includes multiple secondary detection units 4, which are arranged sequentially along the length of the lip 10. Each secondary detection unit 4 corresponds to one or more execution components.

[0046] In this embodiment, one secondary detection unit 4 corresponds to five execution components. That is, a secondary detection unit 4 is set at a preset distance along the length of the lip 10. It is used to perform overall verification and detection of the adjustment results of multiple sets of execution components within the range corresponding to the detection unit. This can reduce the number of detection elements and reduce the overall equipment cost. It can also complete the secondary calibration through the final discharge detection, and further ensure the adjustment accuracy in conjunction with the front-end primary detection mechanism.

[0047] The secondary detection mechanism is used to directly detect the thickness of the slurry flowing out from the lip 10. This detection method does not directly contact the flowing slurry and will not interfere with the slurry's discharge state. Furthermore, ultrasonic detection has higher resolution and can accurately capture micron-level thickness fluctuations, adapting to the detection requirements of high-precision extrusion processes. Once the slurry flows out stably from the lip 10, each secondary detection unit 4 can acquire the thickness data of the discharged slurry at the corresponding position in real time and convert this data into an electrical signal, feeding it back to the control terminal. This provides a precise closed-loop calibration basis for the fine-tuning of the actuator components.

[0048] The secondary detection unit 4 is an ultrasonic flow meter. It emits ultrasonic signals through an ultrasonic probe and aims them at the slurry. It calculates the actual thickness of the slurry at the current position based on the echo reflection time. The thickness data is then converted into an electrical signal and sent to the controller. The controller combines the predicted data from the primary detection mechanism with the actual discharge data from the secondary detection mechanism to perform a secondary calibration and correction on the opening of the execution component. This further eliminates the prediction error of the primary detection mechanism and ensures that the final discharge thickness fully meets the preset accuracy requirements.

[0049] The die head 1 includes an upper die 15 and a lower die 16. A gasket 7 is disposed between the upper die 15 and the lower die 16. The first slit 11 is formed between the upper die 15 and the lower die 16. The gasket 7 is located on the feed side of the upper die 15 and the lower die 16 and is used to limit the initial opening of the first slit 11. The gasket 7 is installed in the upper die 15 by a flow buffer 8. The flow buffer 8 is disposed in the cavity. The barrier 2 is installed on the flow buffer 8. Both ends of the flow buffer 8 are arc-shaped convex surfaces. The arc-shaped convex surfaces can divert and guide the slurry entering the cavity, avoiding direct impact of the slurry on the barrier 2 to generate turbulence, ensuring that the slurry flows more smoothly at the second slit 12, reducing the error of flow detection, and improving the accuracy of the detection results.

[0050] Under normal production conditions, the upper mold 15 and the lower mold 16 are fixedly connected by locking bolts, ensuring a stable connection structure. This maintains overall structural stability under high-pressure feeding conditions and prevents unexpected deviations in the opening of the first slit 11. When maintenance or repair is required, the locking bolts can be loosened, allowing the upper mold 15 to open and close along the rear hinge. This facilitates cleaning the interior of the first slit 11, replacing the gasket 7, or inspecting components, making maintenance simple and convenient.

[0051] Specifically, the primary detection mechanism comprises several primary detection units 3 arranged in a matrix, equidistantly embedded in the flow channel of the second slit 12 along the length of the die head 1. It can simultaneously collect initial flow data for each subdivided control zone (e.g., one zone every 15mm) across the entire width of the slurry after it is initially distributed from the second slit 12 by the barrier 2, with a response speed of ≤1ms, generating an initial flow distribution cloud map, and providing a high-resolution, high-frequency data baseline for subsequent adjustments.

[0052] Specifically, the secondary detection mechanism also consists of a high-density array of ultrasonic flow meters, located at the lip 10 of the die head 1, and very close to the outlet of the lip 10 (the distance is typically ≤20mm). It measures the state of the slurry (flow rate and lip thickness) before it leaves the lip 10 after all adjustments, and the data directly corresponds to the slurry morphology to be coated onto the substrate. The secondary detection can correct residual systematic errors that could not be eliminated in the primary closed loop due to primary sensor drift, actuator mechanical hysteresis, or time-varying fluid characteristics.

[0053] Specifically, the electric actuator 5 of the actuation component can be activated within 2ms after receiving a command, precisely controlling the depth to which the flow-blocking block 6 extends into the first slit 11 with a resolution of 0.1μm. Through micrometer-level depth variations, the flow cross-sectional area and flow resistance of the first slit 11 at that point can be locally and independently altered. For example, when the flow rate at a certain point is too high, the corresponding flow-blocking block 6 is slightly recessed, increasing local resistance and causing the flow rate to decrease; conversely, the same applies. This precise "point-to-point" fine-tuning is the physical basis for achieving high lateral consistency (COV < 0.15).

[0054] Specifically, the control unit includes an embedded real-time multi-axis motion controller and an adaptive predictive closed-loop algorithm running on it. The controller is directly integrated into the electrical box on the side of the mold head 1, and communicates with all sensors, actuators, and the host computer via a high-speed fieldbus (such as EtherCAT). It achieves a total cycle time of ≤50ms from signal acquisition and calculation to drive execution ("sensing-decision-execution"). Its algorithm can predict the adjustment amount based on first-level detection data and iteratively optimize based on second-level detection feedback, avoiding overshoot oscillations and ensuring the system quickly converges to a stable state.

[0055] Based on the specific features described above, the automatic closed-loop workflow of this embodiment is as follows: Step 1. The slurry enters the cavity and is distributed sequentially from the feed cavity 13 and the second slit 12 to the discharge cavity 14. As it flows through the second slit 12, the initial flow data of hundreds of points across the entire width is instantly captured by the high-density flow meter matrix of the primary detection mechanism.

[0056] Step 2. The controller compares the initial flow data with the preset target curve and calculates the deviation vector. Then, the algorithm calculates the required compensation displacement for each flow obstruction block 6 and drives the corresponding servo electric actuator 5 to execute it. This process is completed within 20ms, performing the first active correction to the initial distribution.

[0057] Step 3. Before the corrected slurry flows to the lip 10, the final state data is captured by the secondary detection mechanism (ultrasonic sensor).

[0058] Step 4. The controller calculates the residual between the final state data and the preset target curve. If the residual is less than the set threshold (e.g., corresponding to COV < 0.1%), the first-level regulation is considered successful, and the system enters steady-state maintenance mode.

[0059] Step 5. If the residual exceeds the threshold, initiate a second refinement. This step ensures the closed loop of the core logic that "a lip opening of 10 is acceptable".

[0060] Step 6. At the same time, the controller, based on the total flow rate summarized by the first-level detection, forms a flow closed loop with the feeding gear pump, and stabilizes the total inlet pressure by fine-tuning the pump speed, thus eliminating longitudinal fluctuations.

[0061] The dual-level detection achieves a qualitative leap from "open-loop adjustment" to "closed-loop verification," moving the quality control point forward to the physical source. Theoretically, this can minimize the scrap rate caused by the lag in mold head 1 adjustment and ensure that the CPK throughout the entire production process is greater than 1.67. The high-density execution components achieve "pixel-level" precise control in the lateral direction, providing hardware assurance for achieving extremely high lateral consistency (COV < 0.15).

[0062] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some changes or modifications to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present invention. Any simple modifications, equivalent changes, and modifications made to the above embodiments based on the present invention without departing from the scope of the present invention are within the scope of the present invention.

Claims

1. A high-precision, self-adjusting, self-testing, fully automatic intelligent closed-loop die head (1), wherein a first slit (11) is provided inside the die head (1), and a lip (10) for slurry to flow out of the first slit (11) is provided on one side of the die head (1), and one end of the first slit (11) away from the lip (10) is connected to an external feed pipe through a cavity; characterized in that: The mold head (1) is provided with an adjustment module and a detection module. The detection module includes a primary detection mechanism and a secondary detection mechanism. The secondary detection mechanism is located at the lip (10). The primary detection mechanism includes a barrier (2) and several primary detection units (3). The barrier (2) is installed in the cavity and divides the cavity into a feeding chamber (13) and a discharging chamber (14). The feeding chamber (13) is connected to an external feeding pipe, and the discharging chamber (14) is connected to the first slit (11). A second slit (12) for connecting the feeding chamber (13) and the discharging chamber (14) is formed between the lower end of the barrier (2) and the inner side of the cavity. Along the length of the second slit (12), several primary detection units (3) are arranged sequentially on the second slit (12). The adjustment module adjusts the slurry flow rate of the first slit (11) in response to the flow detection signals issued by the primary and secondary detection mechanisms.

2. The high-precision self-adjusting and self-testing fully automatic intelligent closed-loop mold head (1) according to claim 1, characterized in that: The primary detection unit (3) is a bridge flow meter. The primary detection unit (3) includes an electrode plate A located at the end of the barrier (2) and an electrode plate B located on one side of the second slit (12). The electrode plate A and the electrode plate B are arranged opposite each other. The electrode plate A is connected to the positive and negative poles of the external power supply as the input terminal of the bridge signal, and the electrode plate B is the output terminal of the bridge signal.

3. The high-precision self-adjusting and self-testing fully automatic intelligent closed-loop mold head (1) according to claim 1, characterized in that: The adjustment module includes multiple execution components, which are arranged sequentially on the lip (10).

4. The high-precision self-adjusting and self-testing fully automatic intelligent closed-loop mold head (1) according to claim 3, characterized in that: The actuation component includes an electric push rod (5) and a flow-blocking block (6), the flow-blocking block (6) being mounted on the output end of the electric push rod (5), and the electric push rod (5) being mounted on the mold head (1).

5. The high-precision self-adjusting and self-testing fully automatic intelligent closed-loop mold head (1) according to claim 3, characterized in that: Multiple primary detection units (3) and multiple execution components are arranged side by side along the length direction of the lip (10) and are set in corresponding positions. The execution components adjust the slurry flow rate at the corresponding position in the first slit (11) in response to the flow detection signal issued by the primary detection unit (3) corresponding to the position.

6. The high-precision self-adjusting and self-testing fully automatic intelligent closed-loop mold head (1) according to claim 3, characterized in that: The secondary detection mechanism includes multiple secondary detection units (4), which are arranged sequentially along the length of the lip (10) at the lip (10). Each secondary detection unit (4) corresponds to one or more execution components.

7. The high-precision self-adjusting and self-testing fully automatic intelligent closed-loop mold head (1) according to claim 6, characterized in that: The secondary detection unit (4) is an ultrasonic flow meter.

8. The high-precision self-adjusting and self-testing fully automatic intelligent closed-loop mold head (1) according to claim 1, characterized in that: The mold head (1) includes an upper mold (15) and a lower mold (16). A gasket (7) is provided between the upper mold (15) and the lower mold (16). The gasket (7) is installed in the upper mold (15) through a flow buffer (8). The flow buffer (8) is provided in the cavity. The barrier (2) is installed on the flow buffer (8).

9. The high-precision self-adjusting and self-testing fully automatic intelligent closed-loop mold head (1) according to claim 8, characterized in that: Both ends of the slow-flow block (8) are arc-shaped convex surfaces.

Images