Adhesive tape production control method and system based on multi-device internet of things

Abstract

The application relates to the technical field of industrial production automation control, and discloses a rubber belt production control method and system based on multi-device internet of things, which comprises the following steps: acquiring follow-up error data and encoder position data of servo drivers corresponding to multiple transmission roller cylinders; calculating the synchronization deviation value between adjacent transmission roller cylinders according to the follow-up error data, and judging whether there is phase deviation; for the adjacent transmission roller cylinders with phase deviation, determining the position deviation trajectory and the deviation change rate according to the encoder position sequence and the theoretical position sequence; and generating the speed compensation value and the position compensation value through a PID controller according to the deviation change rate, and writing the values into the corresponding servo drivers for real-time online compensation. The method can timely identify the synchronization deviation of the multiple rollers and continuously compensate, thereby improving the timeliness and the tension stability of the tension adjustment in the rubber belt production process.

Description

Technical Field

[0001] This invention relates to the field of industrial production automation control technology, and in particular to a tape production control method and system based on multi-device Internet of Things. Background Technology

[0002] Currently, adhesive tape is a crucial basic material in fields such as electronics, automotive, medical, and packaging. Its production process typically includes continuous processing steps such as unwinding, coating, conveying, and rewinding. During adhesive tape production, the industrial control system maintains stable tension on the tape during conveying through the coordinated operation of multiple drive rollers, thereby ensuring uniform tape thickness and consistent product quality.

[0003] In a current technology, multiple servo drives corresponding to different drive rollers are typically used to control the conveyor belt process, and data communication between the drive units is achieved via a real-time Ethernet bus. With the application of real-time Ethernet bus technologies such as EtherCAT in industrial production lines, servo drives can acquire the actual operating position of the drive rollers through high-precision encoders and achieve synchronous control between multiple axes. Meanwhile, some existing solutions analyze the conveyor belt's operating status by collecting speed and torque data from servo motors or data detected by tension sensors, and adjust the operating parameters of the drive rollers based on the detection results.

[0004] However, existing control methods typically determine the synchronization status between multiple drive rollers indirectly through operating parameters such as the speed and torque of the servo motor. This fails to fully utilize the following error data calculated in real-time by the servo driver based on position command values ​​and encoder feedback values, making synchronization deviation detection susceptible to load changes and torque fluctuations. Furthermore, existing tension control methods often employ an iterative adjustment approach, adjusting control parameters after detecting tension deviation and then re-detecting. In high-speed conveyor belt production, this is easily affected by communication delays and execution response times, making it difficult to continuously compensate for changes in the drive roller's operating status in a timely manner.

[0005] Therefore, existing technologies suffer from the problem of untimely real-time tension detection and adjustment during tape production, leading to tape tension deviating from the preset reference value. Summary of the Invention

[0006] This invention provides a tape production control method and system based on multi-device Internet of Things to solve the problem of untimely real-time tension detection and adjustment during tape production, which causes the tape tension to deviate from the preset benchmark value.

[0007] Firstly, in order to solve the above-mentioned technical problems, the present invention provides a tape production control method based on multi-device Internet of Things, comprising:

[0008] The system acquires operational feedback data from servo drives corresponding to multiple drive rollers on the tape production line; wherein, the operational feedback data includes synchronously acquired following error data and encoder position data; the following error data is the deviation between the shaft position command value calculated internally by the servo drive and the actual encoder feedback value;

[0009] Based on the following error data, the synchronization deviation value between adjacent drive rollers is calculated. When the synchronization deviation value exceeds a preset deviation threshold, it is determined that there is a phase deviation between the adjacent drive rollers.

[0010] For adjacent transmission rollers with the phase deviation, the encoder position sequence fed back by the corresponding servo driver in real time is obtained. Based on the difference between the encoder position sequence and the theoretical position sequence, the position deviation trajectory is obtained, and the deviation change rate within a continuous sampling period is calculated based on the position deviation trajectory.

[0011] Based on the deviation change rate, a continuous speed compensation value and position compensation value are generated by a PID controller. The speed compensation value and the position compensation value are written into the electronic gear ratio parameter or speed feedforward parameter of the corresponding servo driver to realize real-time online compensation for multi-roller synchronization deviation.

[0012] In one optional implementation, acquiring the operational feedback data from the servo drives corresponding to multiple drive rollers on the tape production line includes:

[0013] Distributed clock synchronization reading is performed on the servo drives corresponding to each transmission roller to obtain the real-time following error register value and encoder position register value of each servo drive, and the sampling time deviation caused by bus transmission delay is compensated to obtain the synchronous operation dataset.

[0014] Based on the synchronous operation dataset, the following error data and encoder position data of the corresponding transmission roller are extracted; wherein, the following error data and the encoder position data constitute the operation feedback data.

[0015] In one optional implementation, the step of calculating the synchronization deviation value between adjacent drive rollers based on the following error data, and determining that there is a phase deviation between the adjacent drive rollers when the synchronization deviation value exceeds a preset deviation threshold, includes:

[0016] Based on the following error data corresponding to each adjacent drive roller, differential calculation is performed under the same sampling time scale to obtain the following error difference sequence between the corresponding adjacent drive rollers;

[0017] The following error difference sequence is statistically analyzed using a sliding time window to calculate the synchronization deviation value within the corresponding time window;

[0018] The synchronization deviation value is compared with a preset deviation threshold. When the synchronization deviation value exceeds the preset deviation threshold, it is determined that there is a phase deviation between the adjacent transmission rollers.

[0019] In one optional implementation, the step of obtaining the encoder position sequence of the corresponding servo driver in real time for adjacent transmission rollers with the phase deviation, obtaining the position deviation trajectory based on the difference between the encoder position sequence and the theoretical position sequence, and calculating the deviation change rate within a continuous sampling period based on the position deviation trajectory includes:

[0020] For adjacent transmission rollers with the aforementioned phase deviation, the actual position value is continuously read from the encoder position register of the corresponding servo driver at a preset sampling period to obtain the encoder position sequence;

[0021] Based on the preset electronic gear ratio and spindle position command, the theoretical position value corresponding to each transmission roller is calculated to obtain the theoretical position sequence;

[0022] The encoder position sequence and the theoretical position sequence are calculated point by point to obtain the position deviation trajectory between the actual position and the theoretical position.

[0023] The deviation change rate, which characterizes the trend of phase deviation change between adjacent transmission rollers, is calculated based on the change in the position deviation trajectory within a continuous sampling period.

[0024] In one optional implementation, the step of generating continuous speed compensation values ​​and position compensation values ​​using a PID controller based on the deviation change rate, and writing the speed compensation values ​​and position compensation values ​​into the electronic gear ratio parameters or speed feedforward parameters of the corresponding servo drive to achieve real-time online compensation for multi-roller synchronization deviation includes:

[0025] The deviation change rate and the position deviation trajectory are input into the PID controller, and the speed compensation value and position compensation value used to adjust the running state of the transmission roller are calculated through proportional, integral and derivative operations.

[0026] The speed compensation value is written into the speed feedforward parameter of the corresponding servo driver, or the position compensation value is written into the electronic gear ratio parameter of the corresponding servo driver.

[0027] The servo driver adjusts the operating state of the corresponding transmission roller according to the speed compensation value or the position compensation value, thereby achieving real-time online compensation for multi-roller synchronization deviation.

[0028] In one optional implementation, the process of generating continuous speed compensation values ​​and position compensation values ​​using a PID controller based on the deviation change rate, and writing the speed compensation values ​​and position compensation values ​​into the electronic gear ratio parameters or speed feedforward parameters of the corresponding servo drive to achieve real-time online compensation for multi-roller synchronization deviation further includes:

[0029] During the real-time online compensation of multi-roller synchronous deviation, the real-time tension signal output by the belt tension sensor is continuously collected;

[0030] The real-time tension signal is compared with a preset tension reference value to obtain a tension deviation value; the speed compensation value and the position compensation value are dynamically adjusted based on the tension deviation value.

[0031] The adjusted speed compensation value is written into the speed feedforward parameter of the corresponding servo drive, and the adjusted position compensation value is written into the electronic gear ratio parameter of the corresponding servo drive, so that the servo drive adjusts the running state of the transmission roller according to the adjusted control parameters, thereby realizing closed-loop control of belt tension.

[0032] In one optional implementation, the step of dynamically adjusting the speed compensation value and the position compensation value based on the tension deviation value includes:

[0033] Data on coating thickness distribution or surface defect detection during the tape production process are collected after the coating station on the tape production line.

[0034] By performing correlation analysis between the coating thickness distribution data or surface defect detection data and the tension deviation value, the quality status information of the tape can be obtained.

[0035] The speed compensation value and the position compensation value are adjusted according to the tape quality status information and sent to the corresponding servo driver.

[0036] In one optional implementation, comparing the real-time tension signal with a preset tension reference value to obtain a tension deviation value includes:

[0037] The corresponding preset tension reference value is determined according to the product type of the tape to be produced; the product types of the tape to be produced include BOPP pressure-sensitive adhesive tape, PET tape, or double-sided pressure-sensitive adhesive tape.

[0038] The tension deviation value is obtained by comparing the real-time tension signal with the preset tension reference value.

[0039] Secondly, the present invention provides a tape production control system based on multi-device Internet of Things, including a memory, a processor, and a computer program stored in the memory and executable on the processor. When the processor executes the program, it implements the steps of the tape production control method based on multi-device Internet of Things described above.

[0040] Thirdly, the present invention provides a computer-readable storage medium having a computer program stored thereon, which, when executed by a processor, implements the steps of the tape production control method based on multi-device Internet of Things described above.

[0041] Compared with the prior art, the present invention has the following beneficial effects:

[0042] (1) By reading the following error data of multiple servo drives under a unified sampling time scale and calculating the synchronization deviation value based on the following error data of adjacent transmission rollers, the present invention can use the following error information formed during the position closed loop of the servo drive to determine the synchronization state between adjacent transmission rollers, thereby reducing the detection lag caused by indirectly judging the synchronization state of multiple rollers based solely on changes in rotational speed, torque or tension, improving the timeliness of phase deviation detection, and providing timely synchronization state basis for subsequent tension adjustment.

[0043] (2) After determining that there is a phase deviation between adjacent transmission rollers, the present invention forms a position deviation trajectory based on the difference between the encoder position sequence and the theoretical position sequence, and calculates the deviation change rate based on the position deviation trajectory, so that the generated compensation amount can simultaneously reflect the current state and change trend of the position deviation; further, the PID controller continuously generates speed compensation value and position compensation value, and writes the corresponding compensation value into the speed feedforward parameter or electronic gear ratio parameter of the servo drive, so as to realize real-time online compensation for the synchronization deviation of multiple rollers, thereby reducing the belt tension fluctuation caused by the continuous accumulation of phase deviation and improving the timeliness of belt tension adjustment.

[0044] (3) The present invention continuously collects the real-time tension signal of the tape, and dynamically adjusts the speed compensation value and position compensation value according to the tension deviation value between the real-time tension signal and the preset tension reference value. Furthermore, it combines the coating thickness distribution data or surface defect detection data to obtain the tape quality status information, and corrects the speed compensation value and position compensation value. This enables the multi-roller synchronous control, tape tension control and tape quality status detection to form a closed loop, thereby enabling the timely adjustment of the operation state of the transmission roller according to the actual tension status and quality status of the tape, keeping the tape tension near the preset tension reference value, and improving the tension stability in the tape production process. Attached Figure Description

[0045] Figure 1This is a schematic diagram of the tape production control method based on multi-device IoT provided in the first embodiment of the present invention. Detailed Implementation

[0046] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0047] Reference Figure 1 The first embodiment of the present invention provides a tape production control method based on multi-device Internet of Things, including the following steps:

[0048] S1, acquire the running feedback data from the servo drives corresponding to multiple transmission rollers on the tape production line; wherein, the running feedback data includes synchronously acquired following error data and encoder position data; the following error data is the deviation between the shaft position command value calculated internally by the servo drive and the actual encoder feedback value;

[0049] S2, based on the following error data, calculate the synchronization deviation value between adjacent transmission rollers. When the synchronization deviation value exceeds a preset deviation threshold, determine that there is a phase deviation between the adjacent transmission rollers.

[0050] S3. For adjacent transmission rollers with the phase deviation, obtain the encoder position sequence fed back by the corresponding servo driver in real time. Based on the difference between the encoder position sequence and the theoretical position sequence, obtain the position deviation trajectory, and calculate the deviation change rate within the continuous sampling period based on the position deviation trajectory.

[0051] S4. Based on the deviation change rate, a continuous speed compensation value and position compensation value are generated by the PID controller. The speed compensation value and the position compensation value are written into the electronic gear ratio parameter or speed feedforward parameter of the corresponding servo driver to realize real-time online compensation for multi-roller synchronization deviation.

[0052] In step S1, it is necessary to obtain the operation feedback data from the servo drives corresponding to multiple drive rollers on the tape production line.

[0053] In one implementable method, acquiring operational feedback data from servo drives corresponding to multiple drive rollers on the tape production line includes:

[0054] Distributed clock synchronization reading is performed on the servo drives corresponding to each transmission roller to obtain the real-time following error register value and encoder position register value of each servo drive, and the sampling time deviation caused by bus transmission delay is compensated to obtain the synchronous operation dataset.

[0055] Based on the synchronous operation dataset, the following error data and encoder position data of the corresponding transmission roller are extracted; wherein, the following error data and the encoder position data constitute the operation feedback data.

[0056] Specifically, the tape production line is equipped with multiple drive rollers for unwinding, coating, guiding, and rewinding, each driven by a corresponding servo motor and servo driver. Each servo driver communicates with the controller via a real-time communication bus that supports distributed clock synchronization. The controller reads the follow-up error register value and encoder position register value from each servo driver according to a unified sampling clock.

[0057] The following error data is generated during the closed-loop position control process of the servo drive. For the i-th drive roller, at the k-th sampling time, the servo drive reads the axis position command value and the actual encoder feedback value, and obtains the corresponding following error data based on the difference between the two. The following error data is used to reflect the following state of the actual position of the corresponding servo axis relative to the position command.

[0058] The encoder position data refers to the actual position data fed back by the encoder installed on the servo motor shaft or the drive shaft of the transmission roller. In this embodiment, the sampling timestamp, transmission roller number, following error data, and encoder position data are stored accordingly, so that the following error data and encoder position data of the same transmission roller at each sampling time have a one-to-one correspondence.

[0059] In this embodiment, a fixed sampling period of 1ms is used for the position feedback data, and the operation feedback data of the corresponding servo drive is read synchronously according to the same sampling time base. For the arrival time difference caused by data transmission and bus transmission between different servo drives, time alignment is performed according to the sampling timestamp corresponding to the distributed clock, so that the data corresponding to each transmission roller at the same sampling moment is at a unified time scale, and a synchronous operation dataset is formed.

[0060] Specifically, the following error data and encoder position data corresponding to each transmission roller are extracted from the synchronous operation dataset. The following error data is used for the synchronization deviation calculation in step S2, and the encoder position data is used for the position deviation trajectory calculation in step S3.

[0061] In step S2, based on the following error data, the synchronization deviation value between adjacent drive rollers is calculated. When the synchronization deviation value exceeds a preset deviation threshold, it is determined that there is a phase deviation between the adjacent drive rollers.

[0062] In one implementable method, the step of calculating a synchronization deviation value between adjacent drive rollers based on the following error data, and determining that a phase deviation exists between the adjacent drive rollers when the synchronization deviation value exceeds a preset deviation threshold, includes:

[0063] Based on the following error data corresponding to each adjacent drive roller, differential calculation is performed under the same sampling time scale to obtain the following error difference sequence between the corresponding adjacent drive rollers;

[0064] The following error difference sequence is statistically analyzed using a sliding time window to calculate the synchronization deviation value within the corresponding time window;

[0065] The synchronization deviation value is compared with a preset deviation threshold. When the synchronization deviation value exceeds the preset deviation threshold, it is determined that there is a phase deviation between the adjacent transmission rollers.

[0066] Specifically, the adjacency relationship between each drive roller is determined according to the conveying direction of the conveyor belt. For the i-th drive roller and the j-th drive roller, the following error data of each is read at the k-th sampling time, and the synchronization error corresponding to that sampling time is calculated.

[0067]

[0068] in, This represents the instantaneous synchronization error between the i-th and j-th drive rollers at the k-th sampling time. and These represent the following errors of two adjacent drive rollers at the same sampling time. The synchronization errors obtained from consecutive sampling times are arranged in chronological order to form a sequence of following error differences between adjacent drive rollers.

[0069] In this embodiment, a sliding time window is used to statistically analyze the following error difference sequence. The sliding time window length is set to 50 sampling points, and the window step size is set to 10 sampling points. For the current sliding time window containing N sampling points, the root mean square value of the synchronization error is used as the synchronization deviation value.

[0070]

[0071] in, This represents the synchronization deviation between the i-th and j-th drive rollers within the current sliding time window, and N represents the number of sampling points included in the current sliding time window.

[0072] Specifically, when the production line is in normal synchronous operation, synchronization deviation values ​​corresponding to multiple time windows are continuously acquired, and a baseline distribution corresponding to the normal synchronous operation state is determined based on these synchronization deviation values. Let the mean synchronization deviation corresponding to the normal synchronous operation state be... The standard deviation is The preset deviation threshold is determined according to the following formula:

[0073]

[0074] The synchronization deviation value corresponding to the current sliding time window Deviation threshold from preset Comparison. When When the value is greater than δ, it is determined that there is a phase deviation between the corresponding adjacent transmission rollers, and the corresponding transmission roller is identified as the object to be compensated; when Not greater than At this time, maintain the current operating parameters and continue to calculate the synchronization deviation for the next sliding time window.

[0075] In step S3, for adjacent transmission rollers with the phase deviation, the encoder position sequence fed back by the corresponding servo driver in real time is obtained. Based on the difference between the encoder position sequence and the theoretical position sequence, the position deviation trajectory is obtained, and the deviation change rate within a continuous sampling period is calculated based on the position deviation trajectory.

[0076] In one feasible method, for adjacent drive rollers exhibiting the phase deviation, obtaining the encoder position sequence fed back in real time by the corresponding servo driver, obtaining the position deviation trajectory based on the difference between the encoder position sequence and the theoretical position sequence, and calculating the deviation change rate within a continuous sampling period based on the position deviation trajectory, includes:

[0077] For adjacent transmission rollers with the aforementioned phase deviation, the actual position value is continuously read from the encoder position register of the corresponding servo driver at a preset sampling period to obtain the encoder position sequence;

[0078] Based on the preset electronic gear ratio and spindle position command, the theoretical position value corresponding to each transmission roller is calculated to obtain the theoretical position sequence;

[0079] The encoder position sequence and the theoretical position sequence are calculated point by point to obtain the position deviation trajectory between the actual position and the theoretical position.

[0080] The deviation change rate, which characterizes the trend of phase deviation change between adjacent transmission rollers, is calculated based on the change in the position deviation trajectory within a continuous sampling period.

[0081] Specifically, after determining in step S2 that there is a phase deviation between adjacent transmission rollers, the actual position value is continuously read from the encoder position register of the corresponding servo driver and the encoder position sequence is formed according to the order of sampling time.

[0082] In this embodiment, the encoder position data is read at a fixed sampling period of 1ms, and the continuously read position data is serialized and stored using a data buffer with a length of 1024 data points. For example, the physical resolution of the encoder is set to 2048 pulses per revolution to convert the mechanical rotation position of the drive roller into a corresponding position count value.

[0083] Specifically, the main shaft is the servo shaft corresponding to the transmission rollers that serve as position references on the conveyor belt production line. The electronic gear ratios corresponding to each transmission roller are pre-set and stored in the corresponding servo driver parameters based on the mechanical transmission ratio and linear velocity matching relationship between the main shaft and the corresponding transmission roller; let the electronic gear ratio corresponding to the i-th transmission roller be... The spindle position command at the k-th sampling time is Then, based on the electronic gear ratio relationship, the theoretical position value corresponding to the i-th transmission roller is determined:

[0084]

[0085] Arrange the theoretical position values ​​corresponding to each sampling time in chronological order to obtain the theoretical position sequence.

[0086] Let the actual position value of the i-th drive roller fed back by the encoder at the k-th sampling time be... The corresponding positional deviation is:

[0087]

[0088] The positional deviations at each sampling time within a continuous sampling period are calculated sequentially and arranged in chronological order to obtain the positional deviation trajectory.

[0089] Furthermore, let the sampling period between two adjacent sampling times be . Then the rate of change of position deviation at the k-th sampling time is:

[0090]

[0091] In this embodiment, the sampling period Ts is 1ms. Therefore, the actual magnitude of the current phase deviation is determined by the position deviation trajectory, and the position deviation is determined to be in an increasing, decreasing, or stabilizing state by the deviation change rate. The position deviation trajectory and deviation change rate are then provided to the PID controller in step S4.

[0092] In step S4, based on the deviation change rate, continuous speed compensation values ​​and position compensation values ​​are generated by the PID controller. The speed compensation values ​​and position compensation values ​​are written into the electronic gear ratio parameters or speed feedforward parameters of the corresponding servo driver to realize real-time online compensation for multi-roller synchronization deviation.

[0093] In one feasible method, the process of generating continuous speed compensation values ​​and position compensation values ​​through a PID controller based on the deviation change rate, and writing the speed compensation values ​​and position compensation values ​​into the electronic gear ratio parameters or speed feedforward parameters of the corresponding servo drive to achieve real-time online compensation for multi-roller synchronization deviation further includes:

[0094] The deviation change rate and the position deviation trajectory are input into the PID controller, and the speed compensation value and position compensation value used to adjust the running state of the transmission roller are calculated through proportional, integral and derivative operations.

[0095] The speed compensation value is written into the speed feedforward parameter of the corresponding servo driver, or the position compensation value is written into the electronic gear ratio parameter of the corresponding servo driver.

[0096] The servo driver adjusts the operating state of the corresponding transmission roller according to the speed compensation value or the position compensation value, thereby achieving real-time online compensation for multi-roller synchronization deviation.

[0097] Specifically, the PID controller employs discrete PID control and includes a speed compensation branch and a position compensation branch. Both compensation branches use the position deviation trajectory and deviation change rate obtained in step S3 as the control basis.

[0098] For the speed compensation branch, the speed compensation value is generated in the kth control cycle according to the following formula:

[0099]

[0100] in, , and These are the proportional coefficient, integral coefficient, and differential coefficient of the speed-compensated branch, respectively. This represents the position deviation during the current control cycle. This represents the rate of change of position deviation during the current control cycle.

[0101] For the position compensation branch, the position compensation value is generated in the kth control cycle according to the following formula:

[0102]

[0103] in, , and These are the proportional coefficient, integral coefficient, and differential coefficient of the location compensation branch; the location compensation value. This is a dimensionless compensation quantity used to correct the electronic gear ratio parameters. The proportional coefficient, integral coefficient, and derivative coefficient are converted to dimensions based on the unit of measurement of the position deviation and the control cycle, so that the output of the position compensation branch can be used as a correction quantity for the electronic gear ratio parameters.

[0104] In this embodiment, during the equipment commissioning phase, the PID parameters of the speed compensation branch and the position compensation branch are tuned separately, and the tuned PID parameters are associated with and stored with the corresponding product's process parameters. During production, the corresponding PID parameters are called according to the current product, with the goal of gradually reducing the position deviation and preventing continuous oscillations during the compensation process.

[0105] Specifically, the speed compensation value is written into the speed feedforward parameter of the corresponding servo drive, enabling the servo drive to adjust the speed following state of the corresponding transmission roller according to the current phase deviation change trend. For the position compensation branch, the current position compensation value is used as a correction amount for the electronic gear ratio parameter, and is superimposed with the current electronic gear ratio parameter to obtain the corrected electronic gear ratio parameter. The corrected electronic gear ratio parameter is then written into the corresponding servo drive to adjust the position mapping relationship between the spindle position command and the target position of the corresponding transmission roller. As the next control cycle arrives, the following error data and encoder position data are reacquired, and the above calculations are repeated, so that the speed compensation value and position compensation value are continuously updated according to the change of the synchronization state of the transmission roller.

[0106]

[0107] in, This represents the electronic gear ratio parameter currently used by the i-th drive roller. This represents the electronic gear ratio parameter after correction in the k-th control cycle. This represents the dimensionless position compensation value output by the position compensation branch.

[0108] In one feasible method, during the real-time online compensation of multi-roll synchronization deviation, the real-time tension signal output by the belt tension sensor is continuously acquired;

[0109] The real-time tension signal is compared with a preset tension reference value to obtain a tension deviation value; the speed compensation value and the position compensation value are dynamically adjusted based on the tension deviation value.

[0110] The adjusted speed compensation value is written into the speed feedforward parameter of the corresponding servo drive, and the adjusted position compensation value is written into the electronic gear ratio parameter of the corresponding servo drive, so that the servo drive adjusts the running state of the transmission roller according to the adjusted control parameters, thereby realizing closed-loop control of belt tension.

[0111] For example, the tension sensor is installed at the tension detection roller on the tape conveying path between the coating station and the winding station; it continuously acquires the real-time tension signal of the tape within one compensation cycle and records the real-time tension value. Tension reference value corresponding to the current product type By comparison, the tension deviation value is obtained:

[0112]

[0113] In one feasible method, the dynamic adjustment of the velocity compensation value and the position compensation value based on the tension deviation value includes:

[0114] Data on coating thickness distribution or surface defect detection during the tape production process are collected after the coating station on the tape production line.

[0115] By performing correlation analysis between the coating thickness distribution data or surface defect detection data and the tension deviation value, the quality status information of the tape can be obtained.

[0116] The speed compensation value and the position compensation value are adjusted according to the tape quality status information and sent to the corresponding servo driver.

[0117] Specifically, after the tape passes through the coating station, a thickness detection device installed after the coating station continuously collects coating thickness data of the tape, and forms coating thickness distribution data according to the detection position and sampling time. At the same time, the coating thickness distribution data is time-aligned with the tension deviation value within the corresponding time period according to the sampling time, so that each tension deviation value is correlated with the coating thickness detection results of the corresponding production section.

[0118] In this embodiment, the tension deviation state is determined based on the preset allowable tension deviation range corresponding to the current product, and the coating thickness state is determined based on whether the coating thickness deviation is within the preset allowable thickness range. When both the tension deviation and coating thickness deviation are within the preset allowable tension deviation range, the current production section is determined to be in a normal quality state. When the tension deviation exceeds the preset allowable tension deviation range, but the coating thickness deviation is still within the preset allowable thickness range, the current production section is determined to be in a tension deviation state. When the tension deviation is within the preset allowable tension deviation range, but the coating thickness deviation exceeds the preset allowable thickness range, the current production section is determined to be in a coating quality deviation state. When both the tension deviation and coating thickness deviation exceed the preset allowable tension deviation range, the current production section is determined to be in a tension-quality coupling deviation state. Thus, based on the combination relationship between the tension deviation state and the coating thickness state, the tape quality state information for the corresponding production section is obtained. The preset tension allowable deviation range and the preset thickness allowable range are both calibrated during the equipment debugging phase based on the measured data of the corresponding product type under stable production conditions, and stored in the process parameter table in association with the product type; for example, for a production batch with a preset tension reference value of 140 N, the preset tension allowable deviation range is set to ±10 N, and for a production batch with a target coating thickness of 50 μm, the preset thickness allowable range is set to ±2 μm.

[0119] For example, the center coating thickness on the current tape surface is 50 μm. The current coating thickness distribution is compared with the target thickness corresponding to the product; when the coating thickness distribution deviation is within 2 μm, the current production section is determined to be in a normal quality state; when the coating thickness distribution deviation exceeds 2 μm, the current production section is determined to be in a quality deviation state.

[0120] In another implementation, surface defect detection data of the tape can be acquired using a surface defect detection device installed after the coating station. This data is then time-aligned with the tension deviation value within the corresponding time period based on the sampling time. When the surface defect detection result is within the allowable range for the corresponding product, the surface defect state is determined to be normal; when the result exceeds the quality control threshold for the corresponding product, the surface defect state is determined to be abnormal. The quality control threshold is calibrated during equipment debugging based on the appearance quality requirements of the corresponding product type and the detection sensitivity of the surface defect detection device, and is stored in association with the product type. The upper limit of the allowable range is the quality control threshold. Based on the combination relationship between the tension deviation state and the surface defect state, the tape quality status information corresponding to the current production section is determined.

[0121] Specifically, corresponding speed tension correction coefficients and position tension correction coefficients are set according to different tape quality states. These correction coefficients are calibrated during equipment debugging based on tension deviation data, coating thickness distribution data, or surface defect detection data under stable production conditions for the corresponding product, and are stored in association with the product type and tape quality state. During production, the corresponding speed tension correction coefficients and position tension correction coefficients are invoked based on the current tension deviation value and the determined tape quality state to dynamically correct the speed compensation value and position compensation value generated by the PID controller, resulting in the corrected speed compensation value and position compensation value.

[0122]

[0123]

[0124] in, This represents the speed tension correction factor. This represents the position tension correction factor.

[0125] Subsequently, the corrected speed compensation value obtained based on the current belt quality condition is written into the speed feedforward parameter of the corresponding servo driver, and the corrected position compensation value is written into the electronic gear ratio parameter of the corresponding servo driver, so that the tension deviation and belt quality condition participate together in the adjustment of the transmission roller running state in the same compensation process.

[0126] In this embodiment, for example, the current real-time tension value of the tape is 150 N, and the preset tension reference value of the corresponding production batch is 140 N, so the current tension deviation value is 10 N. According to the tape quality status corresponding to the current production section, the corresponding speed tension correction coefficient and position tension correction coefficient are called, and the speed compensation value and position compensation value are dynamically corrected once to realize the closed-loop adjustment of tape tension and production quality status.

[0127] In one feasible method, comparing the real-time tension signal with a preset tension reference value to obtain a tension deviation value includes:

[0128] The corresponding preset tension reference value is determined according to the product type of the tape to be produced; the product types of the tape to be produced include BOPP pressure-sensitive adhesive tape, PET tape, or double-sided pressure-sensitive adhesive tape.

[0129] The tension deviation value is obtained by comparing the real-time tension signal with the preset tension reference value.

[0130] Specifically, before starting the current production batch, the corresponding preset tension reference value is read from a pre-established process parameter table according to the product type of the tape to be produced, and the preset tension reference value is used as the tension control target for the current production batch. The process parameter table is established during the equipment debugging phase, and the preset tension reference values ​​calibrated for each product type under stable production conditions are associated and stored with the product type.

[0131] In this embodiment, BOPP pressure-sensitive adhesive tape, PET tape, and double-sided pressure-sensitive adhesive tape are each associated with a corresponding preset tension reference value. When the production system receives the product type information for the current production batch, it calls the corresponding preset tension reference value according to the product type.

[0132] In summary, this invention discloses a tape production control method based on multi-device IoT, including acquiring operational feedback data from servo drives corresponding to multiple drive rollers on a tape production line; calculating synchronization deviation values ​​between adjacent drive rollers and determining phase deviations based on following error data; determining position deviation trajectories and deviation change rates based on encoder position sequences and theoretical position sequences corresponding to adjacent drive rollers with phase deviations; and generating speed compensation and position compensation values ​​using a PID controller based on the deviation change rate and performing real-time online compensation on the corresponding servo drives. This invention utilizes the position following error information of the servo drives to determine the synchronization state of multiple rollers, and combines this with the position deviation change trend, real-time tape tension status, and tape quality status to continuously adjust the operating state of the drive rollers, achieving timely adjustment of multi-roller synchronization deviations and tape tension deviations, thereby improving tension stability during tape production.

[0133] The second embodiment of the present invention provides a tape production control system based on multi-device Internet of Things, including a memory, a processor, and a computer program stored in the memory and executable on the processor. When the processor executes the program, it implements all the process steps of the tape production control method based on multi-device Internet of Things described above.

[0134] The third embodiment of the present invention provides a computer-readable storage medium having a computer program stored thereon. When the computer program is executed by a processor, it implements all the process steps of the tape production control method based on multi-device Internet of Things described above.

[0135] It should be noted that the tape production control system based on multi-device IoT provided in this embodiment of the invention is used to execute the tape production control method based on multi-device IoT in the above embodiment. The working principles and beneficial effects of the two are one-to-one, so they will not be described again.

[0136] The specific embodiments described above further illustrate the purpose, technical solution, and beneficial effects of the present invention. It should be understood that the above descriptions are merely specific embodiments of the present invention and are not intended to limit the scope of protection of the present invention. In particular, it should be noted that any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention for those skilled in the art.

Claims

1. A method for controlling tape production based on multi-device IoT, characterized in that, include: The system acquires operational feedback data from servo drives corresponding to multiple drive rollers on the tape production line; wherein, the operational feedback data includes synchronously acquired following error data and encoder position data; the following error data is the deviation between the shaft position command value calculated internally by the servo drive and the actual encoder feedback value; Based on the following error data, the synchronization deviation value between adjacent drive rollers is calculated. When the synchronization deviation value exceeds a preset deviation threshold, it is determined that there is a phase deviation between the adjacent drive rollers. For adjacent transmission rollers with the phase deviation, the encoder position sequence fed back by the corresponding servo driver in real time is obtained. Based on the difference between the encoder position sequence and the theoretical position sequence, the position deviation trajectory is obtained, and the deviation change rate within a continuous sampling period is calculated based on the position deviation trajectory. Based on the deviation change rate, a continuous speed compensation value and position compensation value are generated by a PID controller. The speed compensation value and the position compensation value are written into the electronic gear ratio parameter or speed feedforward parameter of the corresponding servo driver to realize real-time online compensation for multi-roller synchronization deviation.

2. The tape production control method based on multi-device IoT according to claim 1, characterized in that, The acquisition of operational feedback data from the servo drives corresponding to multiple drive rollers on the tape production line includes: Distributed clock synchronization reading is performed on the servo drives corresponding to each transmission roller to obtain the real-time following error register value and encoder position register value of each servo drive, and the sampling time deviation caused by bus transmission delay is compensated to obtain the synchronous operation dataset. Based on the synchronous operation dataset, the following error data and encoder position data of the corresponding transmission roller are extracted; wherein, the following error data and the encoder position data constitute the operation feedback data.

3. The tape production control method based on multi-device IoT according to claim 1, characterized in that, The step of calculating the synchronization deviation value between adjacent drive rollers based on the following error data, and determining that there is a phase deviation between the adjacent drive rollers when the synchronization deviation value exceeds a preset deviation threshold, includes: Based on the following error data corresponding to each adjacent drive roller, differential calculation is performed under the same sampling time scale to obtain the following error difference sequence between the corresponding adjacent drive rollers; The following error difference sequence is statistically analyzed using a sliding time window to calculate the synchronization deviation value within the corresponding time window; The synchronization deviation value is compared with a preset deviation threshold. When the synchronization deviation value exceeds the preset deviation threshold, it is determined that there is a phase deviation between the adjacent transmission rollers.

4. The tape production control method based on multi-device IoT according to claim 1, characterized in that, For adjacent transmission rollers with the phase deviation, the encoder position sequence fed back in real time by the corresponding servo driver is obtained. Based on the difference between the encoder position sequence and the theoretical position sequence, the position deviation trajectory is obtained, and the deviation change rate within a continuous sampling period is calculated based on the position deviation trajectory, including: For adjacent transmission rollers with the aforementioned phase deviation, the actual position value is continuously read from the encoder position register of the corresponding servo driver at a preset sampling period to obtain the encoder position sequence; Based on the preset electronic gear ratio and spindle position command, the theoretical position value corresponding to each transmission roller is calculated to obtain the theoretical position sequence; The encoder position sequence and the theoretical position sequence are calculated point by point to obtain the position deviation trajectory between the actual position and the theoretical position. The deviation change rate, which characterizes the trend of phase deviation change between adjacent transmission rollers, is calculated based on the change in the position deviation trajectory within a continuous sampling period.

5. The tape production control method based on multi-device IoT according to claim 1, characterized in that, The step of generating continuous speed compensation and position compensation values ​​through a PID controller based on the deviation change rate, and writing the speed compensation and position compensation values ​​into the electronic gear ratio parameters or speed feedforward parameters of the corresponding servo driver, to achieve real-time online compensation for multi-roller synchronization deviation, includes: The deviation change rate and the position deviation trajectory are input into the PID controller, and the speed compensation value and position compensation value used to adjust the running state of the transmission roller are calculated through proportional, integral and derivative operations. The speed compensation value is written into the speed feedforward parameter of the corresponding servo driver, or the position compensation value is written into the electronic gear ratio parameter of the corresponding servo driver. The servo driver adjusts the operating state of the corresponding transmission roller according to the speed compensation value or the position compensation value, thereby achieving real-time online compensation for multi-roller synchronization deviation.

6. The tape production control method based on multi-device IoT according to claim 5, characterized in that, The process of generating continuous speed compensation values ​​and position compensation values ​​through a PID controller based on the deviation change rate, and writing the speed compensation values ​​and position compensation values ​​into the electronic gear ratio parameters or speed feedforward parameters of the corresponding servo driver to achieve real-time online compensation for multi-roller synchronization deviation also includes: During the real-time online compensation of multi-roller synchronous deviation, the real-time tension signal output by the belt tension sensor is continuously collected; The real-time tension signal is compared with a preset tension reference value to obtain a tension deviation value; the speed compensation value and the position compensation value are dynamically adjusted based on the tension deviation value. The adjusted speed compensation value is written into the speed feedforward parameter of the corresponding servo drive, and the adjusted position compensation value is written into the electronic gear ratio parameter of the corresponding servo drive, so that the servo drive adjusts the running state of the transmission roller according to the adjusted control parameters, thereby realizing closed-loop control of belt tension.

7. The tape production control method based on multi-device IoT according to claim 6, characterized in that, The step of dynamically adjusting the speed compensation value and the position compensation value based on the tension deviation value includes: Data on coating thickness distribution or surface defect detection during the tape production process are collected after the coating station on the tape production line. By performing correlation analysis between the coating thickness distribution data or surface defect detection data and the tension deviation value, the quality status information of the tape can be obtained. The speed compensation value and the position compensation value are adjusted according to the tape quality status information and sent to the corresponding servo driver.

8. The tape production control method based on multi-device IoT according to claim 6, characterized in that, The step of comparing the real-time tension signal with a preset tension reference value to obtain a tension deviation value includes: The corresponding preset tension reference value is determined according to the product type of the tape to be produced; the product types of the tape to be produced include BOPP pressure-sensitive adhesive tape, PET tape, or double-sided pressure-sensitive adhesive tape. The tension deviation value is obtained by comparing the real-time tension signal with the preset tension reference value.

9. A tape production control system based on multi-device Internet of Things, comprising a memory, a processor, and a computer program stored in the memory and executable on the processor, characterized in that, When the processor executes the program, it implements the tape production control method based on multi-device Internet of Things as described in any one of claims 1 to 8.

10. A computer-readable storage medium having a computer program stored thereon, characterized in that, When executed by the processor, the program implements the tape production control method based on multi-device IoT as described in any one of claims 1 to 8.

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