Paper thickness sensing self-adaptive pressure control data processing method and system

Abstract

This application provides a paper thickness sensing adaptive pressure control data processing method and system. The method includes: acquiring thickness sensing data, conveying status data, and pressure zone operation data during the paper conveying process to generate a paper thickness sensing data package; performing periodic error compensation, drift compensation, and disturbance separation on the paper thickness sensing data package to generate a reliable thickness sequence with a reliability identifier; mapping the reliable thickness sequence to a paper coordinate-based thickness status diagram; identifying the paper material compression response and pressure zone contact state based on the paper coordinate-based thickness status diagram, pressure zone operation data, and historical pressure feedback data; generating an adaptive pressure control parameter set including pressure target, timing advance, and execution constraints; and aligning the adaptive pressure control parameter set with the pressure zone arrival timing according to the conveying status data to generate pressure control execution data for the pressure actuator. This application can improve the reliability of thickness recognition, enhance pressure control synchronization, and improve feedback calibration accuracy.

Description

Technical Field

[0001] This application relates to the field of paper processing equipment control technology, and in particular to a paper thickness sensing adaptive pressure control data processing method and system. Background Technology

[0002] Paper thickness detection and pressure control are widely used in paper processing equipment such as printing, laminating, compounding, creasing, cutting, and binding. As the requirements for paper processing speed and precision continue to increase, the equipment needs to adjust the pressure of the pressure rollers, pressure plates, or loading mechanisms in a timely manner according to changes in paper thickness to avoid quality problems such as paper slippage, creasing, wrinkles, poor lamination, or misregistration.

[0003] In existing technologies, paper thickness data is typically collected using contact displacement sensors, laser displacement sensors, or capacitive sensors, and the pressure in the pressure zone is adjusted based on a preset thickness pressure curve or manually set parameters. Some devices also incorporate feedback from conveyor speed, pressure roller gap, or actuators to provide simple compensation for the pressure control, adapting to the processing requirements of different paper sizes.

[0004] However, during high-speed conveying, thickness sensing data is easily affected by factors such as pressure roller eccentricity, equipment vibration, sensor drift, paper bounce, and edge warping. Existing technologies struggle to distinguish between actual thickness changes and disturbances caused by factors other than paper thickness variations. Furthermore, different paper materials exhibit varying compression and rebound characteristics during pressure application, making it difficult to accurately adapt pressure control quantities based solely on thickness values. Additionally, the thickness detection location and the pressure zone's application location typically differ in distance, leading to time lag in existing pressure regulation. Moreover, the lack of a closed-loop mechanism to trace post-pressure quality feedback back to the corresponding paper area and update control parameters results in insufficient pressure control accuracy and stability. Summary of the Invention

[0005] In view of this, embodiments of this application provide a paper thickness sensing adaptive pressure control data processing method and system to solve the problems of thickness recognition interference, pressure control adaptation lag, and insufficient feedback calibration in the prior art.

[0006] A first aspect of this application provides a paper thickness sensing adaptive pressure control data processing method, comprising: acquiring thickness sensing data, conveying status data, and pressure zone operation data during paper conveying, and generating a paper thickness sensing data package; performing periodic error compensation, drift compensation, and disturbance separation on the paper thickness sensing data package based on the pressure zone rotation phase, no-load calibration reference, and sensor status, and generating a reliable thickness sequence with a reliability identifier; mapping the reliable thickness sequence to a paper coordinateized thickness state diagram according to the paper movement coordinates and lateral detection position; identifying the paper material compression response and pressure zone contact state based on the paper coordinateized thickness state diagram, pressure zone operation data, and historical pressure feedback data; generating an adaptive pressure control parameter set including pressure target, timing advance, and execution constraints according to the paper coordinateized thickness state diagram, paper material compression response, pressure zone contact state, and target process parameters; aligning the adaptive pressure control parameter set with the pressure zone arrival timing according to the conveying status data, and generating pressure control execution data for the pressure actuator; acquiring post-pressure feedback data, and tracing the post-pressure feedback data back to the corresponding paper movement coordinates, and updating the thickness reference parameters, compression response parameters, and pressure control calibration parameters.

[0007] A second aspect of this application provides a paper thickness sensing adaptive pressure control data processing system, comprising: an acquisition module for acquiring thickness sensing data, conveying status data, and pressure zone operation data during paper conveying, and generating a paper thickness sensing data package; a first generation module for performing periodic error compensation, drift compensation, and disturbance separation on the paper thickness sensing data package based on the pressure zone rotation phase, no-load calibration reference, and sensor status, and generating a reliable thickness sequence with a reliability identifier; a mapping module for mapping the reliable thickness sequence into a paper coordinate-based thickness state diagram according to the paper movement coordinates and lateral detection position; and an identification module for identifying the paper coordinate-based thickness... The system consists of a first module, a second module, and a third module. The first module uses a thickness state diagram, pressing zone operation data, and historical pressure feedback data to identify the paper material compression response and pressing zone contact state. The second module generates an adaptive pressure control parameter set, including pressure targets, timing advances, and execution constraints, based on the paper coordinate-based thickness state diagram, paper material compression response, pressing zone contact state, and target process parameters. The third module aligns the adaptive pressure control parameter set with the pressing zone arrival timing based on the conveying status data, generating pressure control execution data for the pressure actuator. The fourth module acquires post-pressing feedback data and traces it back to the corresponding paper movement coordinates, updating the thickness reference parameters, compression response parameters, and pressure control calibration parameters.

[0008] The above-described technical solutions adopted in the embodiments of this application can achieve the following beneficial effects: By acquiring thickness sensing data, conveying status data, and pressing zone operation data during the paper conveying process, a paper thickness sensing data package is generated. Based on the pressing zone rotation phase, no-load calibration reference, and sensor status, the paper thickness sensing data package undergoes periodic error compensation, drift compensation, and disturbance separation to generate a reliable thickness sequence with a reliability identifier. The reliable thickness sequence is mapped to a paper coordinate-based thickness status diagram according to the paper movement coordinates and lateral detection position. Based on the paper coordinate-based thickness status diagram, pressing zone operation data, and historical pressure feedback data, the paper material compression response and pressing zone contact state are identified. An adaptive pressure control parameter set, including pressure target, timing advance, and execution constraints, is generated based on the paper coordinate-based thickness status diagram, paper material compression response, pressing zone contact state, and target process parameters. The adaptive pressure control parameter set is aligned with the pressing zone arrival timing according to the conveying status data to generate pressure control execution data for the pressure actuator. Post-pressing feedback data is acquired and traced back to the corresponding paper movement coordinates to update the thickness reference parameters, compression response parameters, and pressure control calibration parameters. This application can improve the reliability of thickness identification, enhance pressure control synchronization, and improve feedback calibration accuracy. Attached Figure Description

[0009] To more clearly illustrate the technical solutions in the embodiments of this application, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0010] Figure 1 This is a schematic flowchart of the paper thickness sensing adaptive pressure control data processing method provided in the embodiments of this application; Figure 2 This is a schematic diagram of the paper thickness sensing adaptive pressure control data processing system provided in the embodiments of this application; Figure 3 This is a schematic diagram of the structure of the electronic device provided in the embodiments of this application. Detailed Implementation

[0011] In the following description, specific details such as particular system architectures and techniques are set forth for illustrative purposes and not for limitation, in order to provide a thorough understanding of the embodiments of this application. However, those skilled in the art will understand that this application may also be implemented in other embodiments without these specific details. In other instances, detailed descriptions of well-known systems, apparatuses, circuits, and methods have been omitted so as not to obscure the description of this application with unnecessary detail.

[0012] Existing paper processing equipment typically collects paper thickness data using contact displacement sensors, laser displacement sensors, or capacitive sensors. Based on preset thickness-pressure curves, paper specifications, or manual adjustment experience, it regulates the pressure of pressure rollers, pressure plates, or loading mechanisms. While some equipment can compensate for pressure control by incorporating feedback from conveyor speed, pressure roller gaps, or actuators, its primary control basis remains the thickness values ​​collected by sensors. This makes it difficult to comprehensively address thickness signal disturbances during high-speed conveying, differences in paper material, and lag in pressure zone execution.

[0013] However, in actual paper feeding and processing, thickness sensing data is easily affected by factors such as the rotation phase of the pressure zone, equipment vibration, sensor drift, paper bounce, and edge warping, resulting in the original thickness data not accurately representing the true thickness of the paper. Furthermore, different paper materials exhibit different compression and rebound characteristics during compression, making it difficult to adapt the pressure control quantity solely based on thickness values ​​to the material state and pressure zone contact state. In addition, there is a transmission distance between the thickness detection position and the pressure zone's position; without alignment of pressure zone arrival times, pressure adjustment is prone to lag; and without a post-pressure feedback and backtracking mechanism, it is difficult to promptly correct the thickness reference and pressure control parameters. Therefore, existing technologies suffer from problems such as interference in thickness recognition, lag in pressure control adaptation, and insufficient feedback calibration.

[0014] To address the aforementioned issues, this application provides a paper thickness sensing adaptive pressure control data processing method. This method acquires thickness sensing data, conveying status data, and pressure zone operation data during the paper conveying process, generating a paper thickness sensing data package. Based on the pressure zone rotation phase, no-load calibration reference, and sensor status, the paper thickness sensing data package undergoes periodic error compensation, drift compensation, and disturbance separation to generate a reliable thickness sequence with a reliability identifier. According to the paper movement coordinates and lateral detection position, the reliable thickness sequence is mapped to a paper coordinateized thickness state diagram, thereby associating the thickness state with the paper's spatial position and the pressure zone arrival time.

[0015] Furthermore, this application identifies the paper material compression response and pressing zone contact state based on the paper coordinate-based thickness state diagram, pressing zone operation data, and historical pressure feedback data. Then, combined with target process parameters, it generates an adaptive pressure control parameter set containing pressure targets, timing advances, and execution constraints. The adaptive pressure control parameter set is then aligned with the pressing zone arrival timing based on the conveying status data to generate pressure control execution data for the pressure actuator. After the paper passes through the pressing zone, this application also acquires post-pressing feedback data and traces it back to the corresponding paper movement coordinates to update the thickness reference parameters, compression response parameters, and pressure control calibration parameters.

[0016] Through the above technical solutions, this application can identify and suppress non-paper thickness disturbances in thickness sensing data, thereby improving the reliability of thickness recognition; it can generate adaptive pressure control parameters by combining the paper material compression response and the contact state of the pressure zone, thereby improving the adaptability of pressure control to the actual state of the paper; it can issue pressure control execution data in advance according to the paper movement coordinates and the arrival sequence of the pressure zone, thereby improving the synchronization of pressure control; and it can also perform closed-loop updates of relevant parameters through post-pressure feedback data, thereby enhancing the accuracy of feedback calibration and the stability of continuous processing.

[0017] The technical solution of this application will now be described in detail with reference to the accompanying drawings and specific embodiments.

[0018] Figure 1 This is a schematic flowchart of the paper thickness sensing adaptive pressure control data processing method provided in the embodiments of this application. Figure 1 As shown, the method may specifically include: S101: Acquire thickness sensing data, conveying status data, and pressure zone operation data during the paper conveying process, and generate a paper thickness sensing data package. S102, based on the rotation phase of the pressure zone, the no-load calibration reference and the sensor status, performs periodic error compensation, drift compensation and disturbance separation on the paper thickness sensing data package to generate a reliable thickness sequence with a reliability identifier; S103, according to the paper movement coordinates and the lateral detection position, the reliable thickness sequence is mapped into a paper coordinateized thickness state diagram; S104 identifies the paper material compression response and pressure zone contact state based on the paper coordinate thickness state diagram, pressure zone operation data and historical pressure feedback data. S105, Based on the paper coordinate thickness state diagram, paper material compression response, pressure zone contact state and target process parameters, generate an adaptive pressure control parameter set including pressure target, timing advance and execution constraints; S106, Align the arrival time of the pressure zone of the adaptive pressure control parameter set according to the delivery status data, and generate pressure control execution data for the pressure actuator; S107: Obtain post-compression feedback data, trace the post-compression feedback data back to the corresponding paper movement coordinates, and update the thickness reference parameters, compression response parameters, and pressure control calibration parameters.

[0019] In some embodiments, thickness sensing data, conveying status data, and pressure zone operation data during the paper conveying process are acquired to generate a paper thickness sensing data package, including: Thickness sensing data of paper along the conveying direction and the transverse detection direction is collected at the thickness detection position, and the thickness sensing data is time-aligned with the conveying status data and the pressure zone operation data based on the same sampling clock and encoder reference. Based on the aligned transport status data, determine the paper movement coordinates and the arrival time of the pressure zone corresponding to the thickness sampling point; Based on the sensor's effective state, sampling stability state, and data synchronization state, the aligned thickness sensing data is marked with sampling quality. The thickness sensing data, paper movement coordinates, pressing zone arrival time, sampling quality markers, and corresponding pressing zone operation data are associated and encapsulated to generate a paper thickness sensing data package.

[0020] Specifically, the paper processing equipment is a high-speed laminating machine. The thickness detection position is set 120mm upstream of the laminating zone entrance. The thickness detection module uses upper and lower opposing laser displacement detection units, with five detection channels arranged in the transverse width direction of the paper, covering the left edge, left center, center, right center, and right edge areas respectively. The equipment controller uses the output pulses of the spindle encoder as a unified reference. The encoder outputs 2000 pulses per revolution, and the synchronous sampling clock frequency is set to 2kHz. After the paper enters the thickness detection position, each detection channel continuously collects the upper and lower surface displacements. The controller calculates the thickness sensing data of the corresponding channel based on the displacement difference between the two sides and records the sampling time, channel number, and sampling sequence number.

[0021] While acquiring thickness sensing data, the controller reads conveying speed, tension feedback, suction negative pressure, and encoder cumulative pulses from the conveying drive module, and reads the pressure roller rotation phase, pressure roller gap, loading mechanism position, and drive current from the pressure zone control module. To ensure that data from different sources can participate in subsequent processing in the same time sequence, the controller triggers data latching with the encoder reference pulse, writing thickness sensing data, conveying status data, and pressure zone operation data into the same time slice buffer. When the sampling time of a certain thickness sampling point falls between two encoder pulses, the controller interpolates based on the adjacent pulse times to obtain the encoder reference position corresponding to that thickness sampling point, thereby completing time alignment.

[0022] After time alignment, the controller calculates the paper movement coordinates corresponding to the thickness sampling point based on the encoder's cumulative pulses, paper feed speed, and detection position reference. For example, using the moment when the leading edge of the paper passes the thickness detection position as the coordinate zero point, when the cumulative displacement corresponding to a certain sampling point is 85mm, the sampling point is marked as 85mm on the paper length coordinate; simultaneously, the lateral detection position is determined according to the detection channel number. The controller further calculates the estimated time when the sampling point arrives at the pressure zone based on the distance from the thickness detection position to the center of the pressure zone, the current feed speed, and the speed change trend. If the feed speed is 1.2m / s and the detection position is 120mm from the center of the pressure zone, the corresponding thickness area is expected to enter the pressure zone in 100ms; if the feed speed has acceleration or deceleration changes, the speed prediction results of the most recent time slices are used to correct the arrival time of the pressure zone.

[0023] Subsequently, the controller marks the sampling quality of the aligned thickness sensing data. Specifically, it determines the effective state of the sensor based on the sensor echo intensity, detection range status, and self-diagnostic status; it determines the sampling stability state based on continuous sampling difference, adjacent time-slot jitter amplitude, and channel noise level; and it determines the data synchronization state based on the timestamp deviation between the thickness sensing data and the transport status data and pressure zone operation data. When the echo intensity of a certain channel is below the threshold, the sampling difference changes abruptly, and the synchronization deviation exceeds the allowable range, the controller marks the corresponding sampling point as a low-quality sample; when the echo intensity is stable, the sampling difference is continuous, and the synchronization deviation is within the allowable range, the controller marks the corresponding sampling point as a high-quality sample. For intermediate states, the controller retains the thickness value but adds a verification mark to prevent the subsequent pressure control model from directly using low-reliability data as the basis for pressure adjustment.

[0024] Finally, the controller associates and encapsulates the thickness sensing data, paper movement coordinates, lateral detection position, pressing zone arrival time, sampling quality markers, and corresponding pressing zone operation data according to a unified data structure to generate a paper thickness sensing data package. Each data package uses the paper batch number and paper running segment number as indexes and contains multiple thickness sampling records, enabling subsequent periodic error compensation, drift compensation, disturbance separation, and pressing zone timing alignment to call upon the same data base. Through the above embodiments, thickness sampling points can be accurately associated with paper spatial position, pressing zone arrival time, and equipment operating status, improving the traceability of thickness data and the timing accuracy of subsequent adaptive pressure control processing.

[0025] In some embodiments, based on the rotation phase of the pressure zone, the no-load calibration reference, and the sensor state, periodic error compensation, drift compensation, and disturbance separation are performed on the paper thickness sensing data package to generate a reliable thickness sequence with a reliability identifier, including: Based on the rotation phase of the pressure zone, the corresponding periodic error reference is matched from the no-load calibration reference to perform phase compensation on the thickness sensing data in the paper thickness sensing data package. The sensing drift is determined based on the sensor status, and drift compensation is performed on the phase-compensated thickness sensing data. Based on the dynamic consistency between the thickness sensing data after drift compensation and the transport status data, the disturbance component not caused by paper thickness change is separated. Based on the perturbation separation results and sampling quality markers, the thickness confidence level of each thickness sampling point is determined, and a confidence thickness sequence with confidence level identifiers is generated.

[0026] Specifically, the paper processing equipment is a high-speed laminating machine. The thickness detection position is located 120mm upstream of the laminating roller inlet, and the pressing zone is formed by the upper and lower laminating rollers. The equipment pre-collects gap fluctuation data for three rotations of the rollers under no-load conditions, and divides one rotation into 720 phase units according to the encoder phase. The steady-state average of the no-load thickness deviation within each phase unit is taken to form the no-load calibration reference. The no-load calibration reference records the periodic error reference caused by roller eccentricity, bearing clearance, and minor roundness errors of the roller surface. For example, when the encoder phase is around 180°, if the no-load detection value is 0.012mm higher than the reference gap, the periodic error reference corresponding to that phase unit is recorded as 0.012mm.

[0027] During paper operation, the controller reads thickness sensing data, sampling time, paper movement coordinates, pressure zone rotation phase, and sampling quality markers from the paper thickness sensing data package. Based on the pressure zone rotation phase corresponding to each thickness sampling point, it matches the closest periodic error reference in the no-load calibration reference. If the original thickness value of a sampling point is 0.238 mm, and the corresponding periodic error reference for the phase unit is 0.011 mm, the controller subtracts this periodic error component from the original thickness value to obtain a phase-compensated thickness value of 0.227 mm. For sampling points where the phase falls between two phase units, the controller performs interpolation compensation based on the error references of adjacent phase units to avoid discontinuities in thickness compensation caused by phase jumps.

[0028] After phase compensation is completed, the controller determines the sensing drift based on the sensor status. Sensor status can include the sensor head temperature, echo intensity, reference sheet calibration results, and continuous paperless area detection results. For example, if the equipment detects a 0.006mm shift in the paperless area reference gap relative to the initial calibration value during a roll change, and the sensor temperature rises by 4°C, the controller determines the current sensing drift to be 0.005mm based on the temperature drift model and the paperless area calibration results, and performs drift compensation on the phase-compensated thickness sensing data. If multiple consecutive sampling windows in a certain detection channel show a slow, unidirectional shift, while adjacent channels and conveying states do not show corresponding changes, the controller classifies this slow shift as sensing drift and does not treat it as an increase in paper thickness.

[0029] Subsequently, the controller performs disturbance separation based on the dynamic consistency between the drift-compensated thickness sensing data and the conveying status data. Specifically, it generates a stable paper operation characterization based on paper conveying speed, tension fluctuations, adsorption negative pressure, and encoder pulse continuity, and matches local thickness mutations with the stable paper operation characterization. If the thickness value suddenly increases by 0.04 mm within 5 ms, while the conveying speed experiences instantaneous fluctuations and the adsorption negative pressure decreases, the mutation is determined to be related to paper drift or conveying vibration, and the corresponding fluctuation is marked as a disturbance component not caused by changes in paper thickness. If continuous thickening occurs in three adjacent lateral detection channels near the same paper movement coordinate, and the conveying status remains stable, it is retained as a true thickness change. For isolated spikes in a single channel, the controller reduces their reliability by combining spatial consistency of adjacent channels and sampling quality marking.

[0030] When generating a reliable thickness sequence, the controller assigns a thickness reliability to each thickness sampling point based on the residual of periodic error compensation, drift compensation stability, disturbance separation results, and sampling quality markers. For example, if the residual of a sampling point is stable after phase and drift compensation and there are no obvious non-paper disturbances, the reliability is set to high; if the sampling point is in the velocity fluctuation range but the thickness change has spatial continuity, the reliability is set to medium; if the sampling point has weak echoes, large synchronization deviations, and isolated spikes, the reliability is set to low. The controller outputs the compensated thickness values ​​and corresponding reliability markers according to the paper movement coordinate sequence, forming a reliable thickness sequence, which provides input for the subsequent construction of the paper coordinateized thickness state diagram.

[0031] Through the above embodiments, the equipment can distinguish the pressure roller cycle error, sensor drift and conveying disturbance from the thickness sensing data, reduce the impact of mechanical errors and sampling anomalies on thickness judgment, improve the stability and authenticity of the reliable thickness sequence, and enable subsequent adaptive pressure control parameters to be generated based on a more reliable thickness state.

[0032] In some embodiments, based on the dynamic consistency relationship between drift-compensated thickness sensing data and transport status data, the disturbance component not caused by paper thickness variation is separated, including: Generate a paper operation stability profile based on conveying status data; Characterization of local changes in paper movement coordinates based on the extracted thickness sensing data after drift compensation; By matching the local change characterization with the paper operation stability characterization, abnormal fluctuations that are inconsistent with the actual changes in paper thickness can be identified. Based on the persistent state and spatial correlation state of abnormal fluctuations, the disturbance components not caused by changes in paper thickness are determined.

[0033] Specifically, the paper processing equipment is a high-speed laminating device. After completing phase compensation and drift compensation, the controller performs perturbation separation on the thickness sensing data based on the paper movement coordinates. The controller first generates a stable paper operation characterization based on the conveying status data. This characterization is jointly determined by encoder pulse continuity, conveying speed fluctuation amplitude, tension feedback changes, adsorption negative pressure changes, and paper feed offset status.

[0034] For example, within a continuous 20ms sampling window, if the encoder pulse interval deviation is less than 2%, the conveying speed fluctuation is less than 0.03m / s, the tension change is less than 5N, and the adsorption negative pressure change is less than 0.8kPa, the controller marks the window as a stable operating state; when the conveying speed suddenly decreases, the adsorption negative pressure decreases synchronously, and the tension spikes, the window is marked as a disturbance operating state, and the start and end coordinates of the disturbance are recorded.

[0035] Subsequently, the controller extracts the local variation representation of the drift-compensated thickness sensing data along the paper movement coordinates. Specifically, within each lateral detection channel, the average thickness, local slope, abrupt change amplitude, and duration are calculated according to a 5mm length window, and spatial variation characteristics are generated by combining the synchronous changes of adjacent lateral channels. For example, if the thickness in the middle channel increases from 0.205mm to 0.246mm at the 260mm paper length coordinate, with a duration of only 2mm, and no corresponding thickening occurs in the left and right middle channels, then this local variation is represented as a short-term spike in a single channel; if the middle, left, and right middle channels all show similar thickening amplitudes within the range of 260mm to 285mm, then this local variation is represented as continuous lateral thickening.

[0036] The controller matches the representation of local changes with the stable representation of paper operation. If a sudden change in thickness occurs in a stable operating state and has continuous length and lateral correlation on the paper movement coordinate, the change is judged to be more likely to be a true change in paper thickness. For example, when laminated paper has a splice tape, multiple adjacent channels will form a continuous increase in width near the same length coordinate, and the conveying speed, tension, and adsorption negative pressure remain stable; the controller retains this thickening information. If a sudden change in thickness occurs simultaneously with an operating disturbance and manifests as a single channel instantaneous spike or multiple channels irregular fluctuations, the abnormal fluctuation is judged to be related to paper drift, unstable adsorption, or conveying vibration, and is not directly used as a true change in thickness for subsequent pressure control.

[0037] When determining the disturbance components not caused by changes in paper thickness, the controller further analyzes the duration and spatial correlation of abnormal fluctuations. For abnormal fluctuations lasting less than three sampling periods and not spatially continuous with adjacent coordinate units, the controller classifies them as transient sampling disturbances and generates corresponding disturbance components. For abnormal fluctuations lasting longer but synchronized with fluctuations in conveyor speed, tension, or decrease in adsorption negative pressure, the controller classifies them as operating state disturbances and suppresses the thickness value according to the disturbance intensity. For thickness changes with lateral continuity, length continuity, and consistency with the stable operating state, the controller does not separate them as disturbances but retains them as effective thickness changes. Thus, the drift-compensated thickness sensing data is split into effective thickness components and non-paper thickness disturbance components, with added disturbance type, disturbance intensity, and coordinate range.

[0038] Through this embodiment, the device can determine the true source of local thickness changes by combining the paper's operating status, avoiding misjudging conveyor jitter, paper drift, and adsorption abnormalities as paper thickening. At the same time, it retains the true thickness changes such as joints, uneven local coating, and multi-layer superposition, improving the accuracy of the reliable thickness sequence and providing a more stable data foundation for the subsequent generation of paper coordinate thickness state diagrams and adaptive pressure control parameters.

[0039] In some embodiments, mapping a reliable thickness sequence to a paper coordinate-based thickness state map according to the paper movement coordinates and the lateral detection position includes: Based on the paper movement coordinates and the lateral detection position, establish a coordinate index corresponding to the paper's pressing area; The thickness sampling points in the reliable thickness sequence are written into the coordinate cells corresponding to the coordinate indices, and the thickness distribution state is generated based on the thickness continuity relationship between adjacent coordinate cells. Based on the thickness distribution status and confidence level, determine the thickness anomaly status and status confidence level of each coordinate unit; Based on the spatial adjacency relationship between each coordinate unit and the arrival time relationship of the pressure zone, a paper coordinate thickness state diagram is generated.

[0040] Specifically, the paper processing equipment is a high-speed laminating device. After receiving the reliable thickness sequence output from the previous processing stage, the controller uses the moment when the leading edge of the paper passes the thickness detection position as the zero point of the length coordinate and the detection area corresponding to the transverse detection channel as the basis of the width coordinate to establish a two-dimensional coordinate index for the paper's pressing area. The length direction can be divided into continuous coordinate segments of 2mm or 5mm, and the transverse direction can be divided into multiple coordinate zones according to the left edge, left center, center, right center, and right edge. For a piece of paper with a width of 600mm and a length of 500mm, the controller can divide the length direction into 100 coordinate segments and the transverse direction into 5 coordinate zones, thus forming 500 coordinate units. Each coordinate unit corresponds to a pressing area on the paper that is about to enter the pressing zone.

[0041] After the coordinate index is established, the controller writes each thickness sampling point into the corresponding coordinate cell according to the paper movement coordinates and lateral detection position carried by the thickness sampling points in the trusted thickness sequence. If there are multiple sampling points in a coordinate cell, the controller performs weighted fusion of the multiple sampling points according to the trustworthiness identifier to obtain the representative thickness value of the coordinate cell. For example, if the length coordinate is 120mm to 125mm and the lateral middle coordinate band contains 4 sampling points, of which 3 sampling points have high trustworthiness and 1 sampling point has low trustworthiness, the controller increases the fusion weight of the high-trust sampling point and reduces the influence of the low-trust sampling point on the representative thickness value. When a coordinate cell lacks a valid sampling point, the controller completes the cell according to the thickness continuity relationship of adjacent length coordinates and adjacent lateral coordinates, and adds a lower state trustworthiness level to the completion result.

[0042] Subsequently, the controller generates the thickness distribution state based on the thickness continuity relationship between adjacent coordinate units. Specifically, it can calculate the thickness gradient between adjacent coordinate units in the length direction, the thickness difference between adjacent coordinate units in the lateral direction, and the range of continuous thickness variation within local regions.

[0043] For example, if the central coordinate band is consistently 0.035 mm thicker than the normal baseline within the length coordinate range of 200 mm to 235 mm, and the left and right central coordinate bands also show similar thickening, the controller identifies this area as a continuous lateral thickening distribution. If only the left edge coordinate band is thicker than the central band by 0.06 mm in multiple length coordinate segments, and the lateral difference gradually increases as it approaches the edge, the controller identifies this area as an edge-lifting distribution. If the thickness of a certain coordinate unit suddenly increases but the adjacent coordinate units do not show continuous changes, the controller identifies this area as an isolated fluctuating distribution.

[0044] When identifying thickness anomalies, the controller jointly judges the thickness distribution status and the confidence level. For coordinate regions where the thickness value exceeds the process reference range and has continuity in the length direction and lateral spatial correlation, the controller marks it as a valid thickness anomaly. For coordinate regions with large thickness variations but low confidence and weak spatial correlation, the controller marks it as an anomaly to be verified. For coordinate regions where the thickness value is within the reference range and adjacent regions are continuous and stable, the controller marks it as a normal state. The confidence level of the state can be determined by sampling quality, thickness fusion stability, neighborhood consistency, and historical baseline deviation. For example, the joint tape area usually shows multiple lateral coordinate bands thickening synchronously and with a stable continuous length; the controller marks the corresponding coordinate unit as a high-confidence effective thickening. Although the thickness value of local spikes caused by paper drift is high, the neighborhood continuity is poor; the controller marks the corresponding coordinate unit as a low-confidence anomaly to be verified.

[0045] Finally, the controller generates a paper coordinate-based thickness state diagram based on the spatial adjacency relationships between each coordinate unit and the arrival time sequence of the pressing zone. In this state diagram, each coordinate unit serves as a state node, and the node data includes the representative thickness value, thickness distribution state, thickness anomaly state, state confidence level, and expected arrival time of the pressing zone. Spatial adjacency relationships are established between adjacent length coordinate units and adjacent horizontal coordinate units, and temporal relationships are established between coordinate units arriving at the pressing zone one after the other. Through this embodiment, the reliable thickness sequence can be transformed into a structured state diagram with spatial distribution, anomaly states, and arrival time sequence, improving the accuracy of locating thickness anomaly areas and providing a stable data foundation for subsequent zoned pressure control, advance pressure control, and feedback backtracking.

[0046] In some embodiments, based on a paper coordinate thickness state diagram, pressing zone operation data, and historical pressure feedback data, the paper material compression response and pressing zone contact state are identified, including: Extract the thickness state changes and state confidence levels of the area to be compressed from the paper coordinate thickness state map, and correlate them with the pressure execution results in the historical pressure feedback data to generate compression response samples. Based on compression response samples, the thickness compression characteristics and springback characteristics of paper during the compression process are determined, and the paper material compression response is generated. Based on the operating data of the pressure zone and historical pressure feedback data, determine the loading stability and pressure transmission status of the pressure actuator; By matching the paper material compression response with the pressure transmission state, the pressure zone contact state is generated to constrain the adaptive pressure control parameter set.

[0047] Specifically, the paper processing equipment is a high-speed laminating machine, and the paper currently being processed is coated paper. The system has already generated a coordinateized thickness state diagram of the paper based on a reliable thickness sequence. The controller reads the coordinate units that are about to enter the laminating pressing zone from this state diagram, extracts the representative thickness value, thickness gradient, thickness anomaly state, and state reliability level of each coordinate unit, and associates this information with the pressure execution results in the historical pressure feedback data according to the paper movement coordinates.

[0048] For example, the length coordinates from 180mm to 230mm and the middle transverse coordinate zone are marked as a high-confidence continuously thickening region. When entering the compression zone, the corresponding actual loading pressure is 420N, the target displacement of the actuator is 0.18mm, and the thickness is detected to have recovered from 0.245mm to 0.232mm after compression. The controller feeds back the thickness state of this region before compression, the pressure execution result, and the state after compression to form a set of compression response samples.

[0049] When generating compression response samples, the controller prioritizes coordinate regions with high state confidence levels, stable operation of the compression zone, and complete post-compression feedback. If the thickness state of a certain region is of low confidence, or if actuator jitter occurs during pressure execution, the samples in that region are only used as auxiliary samples for statistical analysis and are not directly used to update the core response parameters. For the same batch of paper, the controller can establish sample sets separately for normal thickness regions, locally thickened regions, and edge-lifted regions. For example, in the first 500 sheets of the same roll, the system accumulates 1200 sets of samples from the central region, 800 sets of samples from the edge region, and 60 sets of samples from the locally jointed region, assigning different sample weights to different regions to reflect the compression performance of the paper material under different pressure conditions.

[0050] Subsequently, the controller determines the thickness compression characteristics of the paper during the compression process based on the compression response samples. Specifically, it can calculate the thickness compression amount and compression stability range corresponding to a unit pressure based on the relationship between the representative thickness before compression, the pressure execution result, and the immediate thickness after compression. For example, when the pressure increases from 360N to 420N, the average immediate thickness in the high-confidence region after compression decreases by 0.014mm, and no indentation is detected downstream. In this case, the controller determines that the material has high compression adaptability within this pressure range. When the pressure continues to increase to 480N, the decrease in thickness after compression only increases by 0.003mm, but the probability of surface indentation increases. In this case, the controller marks this range as a high-risk, low-return compression range. This yields the compression sensitivity, compression saturation trend, and compression risk status.

[0051] The rebound characteristics are determined by the thickness recovery trend and quality feedback status after the pressing zone ends. The controller can set a retest position downstream of the pressing zone to collect thickness recovery data at 50ms, 150ms, and 300ms after the paper leaves the pressing zone, and make a judgment based on the lamination status, surface indentation status, and paper feed offset status. For example, if a batch of laminated coated paper recovers 60% of its thickness within 50ms after leaving the pressing zone and recovers to 92% of its pre-press thickness after 300ms, and there are no air bubbles in the lamination layer, the system marks the material as having stable rebound. If the paper thickness recovery is slow and lamination air bubbles appear at the same time, it is determined that the material is not compressibly maintained under the current pressure, and the effective contact pressure needs to be increased or the pressure stability range extended in subsequent pressure control parameters.

[0052] When determining the contact state of the pressure zone, the controller analyzes the loading stability and pressure transmission status of the pressure actuator based on the pressure zone operating data and historical pressure feedback data. Pressure zone operating data can include the pressure roller gap, loading mechanism position, left-right loading difference, drive current, and pressure roller temperature rise. If the actual pressure reaches the target range within 20ms after a change in target pressure, the left-right loading difference is less than 3%, and the drive current changes smoothly, the loading stability is considered high. If the actual pressure lags after a change in target pressure, and the left-right loading difference continues to increase, the pressure transmission status is considered to have a deviation. The controller matches the paper material compression response with the pressure transmission status to generate the pressure zone contact state. For example, for paper areas with high compression sensitivity and stable pressure zone transmission, the pressure zone contact state is set to allow small, rapid adjustments; for paper areas with slow rebound and lagging pressure transmission, the pressure zone contact state is set to limit rapid pressure increases and increase the preload.

[0053] Through the above embodiments, the system can form a material compression response that can be used for pressure control decision-making from the paper coordinate thickness state diagram and historical pressure feedback data. Combined with the real contact constraint of the pressure zone actuator state recognition, the subsequent adaptive pressure control parameters no longer depend solely on the thickness value, but simultaneously adapt to the paper material's pressure characteristics and the pressure transmission capability of the pressure zone, thereby improving the accuracy, stability, and processing adaptability of pressure target generation.

[0054] In some embodiments, based on compression response samples, the thickness compression characteristics and springback characteristics of paper during compression are determined, and a paper material compression response is generated, including: Based on the paper movement coordinates, the thickness state before compression, the pressure execution result, and the post-compression state feedback in the compression response sample are correlated. Based on the corresponding results, the response relationship between pressure change and thickness state change is established to determine the thickness compression characteristics; The springback characteristics are determined based on the thickness recovery trend and quality feedback status after the end of the compression zone action; The compression response of paper material is generated by fusing thickness compression characteristics, springback characteristics, and confidence state.

[0055] Specifically, the paper processing equipment is a high-speed laminating machine, and the current batch being processed is 0.23mm laminated coated paper. The controller generates a coordinate-based thickness state diagram of the paper upstream of the pressing zone, and sets up a retesting unit and a surface quality detection unit downstream of the pressing zone. The controller correlates the pre-compression thickness state, pressure execution result, and post-compression state feedback in the compression response sample according to the paper movement coordinates.

[0056] For example, exemplarily, the thickness of the transverse coordinate zone from 150mm to 180mm before pressure is 0.236mm, with a high confidence level. Upon entering the pressure zone, the actual pressure is 410N, the pressure stabilization time is 35ms, the thickness is measured again after 20ms and again after 200ms, showing 0.224mm and 0.231mm respectively. The surface quality inspection results are no indentations and no bubbles. The controller combines the thickness before pressure, actual pressure, immediate thickness after pressure, recovered thickness, and quality status of this coordinate zone into a valid sample.

[0057] During sample matching, the controller uses the paper movement coordinates and the timing of the compression zone as the primary index to avoid mismatches between pre-compression data and post-compression feedback for different paper regions. If the conveyor speed is 1.2 m / s and the distance from the compression zone to the retest unit is 240 mm, the controller will shift the post-compression retest data back 200 ms to the corresponding paper length coordinates and associate it with the sample record corresponding to the compression zone's action time. For cases where the conveyor speed accelerates or decelerates, the controller corrects the backtracking distance based on the encoder's accumulated pulses, rather than using a fixed time delay. If a sample matching process results in missing post-compression images, excessive pressure fluctuations, or excessively low thickness confidence levels, the controller marks that sample as a low-confidence sample, participating only in trend verification and not directly in the core compression response calculation.

[0058] When establishing the response relationship between pressure changes and thickness state changes, the controller groups samples from the same material batch, the same transverse coordinate zone, and similar thickness states into the same response set and compares the thickness compression under different pressure ranges. For example, when the pressure is 360N, the average immediate thickness reduction after compression is 0.007mm; when the pressure is 410N, the average immediate thickness reduction after compression is 0.012mm; and when the pressure is 470N, the average immediate thickness reduction after compression is 0.015mm, but the risk of indentation increases significantly. Based on this, the controller determines that the material has high compression sensitivity in the 360N to 410N range, and compression benefit decreases in the 410N to 470N range. Compression sensitivity, compression saturation trend, and compression risk boundary are used as thickness compression characteristics. For local joint areas, if the thickness compression under the same pressure is less than that in ordinary areas, the controller further generates rigid thickening compression characteristics for the joint area.

[0059] The rebound characteristics are determined based on the thickness recovery trend and quality feedback status after the compression zone ends. The controller collects and remeasures the thickness at 20ms, 100ms, and 300ms after compression, and calculates the recovery ratio and recovery speed. For example, if the thickness of a certain coordinate area is 0.236mm before compression, 0.224mm after 20ms, and 0.232mm after 300ms, it indicates that the area recovers to about 67% of the compression within 300ms, and there are no air bubbles on the coating surface. The controller marks this as having medium rebound and stable adhesion. If another coordinate area recovers quickly after compression, but air bubbles appear at the edge of the coating, the controller judges that although the thickness recovery in this area is sufficient, the effective contact retention is insufficient, and the pressure holding time needs to be increased in subsequent pressure control. If the thickness recovery is slow and indentations appear on the surface, it is judged that the pressure is too strong or the material surface is highly sensitive to damage.

[0060] Subsequently, the controller fuses the thickness compression features, springback features, and their confidence levels to generate the paper material compression response. During fusion, the compression sensitivity and springback speed corresponding to high-confidence samples are given higher weights, while low-confidence samples are only used to limit the magnitude of anomaly updates. The paper material compression response can include pressure compression mapping relationships, springback speed levels, compression saturation boundaries, and quality risk boundaries, and is stored separately according to material batch, lateral coordinate zone, and thickness anomaly type. For example, the recommended pressure adjustment sensitivity is 0.8 for the normal central region, the edge-lifted region corresponds to a higher risk of insufficient springback, and the joint thickening region corresponds to a lower upper limit for pressure increment.

[0061] Through the above embodiments, the system can correspond the pre-press thickness state, pressure execution result and post-press feedback state under the same paper movement coordinate, accurately identify the compression and rebound patterns of different paper regions, so that the paper material compression response can reflect the real pressure behavior, and improve the material adaptability and post-press quality stability of the adaptive pressure control parameters.

[0062] In some embodiments, an adaptive pressure control parameter set, including a pressure target, timing advance, and execution constraints, is generated based on the paper coordinate thickness state diagram, paper material compression response, pressure zone contact state, and target process parameters. Determine the reference pressure control range corresponding to the pressure-to-press area based on the target process parameters; Based on the thickness state changes and state confidence levels in the paper coordinate thickness state diagram, generate thickness compensation parameters corresponding to the paper movement coordinates. Based on the paper material compression response, the thickness compensation parameters are adjusted for material adaptation to generate a pressure target. The response constraints of the pressure actuator are determined based on the contact state of the pressure zone, and the timing advance and execution constraints are generated by combining the arrival time of the pressure zone corresponding to the paper movement coordinate. By associating pressure targets, timing lead times, and execution constraints, an adaptive pressure control parameter set is generated.

[0063] Specifically, the paper processing equipment is a high-speed laminating machine, and the target process parameters are jointly determined by the current laminating work order, paper material file, and pressing zone process formula. The current paper is 0.23mm laminated coated paper, and the target process requirements are stable lamination, no surface indentations, and no edge wrinkles. The controller determines the reference pressure control range corresponding to the area to be pressed based on the process formula. For example, the reference pressure range for the central area is 380N to 430N, the reference pressure range for the edge area is 360N to 410N, and the allowable pressure limit for the thickened joint area is reduced to 420N. The reference pressure control range is also limited by the temperature rise of the pressure roller, the laminating speed, and the maximum response rate of the loading mechanism to prevent the subsequently generated pressure target from exceeding the safe processing boundary.

[0064] The controller reads the coordinate units about to enter the pressing zone from the paper's coordinate-based thickness status diagram, extracts representative thickness values, thickness anomalies, thickness gradients, and status confidence levels, and generates thickness compensation parameters based on the paper's movement coordinates. For example, if the representative thickness of the middle transverse coordinate band between 220mm and 250mm in length coordinates is 0.032mm higher than the current thickness baseline, the status confidence level is high, and adjacent coordinate units form a continuous thickening area, the controller generates positive thickness compensation parameters. If there is an isolated thickness peak in the left edge coordinate band at 300mm in length coordinates, but the status confidence level is low, the controller only generates smaller compensation parameters and adds a conservative adjustment mark. For transversely continuous joint thickening areas, the controller generates area compensation parameters based on the continuous length of the thickening and the transverse coverage width, rather than adjusting the pressure solely based on the maximum thickness value at a single point.

[0065] When generating the pressure target, the controller uses the paper material compression response to adjust the thickness compensation parameters for material adaptation. If the current batch of paper has high compression sensitivity in the 380N to 430N range, and the compression benefit decreases and indentation risk increases beyond 450N, the controller limits the pressure compensation for high-confidence thickened areas. For example, if the initial calculation based on the thickness increment requires an increase of 35N, but the paper material compression response indicates that only an increase of 24N is needed to achieve stable bonding in the current pressure range, the pressure target is adjusted from 400N to 424N. For edge-lifted areas, if the springback characteristics show that the edge area recovers quickly and is prone to warping, the controller increases the pressure in the corresponding edge zone while limiting the synchronous pressure increase in the central area to avoid over-pressure on the entire sheet. For joint-thickened areas, if the compression response shows high rigidity, the controller can appropriately increase the pressure target, but at the same time set a gentler pressure change slope.

[0066] The controller further determines the response constraints of the pressure actuator based on the contact state of the pressure zone. The contact state of the pressure zone records loading stability, pressure transmission delay, left-right loading difference, and allowable pressure variation range. For example, the current actual pressure in the pressure zone takes an average of 28ms to reach the target pressure, the allowable range for the left-right loading difference is within 3%, and the upper limit of the pressure rise slope is 12N / ms. The controller generates a timing advance based on the arrival time of the pressure zone corresponding to the paper movement coordinates.

[0067] In some examples, if a certain coordinate region is expected to reach the pressure zone in 100ms, the pressure actuator has a response delay of 28ms and reserves 8ms for stabilization time, then the pressure control action corresponding to that region is triggered 36ms in advance. If the pressure zone contact status indicates a loading lag, the controller increases the timing advance and reduces the pressure change slope; if the loading is stable and the thickness is abnormally continuous, a shorter advance and continuous pressure following are allowed.

[0068] Finally, the controller correlates the pressure target, timing advance, and execution constraints according to the paper movement coordinates to generate an adaptive pressure control parameter set. Each parameter unit corresponds to one or more paper coordinate units, and the data content includes the target pressure value, zone effective range, trigger advance time, pressure change slope, loading limit, left and right balance constraints, and low confidence degradation flag. For example, the continuous thickening area in the middle corresponds to a pressure target of 424N, an advance of 36ms, and a slope limit of 10N / ms; the low confidence peak area on the left edge corresponds to a pressure target of 385N, an advance of 30ms, and a degradation adjustment flag; the thickening area at the joint corresponds to a pressure target of 438N, an advance of 42ms, and a pressure holding time of 45ms. Through this embodiment, the system can unify the thickness status, material compression characteristics, and pressure zone execution capability into directly quantifiable pressure control parameters, improving the material adaptability, timing synchronization, and execution safety of the pressure target, and reducing the probability of processing anomalies such as indentation, slippage, and wrinkles.

[0069] In some embodiments, the adaptive pressure control parameter set is aligned with the pressure zone arrival time based on the delivery status data to generate pressure control execution data for the pressure actuator, including: Based on the conveying status data, determine the paper moving speed and the conveying distance from the thickness detection position to the pressure zone position, and calculate the arrival time of the pressure zone corresponding to each paper moving coordinate; Based on the arrival time of the pressure zone and the timing advance in the adaptive pressure control parameter set, the pressure control trigger time is generated; According to the pressure control trigger time, the pressure target and corresponding execution constraints in the adaptive pressure control parameter set are written into the pressure control queue; Based on the response status of the pressure actuator, the pressure targets in the pressure control queue are continuously corrected to generate pressure control execution data that matches the timing of the pressure zone action.

[0070] Specifically, the paper processing equipment is a high-speed laminating machine. The thickness detection position is set 120mm upstream of the laminating pressure zone inlet, and the pressure zone's action position is located at the contact center of the upper and lower laminating pressure rollers. After generating an adaptive pressure control parameter set, the controller reads the current conveying speed, encoder cumulative pulses, speed change trend, and paper leading edge position from the conveying status data. Based on the conveying distance from the thickness detection position to the pressure zone's action position, it calculates the pressure zone arrival time corresponding to each paper movement coordinate.

[0071] For example, if a coordinate unit corresponds to a length coordinate of 240mm, the current conveying speed is 1.2m / s, and the distance from the detection position to the pressure zone is 120mm, the controller determines that the coordinate unit will reach the pressure zone in 100ms based on the cumulative displacement of the encoder. If the conveying speed is detected to have decreased from 1.2m / s to 1.1m / s in the last 30ms, the controller will recalculate the arrival time of the pressure zone using the speed prediction result to avoid triggering deviation caused by the fixed speed assumption.

[0072] After determining the arrival time of the pressure zone, the controller reads the timing advance from the adaptive pressure control parameter set and generates the corresponding pressure control trigger time. The timing advance can be determined by the response delay of the pressure actuator, the pressure stabilization time, and the contact state of the pressure zone. For example, if the average response delay of the pressure actuator in the continuously thickened central region is 26ms and the pressure stabilization time is 8ms, the controller sets the timing advance to 34ms; if the loading mechanism at the left edge has a slight lag, the controller corrects the timing advance for the corresponding edge region to 42ms. For the thickened central region expected to enter the pressure zone in 100ms, the pressure control trigger time is 66ms after the current time; for the raised left edge region expected to enter the pressure zone in 90ms, the pressure control trigger time is 48ms after the current time.

[0073] Subsequently, the controller writes the pressure target and corresponding execution constraints from the adaptive pressure control parameter set into the pressure control queue according to the pressure control trigger time. The pressure control queue is sorted according to the trigger time, and independent queues are established for different horizontal zones. For example, the continuously thickened area in the central coordinate zone corresponds to a pressure target of 424N, a pressure rise slope upper limit of 10N / ms, and a pressure holding time of 40ms; the low-confidence spike area in the left edge coordinate zone corresponds to a pressure target of 385N, a pressure rise slope upper limit of 6N / ms, and a degradation adjustment mark; the thickened area at the joint corresponds to a pressure target of 438N, a pressure holding time of 45ms, and a left-right balance constraint of 3%. When the trigger times of multiple coordinate zones are close, the controller merges adjacent control segments according to spatial adjacency and pressure continuity to avoid frequent reciprocating adjustments of the pressure actuator.

[0074] Before generating pressure control execution data, the controller continuously corrects the pressure targets in the pressure control queue based on the response status of the pressure actuator. The response status can include the actual loading position, current pressure feedback, servo valve opening, drive current, and pressure change in the previous control cycle. If the pressure target difference between two adjacent control segments is large, but the paper coordinate area is spatially continuous, the controller inserts transition control points according to the allowable pressure change slope to smooth the pressure curve. For example, if the target pressure of the previous control segment is 390N and the target pressure of the next control segment is 438N, and the upper limit of the pressure rise slope is 10N / ms, the controller will break the pressure increase process into multiple continuous control points and ensure that the target pressure stabilizes before reaching the pressure zone in the joint area. If the actual pressure of the actuator lags behind the queue target, the controller releases the trigger signal of the next control segment in advance based on the lag, or reduces the subsequent pressure change slope to avoid overpressure caused by catch-up loading.

[0075] For low-confidence thickness regions, the controller performs conservative processing during continuous correction. For example, if a single-point thickness anomaly corresponds to a short-term increase in the pressure target, but adjacent coordinate regions are in a normal state, the controller will not immediately output a sudden pressure change. Instead, it will limit the target to near the reference pressure range and retain the observation mark. For high-confidence continuously thickening regions, the controller allows the pressure target to enter the stable section in advance according to the timing lead, so that when the paper thickening area enters the pressure zone, the actual pressure has already matched the target pressure. Finally, the controller outputs pressure control execution data, including execution zone, trigger time, target pressure, target displacement, change slope, hold duration, and safety boundary, and sends it to the corresponding pressure actuator.

[0076] Through the above embodiments, the adaptive pressure control parameter set can be precisely aligned with the actual paper conveying state and the timing of the pressure zone action, so that the pressure actuator can complete preloading and stable control before the target paper area enters the pressure zone, reducing pressure control deviations caused by changes in conveying distance, speed and execution lag, and improving the synchronization of pressure regulation and the stability of continuous processing.

[0077] In some embodiments, post-compression feedback data is acquired and traced back to the corresponding paper movement coordinates to update the thickness reference parameters, compression response parameters, and pressure control calibration parameters, including: Collect quality inspection data and pressure execution feedback of the paper after it passes through the pressing zone, and generate post-pressing feedback data; Based on the timing of the pressure zone action and the paper movement coordinates, the post-pressure feedback data is associated with the corresponding coordinate units and pressure control execution data; Based on the correlation results, thickness identification deviation, compression response deviation, and pressure control execution deviation are determined. Update the corresponding thickness reference parameters, compression response parameters, and pressure control calibration parameters according to the reliability of each deviation.

[0078] Specifically, the paper processing equipment is a high-speed laminating machine. After the paper passes through the laminating pressing zone, the controller synchronously acquires post-pressing feedback data from the downstream quality detection unit and the pressure execution feedback unit. The downstream quality detection unit can be set 300mm behind the pressing zone and uses a line scan camera, a re-measurement thickness sensor, and a paper feed offset detector to detect indentations on the paper surface, laminating bubbles, edge wrinkles, post-pressing thickness recovery, and lateral offset.

[0079] The pressure execution feedback unit reads the actual pressure, target pressure, executed displacement, servo valve opening, drive current, and pressure settling time from the loading mechanism. The controller aligns the quality detection data and pressure execution feedback with the same encoder reference to generate post-pressure feedback data. For example, if slight bubbles appear in the post-pressure image in the lateral coordinate band from 260mm to 285mm on the length coordinate, the actual pressure is 412N, the target pressure is 424N, and the pressure settling time is only 18ms, the controller marks this area as insufficient fit feedback.

[0080] During the backtracking correlation, the controller correlates the post-pressing feedback data with the corresponding coordinate units and pressure control execution data based on the pressing zone action timing, paper movement coordinates, and encoder cumulative pulses. If the distance from the pressing zone to the linear scan camera is 300mm and the current conveying speed is 1.2m / s, then a detection point in the post-pressing image corresponds to the paper area that passed through the pressing zone approximately 250ms ago. When there are fluctuations in the conveying speed, the controller does not use fixed-time backtracking but determines the true backtracking coordinates based on the encoder's cumulative displacement. For the remeasured thickness data, the controller also correlates the post-pressing thickness recovery state with the coordinate units in the paper coordinateized thickness state diagram according to the distance from the detection point to the pressing zone and the encoder pulses, and simultaneously retrieves the pre-pressing thickness, state confidence level, pressure target, timing advance, and execution constraints of that coordinate unit.

[0081] After the association is completed, the controller determines different types of deviations based on the pre-compression thickness status, pressure control execution data, and post-compression feedback results. If a coordinate unit is identified as having high-confidence thickening before compression, but the post-compression thickness retest and image quality show that the area has not actually formed continuous thickening, and the adjacent areas are all normal, then a thickness identification deviation is determined to exist. If the pre-compression thickness identification is accurate and the pressure target is executed as planned, but insufficient adhesion or air bubbles still appear after compression, then a compression response deviation is determined to exist, indicating that the current paper material compression response has underestimated the pressure requirement for this area. If the pressure target is 424N, the actual pressure only reaches 412N, and the pressure stabilization time is shorter than the execution constraint requirement, then a pressure control execution deviation is determined to exist. For indentation feedback, the controller also determines whether the indentation is related to excessive pressure, false triggering of low-confidence thickness spikes, or edge pressure imbalance, in order to avoid mixing different anomalies into the same parameter update process.

[0082] When updating parameters, the controller first determines the credibility status of each deviation. Credibility status can be determined based on the integrity of post-compression detection, the credibility level of the pre-compression state, the stability of execution feedback, and the recurrence of deviations across multiple sheets. If 30 consecutive sheets from the same batch exhibit the same insufficient bonding in similar coordinate areas, and the execution feedback is stable, the compression response deviation is marked as high credibility. If the anomaly only occurs in a single sheet, and image detection is obstructed or the sampling quality is low, the corresponding deviation is marked as low credibility. For high-credibility thickness recognition deviations, the controller updates the thickness baseline parameters, such as adjusting the thickness baseline or credibility judgment threshold of the corresponding transverse channel. For high-credibility compression response deviations, the controller updates the compression response parameters, such as increasing the pressure compensation coefficient or extending the pressure holding time under the same material and thickness conditions. For high-credibility pressure control execution deviations, the controller updates the pressure control calibration parameters, such as correcting the actuator response delay, pressure transmission gain, and pressure change slope limit. For low-credibility deviations, the controller only records them as observation samples and does not immediately change the core parameters to avoid model drift caused by occasional detection anomalies.

[0083] Through the above embodiments, the post-press quality inspection results and pressure execution feedback can be accurately traced back to the corresponding paper movement coordinates, forming a closed-loop correlation with the pre-press thickness status and pressure control execution data. This processing can distinguish between thickness identification errors, material response estimation errors, and pressure execution errors, improving the update accuracy of thickness reference parameters, compression response parameters, and pressure control calibration parameters, thereby enhancing the pressure control stability and processing quality consistency of subsequent batches.

[0084] The following are system embodiments of this application, which can be used to execute the method embodiments of this application. For details not disclosed in the system embodiments of this application, please refer to the method embodiments of this application.

[0085] Figure 2 This is a schematic diagram of the paper thickness sensing adaptive pressure control data processing system provided in an embodiment of this application. Figure 2 As shown, the system includes: The acquisition module 201 is used to acquire thickness sensing data, conveying status data and pressure zone operation data during the paper conveying process, and generate paper thickness sensing data package; The first generation module 202 is used to perform periodic error compensation, drift compensation and disturbance separation on the paper thickness sensing data packet based on the pressure zone rotation phase, no-load calibration reference and sensor status, and generate a reliable thickness sequence with a reliability identifier. The mapping module 203 is used to map the reliable thickness sequence into a paper coordinate-based thickness state diagram according to the paper movement coordinates and the lateral detection position. The identification module 204 is used to identify the paper material compression response and the contact state of the pressure zone based on the paper coordinate thickness state diagram, the pressure zone operation data and historical pressure feedback data. The second generation module 205 is used to generate an adaptive pressure control parameter set containing pressure target, timing advance and execution constraints based on the paper coordinate thickness state diagram, paper material compression response, pressure zone contact state and target process parameters. Alignment module 206 is used to align the arrival time of the pressure zone of the adaptive pressure control parameter set according to the delivery status data, and generate pressure control execution data for the pressure actuator. The update module 207 is used to acquire post-compression feedback data and trace the post-compression feedback data back to the corresponding paper movement coordinates to update the thickness reference parameters, compression response parameters, and pressure control calibration parameters.

[0086] In some embodiments, Figure 2The acquisition module 201 collects thickness sensing data of the paper along the conveying direction and the transverse detection direction at the thickness detection position, and aligns the thickness sensing data with the conveying status data and the pressing zone operation data based on the same sampling clock and encoder reference. According to the aligned conveying status data, the paper movement coordinates and pressing zone arrival time corresponding to the thickness sampling point are determined. According to the sensor effective state, sampling stable state and data synchronization state, the aligned thickness sensing data is marked with sampling quality. The thickness sensing data, paper movement coordinates, pressing zone arrival time, sampling quality mark and corresponding pressing zone operation data are associated and encapsulated to generate a paper thickness sensing data package.

[0087] In some embodiments, Figure 2 The first generation module 202 matches the corresponding periodic error reference from the no-load calibration reference according to the rotation phase of the pressure zone, and performs phase compensation on the thickness sensing data in the paper thickness sensing data package; determines the sensing drift amount according to the sensor state, and performs drift compensation on the phase-compensated thickness sensing data; based on the dynamic consistency relationship between the drift-compensated thickness sensing data and the transport status data, separates the disturbance components not caused by changes in paper thickness; and determines the thickness confidence of each thickness sampling point according to the disturbance separation result and the sampling quality mark, and generates a reliable thickness sequence with confidence mark.

[0088] In some embodiments, Figure 2 The first generation module 202 generates a stable paper running characterization based on the conveying status data; extracts the local change characterization of the thickness sensing data after drift compensation on the paper movement coordinates; performs consistency matching between the local change characterization and the stable paper running characterization to identify abnormal fluctuations that are inconsistent with the actual paper thickness change; and determines the disturbance components not caused by the paper thickness change based on the continuous state and spatial correlation state of the abnormal fluctuations.

[0089] In some embodiments, Figure 2 The mapping module 203 establishes a coordinate index corresponding to the paper's pressing area based on the paper's movement coordinates and lateral detection position; writes the thickness sampling points in the reliable thickness sequence into the coordinate units corresponding to the coordinate index, and generates a thickness distribution state based on the thickness continuity relationship between adjacent coordinate units; determines the thickness anomaly state and state reliability level of each coordinate unit based on the thickness distribution state and reliability identifier; and generates a paper coordinateized thickness state diagram based on the spatial adjacency relationship between each coordinate unit and the timing relationship of the pressing area arrival.

[0090] In some embodiments, Figure 2The identification module 204 extracts the thickness state change and state confidence level of the area to be compressed from the paper coordinate thickness state map, and correlates it with the pressure execution results in the historical pressure feedback data to generate a compression response sample; based on the compression response sample, it determines the thickness compression characteristics and rebound characteristics of the paper during the compression process and generates the paper material compression response; according to the compression zone operation data and historical pressure feedback data, it determines the loading stability and pressure transmission state of the pressure actuator; and it matches the paper material compression response with the pressure transmission state to generate the compression zone contact state used to constrain the adaptive pressure control parameter set.

[0091] In some embodiments, Figure 2 The second generation module 205 determines the reference pressure control range corresponding to the area to be pressed based on the target process parameters; generates thickness compensation parameters corresponding to the paper movement coordinates based on the thickness state changes and state confidence levels in the paper coordinate thickness state diagram; performs material adaptation correction on the thickness compensation parameters based on the paper material compression response to generate a pressure target; determines the response constraints of the pressure actuator based on the contact state of the pressing zone, and generates timing advance and execution constraints in combination with the arrival time of the pressing zone corresponding to the paper movement coordinates; and associates the pressure target, timing advance, and execution constraints to generate an adaptive pressure control parameter set.

[0092] In some embodiments, Figure 2 The alignment module 206 determines the paper movement speed and the transmission distance from the thickness detection position to the pressure zone's action position based on the conveying status data, and calculates the pressure zone arrival time corresponding to each paper movement coordinate; based on the pressure zone arrival time and the timing advance in the adaptive pressure control parameter set, it generates the pressure control trigger time; according to the pressure control trigger time, it writes the pressure target and corresponding execution constraints in the adaptive pressure control parameter set into the pressure control queue; based on the response status of the pressure actuator, it continuously corrects the pressure target in the pressure control queue, and generates pressure control execution data that matches the pressure zone's action timing.

[0093] In some embodiments, Figure 2 The update module 207 collects the quality inspection data and pressure execution feedback of the paper after it passes through the pressing zone, and generates post-pressing feedback data; according to the pressing zone action sequence and paper movement coordinates, it associates the post-pressing feedback data with the corresponding coordinate units and pressure control execution data; based on the association results, it determines the thickness identification deviation, compression response deviation and pressure control execution deviation; according to the credibility status of each deviation, it updates the corresponding thickness reference parameters, compression response parameters and pressure control calibration parameters.

[0094] It should be understood that the sequence number of each step in the above embodiments does not imply the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of this application.

[0095] Figure 3 This is a schematic diagram of the electronic device 3 provided in an embodiment of this application. Figure 3 As shown, the electronic device 3 of this embodiment includes: a processor 301, a memory 302, and a computer program 303 stored in the memory 302 and executable on the processor 301. When the processor 301 executes the computer program 303, it implements the steps in the various method embodiments described above. Alternatively, when the processor 301 executes the computer program 303, it implements the functions of each module / unit in the various system embodiments described above.

[0096] Electronic device 3 can be a desktop computer, laptop, handheld computer, cloud server, or other electronic device. Electronic device 3 may include, but is not limited to, processor 301 and memory 302. Those skilled in the art will understand that... Figure 3 This is merely an example of electronic device 3 and does not constitute a limitation on electronic device 3. It may include more or fewer components than shown, or different components.

[0097] The processor 301 may be a central processing unit (CPU), or other general-purpose processors, digital signal processors (DSPs), application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc.

[0098] The memory 302 can be an internal storage unit of the electronic device 3, such as a hard disk or memory of the electronic device 3. The memory 302 can also be an external storage device of the electronic device 3, such as a plug-in hard disk, smart media card (SMC), secure digital (SD) card, flash card, etc., equipped on the electronic device 3. The memory 302 can also include both internal and external storage units of the electronic device 3. The memory 302 is used to store computer programs and other programs and data required by the electronic device.

[0099] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the above-described division of functional units and modules is merely an example. In practical applications, the above functions can be assigned to different functional units and modules as needed, that is, the internal structure of the system can be divided into different functional units or modules to complete all or part of the functions described above. The functional units and modules in the embodiments can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The integrated unit can be implemented in hardware or as a software functional unit.

[0100] If integrated modules / units are implemented as software functional units and sold or used as independent products, they can be stored in a readable storage medium (e.g., a computer-readable storage medium). Based on this understanding, all or part of the processes in the methods of the above embodiments can also be implemented by a computer program instructing related hardware. The computer program can be stored in a computer-readable storage medium, and when executed by a processor, it can implement the steps of the various method embodiments described above. The computer program may include computer program code, which may be in the form of source code, object code, executable files, or certain intermediate forms. The computer-readable storage medium may include: any entity or device capable of carrying computer program code, recording media, USB flash drives, portable hard drives, magnetic disks, optical disks, computer memory, read-only memory (ROM), random access memory (RAM), electrical carrier signals, telecommunication signals, and software distribution media, etc.

[0101] The above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this application, and should all be included within the protection scope of this application.

Claims

1. A paper thickness sensing self-adaptive pressure control data processing method, characterized in that, The method comprises: acquiring thickness sensing data, conveying state data and press running data in a paper conveying process, and generating a paper thickness sensing data package; based on the press rotation phase, the no-load calibration reference and the sensor state, performing cycle error compensation, drift compensation and disturbance separation on the paper thickness sensing data package to generate a reliable thickness sequence with a reliability identifier; mapping the reliable thickness sequence to a paper coordinate thickness state graph according to the paper movement coordinates and the transverse detection positions; based on the paper coordinate thickness state graph, the press running data and the historical pressure feedback data, identifying the paper material compression response and the press contact state; generating an adaptive pressure control parameter set containing pressure targets, timing advance and execution constraints according to the paper coordinate thickness state graph, the paper material compression response, the press contact state and the target process parameters; aligning the adaptive pressure control parameter set with the press arrival timing according to the conveying state data to generate pressure control execution data for the pressure execution mechanism; acquiring post-press feedback data and backtracking the post-press feedback data to corresponding paper movement coordinates to update the thickness reference parameters, the compression response parameters and the pressure control calibration parameters.

2. The method of claim 1, wherein, The method comprises: collecting thickness sensing data formed by the paper in the conveying direction and the transverse detection direction at the thickness detection position, and time-aligning the thickness sensing data with the conveying state data and the press running data based on the same sampling clock and the encoder reference; determining the paper movement coordinates and the press arrival time corresponding to the thickness sampling points according to the aligned conveying state data; performing sampling quality marking on the aligned thickness sensing data according to the sensor effective state, the sampling stable state and the data synchronization state; associating and packaging the thickness sensing data, the paper movement coordinates, the press arrival time, the sampling quality marking and the corresponding press running data to generate the paper thickness sensing data package.

3. The method of claim 1, wherein, The method comprises: performing phase compensation on the thickness sensing data in the paper thickness sensing data package from the no-load calibration reference according to the press rotation phase; determining the sensing drift amount according to the sensor state and performing drift compensation on the phase-compensated thickness sensing data; based on the dynamic consistent relationship between the drift-compensated thickness sensing data and the conveying state data, separating the disturbance components caused by non-paper thickness changes; determining the thickness reliability of each thickness sampling point according to the disturbance separation result and the sampling quality marking, and generating a reliable thickness sequence with the reliability identifier.

4. The method of claim 3, wherein, The method comprises: generating a paper running stability representation according to the conveying state data; extracting a local variation representation of the thickness sensing data after drift compensation on the paper moving coordinate; performing consistency matching between the local variation representation and the paper running stability representation to identify abnormal fluctuations inconsistent with the real thickness variation of the paper; determining a disturbance component caused by non-paper thickness variation based on the persistence state and the spatial correlation state of the abnormal fluctuations.

5. The method of claim 1, wherein, The mapping of the trusted thickness sequence into a paper coordinate thickness state map according to the paper moving coordinate and the transverse detection position includes: establishing a coordinate index corresponding to the paper to-be-pressed area according to the paper moving coordinate and the transverse detection position; writing the thickness sampling points in the trusted thickness sequence into the coordinate units corresponding to the coordinate index, and generating a thickness distribution state based on the thickness continuity between adjacent coordinate units; determining the thickness abnormal state and the state trust level of each coordinate unit according to the thickness distribution state and the trust level identification; generating a paper coordinate thickness state map based on the spatial adjacency relationship between the coordinate units and the pressing area arrival timing relationship.

6. The method of claim 1, wherein, The identification of the paper material compression response and the pressing area contact state based on the paper coordinate thickness state map, the pressing area running data and the historical pressure feedback data includes: extracting the thickness state variation and the state trust level of the to-be-pressed area from the paper coordinate thickness state map, and performing coordinate correlation with the pressure execution result in the historical pressure feedback data to generate a compression response sample; determining the thickness compression characteristics and the rebound characteristics of the paper in the pressing process based on the compression response sample, and generating a paper material compression response; determining the loading stability and the pressure transmission state of the pressure execution mechanism according to the pressing area running data and the historical pressure feedback data; matching the paper material compression response with the pressure transmission state to generate a pressing area contact state used to constrain the adaptive pressure control parameter set.

7. The method of claim 1, wherein, The generation of the adaptive pressure control parameter set containing the pressure target, the timing advance and the execution constraint according to the paper coordinate thickness state map, the paper material compression response, the pressing area contact state and the target process parameter includes: determining a reference pressure control range corresponding to the to-be-pressed area based on the target process parameter; generating a thickness compensation parameter corresponding to the paper moving coordinate according to the thickness state variation and the state trust level in the paper coordinate thickness state map; performing material adaptation correction on the thickness compensation parameter according to the paper material compression response to generate a pressure target; determining a response constraint of the pressure execution mechanism based on the pressing area contact state, and combining the pressing area arrival time corresponding to the paper moving coordinate to generate a timing advance and an execution constraint; associating the pressure target, the timing advance and the execution constraint to generate the adaptive pressure control parameter set.

8. The method of claim 1, wherein, The timing alignment of the adaptive pressure control parameter set according to the conveying state data to generate the pressure control execution data for the pressure execution mechanism includes: Determine a paper moving speed and a transfer distance from a thickness detection position to a nip action position according to the conveying state data, and calculate a nip arrival time corresponding to each paper moving coordinate; Generate a pressure control trigger time based on the nip arrival time and a timing advance in the adaptive pressure control parameter set; Write a pressure target in the adaptive pressure control parameter set into a pressure control queue according to the pressure control trigger time and corresponding execution constraints; According to the response state of the pressure execution mechanism, continuously correct the pressure target in the pressure control queue to generate pressure control execution data matched with the nip action timing.

9. The method of claim 1, wherein, The post-press feedback data is obtained, and the post-press feedback data is traced back to the corresponding paper moving coordinate to update the thickness reference parameter, the compression response parameter and the pressure control calibration parameter, including: Collect quality detection data and pressure execution feedback after the paper passes through the nip to generate post-press feedback data; According to the nip action timing and the paper moving coordinate, the post-press feedback data is associated to the corresponding coordinate unit and the pressure control execution data; Determine the thickness identification deviation, the compression response deviation and the pressure control execution deviation based on the association result; According to the credibility state of each deviation, update the corresponding thickness reference parameter, compression response parameter and pressure control calibration parameter.

10. A paper thickness sensing self-adaptive pressure control data processing system, characterized in that, Including: An acquisition module is configured to acquire thickness sensing data, conveying state data and nip running data in a paper conveying process to generate a paper thickness sensing data packet; A first generation module is configured to compensate for periodic errors, drifts and disturbances in the paper thickness sensing data packet based on a nip rotation phase, an empty load calibration reference and a sensor state to generate a credible thickness sequence with a credibility identifier; A mapping module is configured to map the credible thickness sequence to a paper coordinate thickness state graph according to paper moving coordinates and transverse detection positions; An identification module is configured to identify paper material compression response and nip contact state based on the paper coordinate thickness state graph, nip running data and historical pressure feedback data; A second generation module is configured to generate an adaptive pressure control parameter set containing a pressure target, a timing advance and an execution constraint according to the paper coordinate thickness state graph, paper material compression response, nip contact state and target process parameters; An alignment module is configured to align the adaptive pressure control parameter set according to the conveying state data to generate pressure control execution data for a pressure execution mechanism; An update module is configured to obtain post-press feedback data and trace the post-press feedback data back to the corresponding paper moving coordinate to update the thickness reference parameter, the compression response parameter and the pressure control calibration parameter.

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