A dynamic pressure regulating continuous die pressing method for composite texture aluminum plate

Abstract

The present application relates to the field of metal plate surface forming processing, and discloses a dynamic pressure regulating continuous die pressing preparation method of composite texture aluminum plate; the method comprises the following steps: after aluminum alloy coiled material is unwound, the coiled material is conveyed to a die pressing station through a feeding side S roller; coiled material thickness data is collected in real time, a PLC control system controls a hydraulic mechanism to adjust die pressing pressure according to thickness changes, and a composite engraving die pressing die is used to continuously form composite texture; the coiled material after die pressing is sequentially subjected to decreasing pressure straightening through a first straightening section, a second straightening section and a third straightening section; and then the coiled material is conveyed to a winding station through a receiving side S roller, and the coiled material is subjected to slitting and numerical control fixed-length shearing. The present application reduces the influence of coiled material thickness fluctuation and opening and winding tension disturbance on texture forming through the synergistic control of dynamic pressure regulation, front and rear S roller tension isolation and three-stage gradient straightening, and improves the stability of the plate shape after die pressing.

Description

Technical Field

[0001] This invention relates to the field of metal sheet surface forming and processing, specifically to a dynamic pressure-adjusting continuous molding preparation method for composite textured aluminum sheets. Background Technology

[0002] With the increasing application of aluminum alloy materials in 3C products, automotive decoration, architectural decoration, and other appearance structural components, it is common practice to create textures on the surface of aluminum alloy coils using methods such as roll forming, embossing, or molding to obtain aluminum sheets with three-dimensional layers and surface texture. For continuous coil molding production, aluminum alloy coils need to undergo uncoiling, conveying, molding, straightening, and rewinding processes sequentially. Not only is there a continuous material transfer relationship between each station, but the coil thickness, molding pressure, conveying tension, and the shape of the sheet after molding all affect the texture formation quality. In existing continuous embossing production processes, the molding pressure is usually set according to the nominal specifications of the coil. During continuous operation, when the actual thickness of the coil fluctuates, the molding pressure is difficult to adjust in a timely manner, easily causing uneven local texture penetration, leading to inconsistent texture depth or decreased forming stability.

[0003] Meanwhile, during continuous roll material production, variations in unwinding diameter, roll eccentricity, braking status, and continuous changes in winding diameter and winding torque can all cause tension fluctuations. While existing production lines can use tension rollers or S-rollers to traction and tension the roll material, if there is a lack of clear tension zoning and disturbance isolation between the unwinding side, the molding and straightening area, and the winding side, tension changes at the unwinding end may be transmitted to the molding area, and tension changes at the winding end may also affect the molding and straightening areas in reverse, altering the contact state between the roll material and the molding rollers, thus affecting the consistency of continuous texture replication. In particular, if roll materials with already formed embossed textures are continuously subjected to high winding tension and roll layer compression during winding, it may also cause localized damage to the texture or changes in texture depth.

[0004] Furthermore, aluminum alloy coils undergo localized plastic deformation during the molding process to form composite textures, accompanied by changes in sheet shape and residual stress. If only a single degree of straightening is applied after molding, excessive straightening can easily lead to new springback or localized deformation, while insufficient straightening makes it difficult to adequately correct warping and residual stress after molding. Therefore, how to dynamically adjust the molding pressure according to changes in coil thickness, and how to isolate tension on the uncoiling side, the molding and straightening process area, and the rewinding side during continuous molding, while continuously straightening the molded coil by gradually reducing the degree of straightening, are technical problems that need to be further solved in the current continuous production process of composite textured aluminum sheets. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides a dynamic pressure-adjustable continuous molding method for preparing composite textured aluminum plates, thereby solving the technical problems existing in the prior art.

[0006] The above-mentioned technical objective of the present invention is achieved through the following technical solution: A method for preparing composite textured aluminum plates by dynamic pressure adjustment and continuous molding includes the following steps: S1: After the aluminum alloy coil is uncoiled, it is conveyed to the molding station via the uncoiling side S roller. The tension fluctuations generated during the uncoiling process are isolated by the uncoiling side S roller. S2: Obtain the thickness data of the aluminum alloy coil entering the molding station, send the thickness data to the PLC control system, and control the hydraulic mechanism to adjust the molding pressure according to the thickness data. The molding pressure increases with the increase of the thickness of the aluminum alloy coil and decreases with the decrease of the thickness of the aluminum alloy coil. A composite engraving molding die is used to continuously mold the aluminum alloy coil to form a composite texture on the surface of the aluminum alloy coil. S3: The molded aluminum alloy coil is continuously straightened by passing it through the first straightening section, the second straightening section and the third straightening section in sequence. The first straightening section uses the maximum relative reduction among the three straightening sections, the relative reduction of the second straightening section is 70% to 75% of the relative reduction of the first straightening section, and the relative reduction of the third straightening section is 40% to 50% of the relative reduction of the first straightening section, so that the curvature of the first straightening section, the second straightening section and the third straightening section decreases in sequence. S4: The straightened aluminum alloy coil is conveyed to the winding station via the take-up side S roller. The tension fluctuations generated during the winding process are isolated by the take-up side S roller, and the tension in the process area where the molding station and the three straightening sections are located is higher than the tension at the unloading side S roller and the take-up side S roller. S5: The aluminum alloy coil obtained from the winding is slit, and the slit aluminum alloy coil is CNC cut to length to obtain composite textured aluminum plate.

[0007] Preferably, the thickness of the aluminum alloy coil is 0.3–2.0 mm; The aluminum alloy coil has a hardness of 65-75HV, a tensile strength of not less than 200MPa, and an elongation of not less than 8%.

[0008] Preferably, in S2, the thickness data is collected in real time by a plate thickness infrared sensor. The plate thickness infrared sensor sends the collected thickness data to the PLC control system every second. The PLC control system controls the hydraulic mechanism to adjust the molding pressure of the composite engraving mold according to the received thickness data. The adjustment range of the molding pressure is 10 to 60t.

[0009] Preferably, in S2, the aluminum alloy coil passes through the molding station continuously at a speed of 5-15 m / min, and the molding temperature is 40-60℃; The molding surface of the composite engraving mold has a multi-layered composite texture formed by the superposition of grating dot matrix, geometric array and biomimetic texture. The aluminum alloy coil forms a composite texture with a depth of 10 to 80 μm after continuous molding.

[0010] Preferably, the wrap angle between the feeding side S-roller and the aluminum alloy coil is 120° to 160°, and a pre-compression of 0.02 to 0.05 mm is applied to the aluminum alloy coil before it enters the molding station; The wrap angle between the S-roller on the receiving side and the aluminum alloy coil is 120° to 145°. The running speed of the feeding side S-roller and the receiving side S-roller is synchronized with the continuous molding speed of the molding station.

[0011] Preferably, the tension after uncoiling, the tension at the S-roller on the unwinding side, the tension in the process area where the molding station and the three straightening sections are located, the tension at the S-roller on the rewinding side, and the tension at the rewinding station are determined according to the thickness of the aluminum alloy coil. When the thickness of the aluminum alloy coil is 0.3 to 0.5 mm, the tension at each point is selected from the ranges of 70 to 100 N, 70 to 100 N, 80 to 110 N, 60 to 90 N, and 50 to 80 N respectively. When the thickness of the aluminum alloy coil is 0.5 to 0.8 mm, the tension at each point is selected from the ranges of 80 to 120 N, 80 to 110 N, 90 to 130 N, 70 to 100 N, and 60 to 100 N respectively. When the thickness of the aluminum alloy coil is 0.8 to 1.5 mm, the tension at each point is selected from the ranges of 90 to 130 N, 110 to 130 N, 110 to 160 N, 90 to 120 N, and 80 to 130 N respectively. When the thickness of the aluminum alloy coil is 1.5 to 2.0 mm, the tension at each point is selected from the range of 100 to 140 N, 120 to 150 N, 130 to 180 N, 100 to 140 N and 90 to 150 N respectively. Then, determine the tension at each point within the corresponding tension range, so that the process area where the molding station and the three straightening sections are located forms a tension zone higher than that at the S-roller on the feeding side and the S-roller on the receiving side.

[0012] Preferably, the first straightening section, the second straightening section, and the third straightening section together constitute a three-stage straightening station. The three-stage straightening station includes 5 shaping rollers, 10 auxiliary shaping rollers, 8 shaping roller supports, 2 parallel pressure rollers, and shaping pressure rollers. The diameter of the shaping rollers and auxiliary shaping rollers is 40mm, the diameter of the shaping roller supports is 75mm, and the diameter of the parallel pressure rollers and shaping pressure rollers is 185mm.

[0013] Preferably, the first straightening section, the second straightening section, and the third straightening section adopt a servo adjustment structure to adjust the relative reduction amount. The first straightening section is the inlet initial straightening section, the second straightening section is the middle main straightening section, and the third straightening section is the outlet fine straightening section. The relative reduction amount is reduced segment by segment in the order of the first straightening section, the second straightening section, and the third straightening section.

[0014] Preferably, the running speed of the take-up side S-roller is synchronized with the continuous molding speed of the molding station, and the take-up motor of the winding station uses the running speed of the take-up side S-roller as the winding speed reference. The winding station winds the aluminum alloy coil with a tension taper of 10% to 20%, and the winding tension is reduced as the winding diameter of the aluminum alloy coil increases.

[0015] Preferably, in S5, the blade gap during slitting is 0.02 to 0.06 mm, the blade shaft runout is no more than 0.015 mm, the spacer accuracy is ±0.005 mm, and the width tolerance after slitting is ±0.05 to ±0.15 mm. The shearing gap during CNC fixed-length shearing is 0.02~0.06mm, the length tolerance is ±0.1~0.2mm, and the diagonal tolerance is no more than 0.3mm.

[0016] In summary, the present invention has the following main beneficial effects: This application uses an infrared sensor to collect the thickness data of aluminum alloy coils in real time, and a PLC control system controls the hydraulic mechanism to dynamically adjust the molding pressure within a set pressure range according to the thickness changes. This allows the coils of different thicknesses to receive molding action corresponding to their thickness changes. At the same time, a composite engraving mold is used for continuous molding, which reduces uneven texture depth, insufficient local molding, or excessive pressing caused by coil thickness fluctuations, and improves the consistency and stability of composite texture molding during continuous molding.

[0017] This application creates a stable tension zone higher than the sides by setting up a feeding-side S-roller and a take-up-side S-roller before and after the molding station, respectively. The feeding-side S-roller isolates tension disturbances during the unwinding process, and the take-up-side S-roller isolates reverse tension disturbances caused by changes in the winding diameter and winding torque. This reduces the impact of changes in the unwinding and winding states on the continuous molding and straightening process, and ensures that the roll material maintains a stable conveying state during texture formation and subsequent straightening.

[0018] This application sets up a first straightening section, a second straightening section, and a third straightening section in sequence after continuous molding, and gradually reduces the relative reduction of the three straightening sections. This allows the molded roll material to undergo initial straightening, main straightening, and fine straightening in sequence. In addition, the tension taper at the winding station is used to reduce the winding tension as the roll diameter increases. This achieves the effect of gradually correcting the changes in the sheet shape caused by molding, mitigating residual stress and springback, and reducing the squeezing and damage to the formed composite texture during the winding process. Thus, it takes into account both the continuous forming quality of the composite texture and the flatness of the finished sheet surface. Attached Figure Description

[0019] Figure 1 This is a flowchart of the method of the present invention. Detailed Implementation

[0020] 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.

[0021] Example 1 refer to Figure 1 A method for preparing composite textured aluminum plates by dynamic pressure adjustment and continuous molding includes the following steps: S1: After the aluminum alloy coil is uncoiled, it is conveyed to the molding station via the uncoiling side S roller. The tension fluctuations generated during the uncoiling process are isolated by the uncoiling side S roller. S2: Obtain the thickness data of the aluminum alloy coil entering the molding station, send the thickness data to the PLC control system, and control the hydraulic mechanism to adjust the molding pressure according to the thickness data. The molding pressure increases with the increase of the thickness of the aluminum alloy coil and decreases with the decrease of the thickness of the aluminum alloy coil. A composite engraving molding die is used to continuously mold the aluminum alloy coil to form a composite texture on the surface of the aluminum alloy coil. S3: The molded aluminum alloy coil is continuously straightened by passing it through the first straightening section, the second straightening section and the third straightening section in sequence. The first straightening section uses the maximum relative reduction among the three straightening sections, the relative reduction of the second straightening section is 70% to 75% of the relative reduction of the first straightening section, and the relative reduction of the third straightening section is 40% to 50% of the relative reduction of the first straightening section, so that the curvature of the first straightening section, the second straightening section and the third straightening section decreases in sequence. S4: The straightened aluminum alloy coil is conveyed to the winding station via the take-up side S roller. The tension fluctuations generated during the winding process are isolated by the take-up side S roller, and the tension in the process area where the molding station and the three straightening sections are located is higher than the tension at the unloading side S roller and the take-up side S roller. S5: The aluminum alloy coil obtained from the winding is slit, and the slit aluminum alloy coil is CNC cut to length to obtain composite textured aluminum plate.

[0022] This embodiment is used to illustrate the process steps, control parameters, and the synergistic relationship between the parameters, so that those skilled in the art can implement this application accordingly. The preferred process conditions in the embodiment should not be construed as unnecessary limitations on the scope of protection.

[0023] In this embodiment, the aluminum alloy coil sequentially passes through the uncoiling station, the unloading side S-roller, the molding station, the first straightening section, the second straightening section, the third straightening section, the take-up side S-roller, and the winding station along the conveying direction. After winding, it is slitting and CNC cut to length. The molding station, the first straightening section, the second straightening section, and the third straightening section are located between the unloading side S-roller and the take-up side S-roller, together forming a continuous molding and straightening process area.

[0024] The unwinding-side S-roller isolates tension fluctuations generated at the unwinding station, while the take-up-side S-roller isolates tension fluctuations generated at the take-up station. This ensures that the molding and straightening process zone between the two maintains a relatively stable tension that is higher than that on either side. The original process parameters clearly state that the molding tension is higher than that of the unwinding-side S-roller, and the tension of the unwinding-side S-roller is higher than that of the take-up-side S-roller. The two S-rollers are used to limit the transmission of unwinding and take-up disturbances to the intermediate processing area.

[0025] Select aluminum alloy coils with a thickness of 0.3–2.0 mm as the material to be processed. In actual mass production, 5052H32 fine-textured aluminum alloy coils can be used, or other aluminum alloy coils that meet the requirements of continuous molding can be used.

[0026] The aluminum alloy coils entering the production line undergo raw material inspection, with hardness controlled at 65-75 HV, tensile strength not less than 200 MPa, and elongation not less than 8%. These material performance parameters are derived from the raw material specifications and inspection results, and serve as incoming material control indicators to determine whether the coils are suitable for subsequent continuous molding.

[0027] The thickness, hardness, tensile strength, and elongation of the roll material are all determined before entering the continuous production process and are not calculated or generated by the subsequent PLC control system.

[0028] After meeting the above material performance requirements, the aluminum alloy coil is installed at the uncoiling station for continuous unwinding.

[0029] After being fed out from the uncoiling station, the aluminum alloy coil first enters the unloading side S-roller.

[0030] Due to potential variations in roll diameter, roll eccentricity, loosening, and braking status during the actual uncoiling process, the instantaneous tension on the uncoiling side may fluctuate. The S-roller on the unwinding side isolates the uncoiling side from subsequent molding stations through the wrapping contact of the roll material on the roll surface.

[0031] The wrap angle between the aluminum alloy coil and the unloading side S-roller is set to 120° to 160°, so that the coil can form a stable wrapping contact on the surface of the S-roller. The running speed of the unloading side S-roller is synchronized with the continuous molding speed of the molding station, so that the coil can continuously and stably enter the molding station after being fed out by the unloading side S-roller.

[0032] The pre-compression setting of the S-roller on the feeding side is 0.02–0.05 mm. This value is set according to the actual pre-compression adjustment mechanism of the equipment to ensure stable roller surface contact and sheet shape of the roll material before it enters the molding station. The 0.02–0.05 mm is the process pre-compression setting parameter for the S-roller on the feeding side and does not indicate an actual reduction of the roll material thickness by 0.02–0.05 mm.

[0033] In actual operation, the tension on the exit side of the S-roller on the feeding side is higher than that on the inlet side, and is adjusted within the allowable tension range corresponding to the current coil thickness. The instructions do not specify that the inlet tension and the outlet tension must maintain a fixed numerical difference. Therefore, in actual production, the operating condition is that the coil can be stably conveyed and there is no continuous slippage on the surface of the S-roller. No additional fixed tension difference is specified.

[0034] The aluminum alloy coil, after being stably conveyed by the S-roller on the feeding side, enters the molding station.

[0035] The plate thickness infrared sensor collects the thickness data of the aluminum alloy coil in real time during continuous conveying and sends the thickness data to the PLC control system at a feedback frequency of once per second.

[0036] The PLC control system is connected to the hydraulic mechanism of the molding station. The hydraulic mechanism is used to adjust the molding pressure applied by the composite engraving mold to the aluminum alloy coil. The working range of the molding pressure is 10-60T. The existing manual clearly states that infrared sensors collect coil thickness data in real time and provide feedback every second, and the PLC, in conjunction with the hydraulic mechanism, adjusts the mold pressure according to the direction of reducing pressure for thin materials and increasing pressure for thick materials.

[0037] At the start of production, the initial molding pressure is determined within the range of 10 to 60T, based on the thickness of the incoming aluminum alloy coil, the material properties, and the forming requirements of the composite texture to be formed.

[0038] During continuous operation, the PLC control system reads the thickness data fed back by the infrared sensor of the sheet thickness. When the detection result indicates that the thickness of the roll material entering the molding process is increasing, the PLC controls the hydraulic mechanism to adjust in the direction of increasing the molding pressure; when the detection result indicates that the thickness of the roll material is decreasing, the PLC controls the hydraulic mechanism to adjust in the direction of decreasing the molding pressure.

[0039] Therefore, the dynamic pressure adjustment in this embodiment has a clear control relationship, that is, the real-time thickness data of the roll material is used as the control input, the molding pressure of the hydraulic mechanism is used as the control output, and the adjustment is made according to the control direction of increasing pressure for thick materials and decreasing pressure for thin materials.

[0040] Since the existing instructions do not provide a fixed mathematical function, fixed ratio, or fixed pressure step size for the relationship between thickness change and pressure change, this embodiment does not artificially establish a thickness-pressure calculation formula. The specific molding pressure is always limited to the actual process range of 10–60T and adjusted according to the PLC process parameters of the production equipment.

[0041] The molding station is equipped with a composite engraving molding die.

[0042] The molding surface of the composite engraving mold is decorated with multi-layered composite textures formed by the superposition of grating dot matrix, geometric array, and biomimetic texture. The multi-layered composite textures are formed on the same molding surface, so that the aluminum alloy coil can form corresponding composite textures on its surface in one molding process.

[0043] In actual continuous molding, the running speed of the aluminum alloy coil is controlled at 5–15 m / min, the molding temperature is controlled at 40–60℃, and the molding pressure is controlled within the range of 10–60T. All of the above parameters are derived from the actual process parameters of the molding production line.

[0044] After pressure is applied to the composite engraving mold, the surface of the aluminum alloy coil undergoes plastic deformation and replicates the composite texture on the mold surface, thereby forming a composite texture with a depth of 10 to 80 μm.

[0045] In this embodiment, texture depth refers to the height difference between the highest and lowest texture positions within the sampling segment. During actual quality inspection, a sampling segment can be selected within the test area, and the highest and lowest points within that segment can be obtained. The height difference between the two points represents the texture limit depth.

[0046] To evaluate the overall stability of the texture, five high points and five low points within the sampling section can be selected for testing according to the process inspection requirements to reflect the depth stability of the composite texture along the board surface. The above testing method corresponds to the RT and RZ testing methods in the original process parameters.

[0047] After molding, the aluminum alloy coil does not go directly into the winding station, but is continuously conveyed between the unwinding S-roller and the winding S-roller, and then enters the first straightening section, the second straightening section and the third straightening section in sequence.

[0048] The three straightening sections employ different degrees of straightening.

[0049] The first straightening section is the initial straightening section at the entrance. It uses the maximum relative reduction among the three straightening sections to straighten the roll material to a greater extent after molding. The second straightening section is the middle main straightening section, and its relative compression is controlled at 70% to 75% of the relative compression of the first straightening section. The third straightening section is the exit fine straightening section, and its relative reduction is controlled at 40% to 50% of the relative reduction of the first straightening section.

[0050] The relative reduction amount referred to in this embodiment indicates the relationship between the reduction degree of the first straightening section, the second straightening section and the third straightening section under the same equipment adjustment reference, and does not indicate the actual thinning rate of the aluminum alloy coil thickness.

[0051] Specifically, if the degree of compression of the first straightening stage is taken as the 100% comparison benchmark, then the second straightening stage corresponds to 70% to 75% of the first straightening stage, and the third straightening stage corresponds to 40% to 50% of the first straightening stage.

[0052] Therefore, the straightening effect on the aluminum alloy coil decreases segment by segment along the conveying direction.

[0053] The first straightening stage uses a large straightening deformation to initially correct the overall warping and obvious changes in plate shape formed after molding; the second straightening stage continues to process the remaining changes in plate shape and internal stress distribution after the first straightening stage after reducing the degree of compression; the third straightening stage further reduces the degree of compression and corrects the remaining springback and local plate shape after the first two straightening stages.

[0054] This results in a three-stage gradient straightening process that gradually transitions from larger straightening deformation to smaller straightening deformation, rather than continuous and repeated straightening with the same amount of reduction.

[0055] The three straightening sections are adjusted by a servo. When changing to aluminum alloy coils of different thicknesses, the initial compression state of the first straightening section is determined first, and then the relative compression degree of the second and third straightening sections is determined according to the above-mentioned ratios of 70% to 75% and 40% to 50%, respectively.

[0056] After processing through the first, second, and third straightening sections, the flatness of the aluminum alloy coil surface is controlled within the range of 0.5–2 mm / m. The instructions clearly state that the three straightening sections are used to release the internal stress generated by the flow of the molding material and to correct the flatness of the surface, with a correction standard of 0.5–2 mm / m.

[0057] No additional bending curvature formula is used here. Actual control is based primarily on the clearly defined decreasing relative reduction between the three straightening sections.

[0058] The first straightening section, the second straightening section, and the third straightening section together form a three-section straightening station.

[0059] Based on the supplementary parameters of the existing straightening station, the three-section straightening station is configured with 5 shaping rollers, 10 auxiliary shaping rollers, 8 shaping roller supports, 2 parallel pressure rollers, and shaping pressure rollers.

[0060] The forming roller has a diameter of 40mm, the auxiliary forming roller has a diameter of 40mm, the forming roller support has a diameter of 75mm, the parallel pressure roller has a diameter of 185mm, and the forming pressure roller has a diameter of 185mm.

[0061] The above quantities refer to the configuration of the entire three-section straightening station, and do not imply that the first, second, and third straightening sections are each independently equipped with 5 shaping rollers, 10 auxiliary shaping rollers, and 8 shaping roller supports.

[0062] This embodiment uses the name of the shaping roller support from the process parameter table. It refers to the roller component that supports the shaping roller and is not interpreted as a regular fixed bracket.

[0063] Regarding the plate thickness and equipment adjustment parameters such as 0.25–0.35 mm recorded in the supplementary process parameters, since existing technical data do not further clarify their mechanical zero point and actual measurement benchmark, this embodiment does not define them as the absolute roll gap between the upper and lower rolls, nor does it calculate the change in coil thickness based on them. The three straightening sections use the decreasing relationship of relative reduction amount as the clear basis for straightening control.

[0064] In this embodiment, the tension operating range of the uncoiling station, the unloading side S-roller, the molding and three straightening sections, the take-up side S-roller, and the take-up station are determined according to the thickness of the aluminum alloy coil.

[0065] When the thickness of the aluminum alloy coil is 0.3–0.5 mm: The tension at the unwinding station is 70–100 N; The tension at the S-roller on the feeding side is 70-100N; The tension in the process area where the molding station and the three straightening sections are located is 80-110N; The tension at the S-roller on the receiving side is 60–90 N; The tension at the winding station is 50-80N.

[0066] When the thickness of the aluminum alloy coil is 0.5-0.8mm, the tension at the above five points is 80-120N, 80-110N, 90-130N, 70-100N and 60-100N respectively.

[0067] When the thickness of the aluminum alloy coil is 0.8 to 1.5 mm, the tension at the five points mentioned above is 90 to 130 N, 110 to 130 N, 110 to 160 N, 90 to 120 N, and 80 to 130 N, respectively.

[0068] When the thickness of the aluminum alloy coil is 1.5 to 2.0 mm, the tension at the five points mentioned above is 100 to 140 N, 120 to 150 N, 130 to 180 N, 100 to 140 N, and 90 to 150 N, respectively.

[0069] The above values ​​all fall within the operational range for each workstation at the corresponding roll thickness. In actual production, the tension is not arbitrarily selected from each range, but rather the actual operating value is determined from the parameter set corresponding to the thickness, while simultaneously satisfying: The tension in the process area where the molding station and the three straightening sections are located is greater than the tension at the S-roller on the feeding side, which is greater than the tension at the S-roller on the receiving side.

[0070] This tension relationship is the main criterion for determining the tension in the entire zone.

[0071] Because there is overlap between adjacent tension ranges, for example, under certain thickness conditions, the allowable tension ranges of the S-roller on the feeding side and the molding and straightening process area partially overlap. Therefore, during production, the final actual selected operating value should be used as the standard to satisfy the above-mentioned size relationship. The tension relationship between process areas should not be judged solely based on the upper or lower limits of each range.

[0072] The tension at the S-roller on the discharge side represents the process tension range of the tension control area where the S-roller on the discharge side is located. For the S-roller on the discharge side itself, the outlet tension is further required to be higher than the inlet tension.

[0073] The tension at the S-roller on the receiving side indicates the process tension range of the tension control area where the S-roller on the receiving side is located. For the S-roller on the receiving side itself, the inlet tension must be higher than the outlet tension.

[0074] Therefore, the S-roller on the unwinding side serves as the tension isolation function during the transition from the low-tension unwinding zone to the higher-tension molding and straightening process zone, while the S-roller on the take-up side serves as the tension isolation function during the transition from the higher-tension molding and straightening process zone to the low-tension take-up zone.

[0075] After the aluminum alloy coil completes the fine straightening of the third straightening stage, it enters the S-roller on the receiving side.

[0076] The wrap angle between the S-roller on the receiving side and the aluminum alloy coil is controlled at 120° to 145°, and the running speed of the S-roller on the receiving side is synchronized with the continuous molding speed of the molding station.

[0077] The take-up side S-roller adopts a control method where the inlet tension is higher than the outlet tension. This ensures that the changes in roll diameter and winding torque generated at the winding station first act on the winding area after the take-up side S-roller, reducing the degree to which they are transmitted in reverse to the first straightening section, the second straightening section, the third straightening section, and the molding station.

[0078] The take-up motor at the take-up station uses the running speed of the S-roller on the take-up side as the reference for the take-up speed, ensuring that the take-up speed is coordinated with the linear speed of the entire continuous molding production line. The original process data clearly states that the take-up motor uses the speed of the two-stage S-roller as the reference.

[0079] A tension taper of 10% to 20% is used during the winding process.

[0080] As the winding diameter increases, the winding tension is gradually reduced to minimize the continuous compression of the composite texture already formed near the core side by subsequent layers.

[0081] The tension taper of 10% to 20% is the actual process setting range used by the winding machine, which is derived from the existing winding process parameters.

[0082] The existing instructions do not provide a fixed calculation function between tension taper and roll diameter. Therefore, this embodiment does not set an additional tension taper calculation formula. Instead, the winding machine controls the tension to gradually decrease as the roll diameter increases, based on a tension taper parameter of 10% to 20%.

[0083] This completes a continuous process chain: the S-roller on the feeding side isolates unwinding disturbances, a high and stable tension is established in the intermediate process zone, dynamic pressure adjustment is used for continuous molding, three-stage decreasing straightening is performed immediately after molding, the S-roller on the receiving side isolates winding disturbances, and low-tension tapered winding is achieved.

[0084] After the coil is rewound, the aluminum alloy coil is slit.

[0085] The slitting blade gap should be controlled within the range of 0.02 to 0.06 mm, and determined according to the actual thickness of the coil. For thinner aluminum alloy coils, a relatively smaller blade gap should be selected within the above range; as the thickness of the coil increases, the blade gap can be increased accordingly within the above range.

[0086] The reason for using this range is that excessively large blade gaps can easily lead to increased burrs on the cut, while excessively small blade gaps can increase the pressure of the blades on the edge of the coil material, easily forming indentations or micro-cracks. This parameter relationship is derived from existing slitting process parameters.

[0087] The runout of the slitting cutter shaft is controlled to be no more than 0.015mm, and the accuracy of the spacer is controlled to be ±0.005mm.

[0088] The width tolerance after slitting is selected from ±0.05mm to ±0.15mm based on the actual product size requirements. In other words, for products of the same specification, a fixed width tolerance is determined before production, such as ±0.05mm, ±0.10mm, or ±0.15mm. During the production process of that batch, inspection is carried out according to the determined tolerance, rather than allowing the width tolerance of the same product to vary arbitrarily between ±0.05mm and ±0.15mm.

[0089] After being slit, the aluminum alloy coils enter the CNC fixed-length shearing process.

[0090] The shearing gap should be controlled between 0.02 and 0.06 mm, with the specific value determined within this range based on the actual thickness of the board to be sheared.

[0091] The length tolerance after shearing is determined to be a fixed tolerance grade between ±0.1mm and ±0.2mm according to the specific product specifications, and processing and inspection are carried out in accordance with this tolerance grade.

[0092] The diagonal tolerance is controlled to be no more than 0.3mm.

[0093] After shearing, the board surface can be further inspected for flatness. In actual process parameters, the flatness after shearing is controlled to be 0.5–1.5 mm. For boards that need to be protected during subsequent handling, packaging, or surface treatment, a CPP molded texture-specific protective film can be applied to the textured surface. Relevant slitting, shearing, and finished product inspection parameters are all from existing production process data.

[0094] Taking an aluminum alloy coil with a thickness of 0.6mm as an example, its thickness falls within the tension parameter range of 0.5 to 0.8mm.

[0095] During production, the tension at the uncoiling station is determined within the range of 80–120 N, the tension in the area where the S-roller is located on the unwinding side is determined within the range of 80–110 N, the tension in the process area where the molding station and the three straightening sections are located is determined within the range of 90–130 N, the tension in the area where the S-roller is located on the take-up side is determined within the range of 70–100 N, and the tension at the winding station is determined within the range of 60–100 N.

[0096] The specific operating values ​​should be selected within the above range based on the actual condition of the production line. However, the selected operating values ​​must ensure that the tension in the process area where the molding and three straightening sections are located is higher than the tension at the S-roller on the feeding side, and that the tension at the S-roller on the feeding side is higher than the tension at the S-roller on the receiving side.

[0097] After the aluminum alloy coil enters the molding station via the S-roller on the feeding side, the sheet thickness infrared sensor collects thickness data at a feedback frequency of once per second. The PLC control system controls the hydraulic mechanism to adjust the molding pressure within the range of 10–60T according to the direction of thickness change. During the molding process, the coil running speed is maintained within the range of 5–15 m / min, the molding temperature is maintained within the range of 40–60℃, and a composite texture with a depth of 10–80 μm is formed on the surface of the coil.

[0098] Subsequently, the roll material continuously enters the first straightening section, the second straightening section, and the third straightening section. First, the relative compression degree of the first straightening section is determined. The second straightening section is adjusted to 70% to 75% of the first straightening section, and the third straightening section is adjusted to 40% to 50% of the first straightening section, so that the roll material successively undergoes a large degree of initial straightening, a medium degree of main straightening, and a small degree of fine straightening.

[0099] After the three-stage straightening is completed, the roll material enters the winding station via the S-roller on the take-up side. The take-up motor uses the running speed of the S-roller on the take-up side as the winding speed reference and opens the tension taper by 10% to 20% so that the winding tension gradually decreases as the roll diameter increases.

[0100] Finally, the wound-up material is slitted and CNC cut to length to obtain composite textured aluminum sheets of the required specifications.

[0101] When switching to aluminum alloy coils of other thicknesses, it is not necessary to change the entire process control logic. Instead, the corresponding tension parameter range is called according to the actual thickness of the coil, and the molding pressure and the basic pressing state of the first straightening section are re-determined. The second and third straightening sections are still adjusted in gradients according to 70% to 75% and 40% to 50% of the first straightening section, respectively.

[0102] Therefore, the thickness of the roll material in this embodiment is not only used to select a fixed processing parameter, but also participates in the dynamic molding pressure control and the selection of zone tension parameters. The three-stage gradient straightening after molding is carried out continuously within the stable process tension zone established by the front and rear S rollers. After straightening, the take-up side S roller and the tension taper winding together limit the winding disturbance and texture extrusion. A continuous control relationship is formed between each process.

[0103] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A method for preparing composite textured aluminum plates by dynamic pressure adjustment and continuous molding, characterized in that, Includes the following steps: S1: After the aluminum alloy coil is uncoiled, it is conveyed to the molding station via the uncoiling side S roller. The tension fluctuations generated during the uncoiling process are isolated by the uncoiling side S roller. S2: Obtain the thickness data of the aluminum alloy coil entering the molding station, send the thickness data to the PLC control system, and control the hydraulic mechanism to adjust the molding pressure according to the thickness data. The molding pressure increases with the increase of the thickness of the aluminum alloy coil and decreases with the decrease of the thickness of the aluminum alloy coil. A composite engraving molding die is used to continuously mold the aluminum alloy coil to form a composite texture on the surface of the aluminum alloy coil. S3: The molded aluminum alloy coil is continuously straightened by passing it through the first straightening section, the second straightening section and the third straightening section in sequence. The first straightening section uses the maximum relative reduction among the three straightening sections, the relative reduction of the second straightening section is 70% to 75% of the relative reduction of the first straightening section, and the relative reduction of the third straightening section is 40% to 50% of the relative reduction of the first straightening section, so that the curvature of the first straightening section, the second straightening section and the third straightening section decreases in sequence. S4: The straightened aluminum alloy coil is conveyed to the winding station via the take-up side S roller. The tension fluctuations generated during the winding process are isolated by the take-up side S roller, and the tension in the process area where the molding station and the three straightening sections are located is higher than the tension at the unloading side S roller and the take-up side S roller. S5: The aluminum alloy coil obtained from the winding is slit, and the slit aluminum alloy coil is CNC cut to length to obtain composite textured aluminum plate.

2. The method for preparing composite textured aluminum plates by dynamic pressure adjustment and continuous molding according to claim 1, characterized in that: The thickness of the aluminum alloy coil is 0.3–2.0 mm; The aluminum alloy coil has a hardness of 65-75HV, a tensile strength of not less than 200MPa, and an elongation of not less than 8%.

3. The method for preparing composite textured aluminum plates by dynamic pressure adjustment and continuous molding according to claim 2, characterized in that: In S2, the thickness data is collected in real time by the plate thickness infrared sensor. The plate thickness infrared sensor sends the collected thickness data to the PLC control system every second. The PLC control system controls the hydraulic mechanism to adjust the molding pressure of the composite engraving mold according to the received thickness data. The adjustment range of the molding pressure is 10 to 60t.

4. The method for preparing a composite textured aluminum plate by dynamic pressure adjustment and continuous molding according to claim 3, characterized in that: In S2, aluminum alloy coils pass continuously through the molding station at a speed of 5-15 m / min, and the molding temperature is 40-60℃. The molding surface of the composite engraving mold has a multi-layered composite texture formed by the superposition of grating dot matrix, geometric array and biomimetic texture. The aluminum alloy coil forms a composite texture with a depth of 10 to 80 μm after continuous molding.

5. The method for preparing composite textured aluminum plates by dynamic pressure adjustment and continuous molding according to claim 4, characterized in that: The wrap angle between the S-roller on the feeding side and the aluminum alloy coil is 120° to 160°, and a pre-compression of 0.02 to 0.05 mm is applied to the aluminum alloy coil before it enters the molding station. The wrap angle between the S-roller on the receiving side and the aluminum alloy coil is 120° to 145°. The running speed of the feeding side S-roller and the receiving side S-roller is synchronized with the continuous molding speed of the molding station.

6. The method for preparing a composite textured aluminum plate by dynamic pressure adjustment and continuous molding according to claim 5, characterized in that: Based on the thickness of the aluminum alloy coil, determine the tension after uncoiling, the tension at the S-roller on the unwinding side, the tension in the process area where the molding station and the three straightening sections are located, the tension at the S-roller on the rewinding side, and the tension at the rewinding station. When the thickness of the aluminum alloy coil is 0.3 to 0.5 mm, the tension at each point is selected from the ranges of 70 to 100 N, 70 to 100 N, 80 to 110 N, 60 to 90 N, and 50 to 80 N respectively. When the thickness of the aluminum alloy coil is 0.5 to 0.8 mm, the tension at each point is selected from the ranges of 80 to 120 N, 80 to 110 N, 90 to 130 N, 70 to 100 N, and 60 to 100 N respectively. When the thickness of the aluminum alloy coil is 0.8 to 1.5 mm, the tension at each point is selected from the ranges of 90 to 130 N, 110 to 130 N, 110 to 160 N, 90 to 120 N, and 80 to 130 N respectively. When the thickness of the aluminum alloy coil is 1.5 to 2.0 mm, the tension at each point is selected from the range of 100 to 140 N, 120 to 150 N, 130 to 180 N, 100 to 140 N and 90 to 150 N respectively. Then, determine the tension at each point within the corresponding tension range, so that the process area where the molding station and the three straightening sections are located forms a tension zone higher than that at the S-roller on the feeding side and the S-roller on the receiving side.

7. The method for preparing a composite textured aluminum plate by dynamic pressure adjustment and continuous molding according to claim 6, characterized in that: The first, second, and third straightening sections together constitute a three-stage straightening station. The three-stage straightening station includes 5 shaping rollers, 10 auxiliary shaping rollers, 8 shaping roller supports, 2 parallel pressure rollers, and shaping pressure rollers. The diameter of the shaping rollers and auxiliary shaping rollers is 40mm, the diameter of the shaping roller supports is 75mm, and the diameter of the parallel pressure rollers and shaping pressure rollers is 185mm.

8. The method for preparing composite textured aluminum plates by dynamic pressure adjustment and continuous molding according to claim 7, characterized in that: The first, second, and third straightening sections employ a servo adjustment structure to regulate the relative reduction. The first straightening section is the initial straightening section at the inlet, the second straightening section is the main straightening section in the middle, and the third straightening section is the fine straightening section at the outlet. The relative reduction is decreased segment by segment in the order of the first, second, and third straightening sections.

9. The method for preparing a composite textured aluminum plate by dynamic pressure adjustment and continuous molding according to claim 8, characterized in that: The running speed of the S-roller on the take-up side is synchronized with the continuous molding speed of the molding station, and the take-up motor of the winding station uses the running speed of the S-roller on the take-up side as the winding speed reference. The winding station winds the aluminum alloy coil with a tension taper of 10% to 20%, and the winding tension is reduced as the winding diameter of the aluminum alloy coil increases.

10. The method for preparing a composite textured aluminum plate by dynamic pressure adjustment and continuous molding according to claim 9, characterized in that: In S5, the blade clearance during slitting is 0.02 to 0.06 mm, the blade shaft runout is no more than 0.015 mm, the spacer accuracy is ±0.005 mm, and the width tolerance after slitting is ±0.05 to ±0.15 mm. The shearing gap during CNC fixed-length shearing is 0.02~0.06mm, the length tolerance is ±0.1~0.2mm, and the diagonal tolerance is no more than 0.3mm.

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