A method and system for designing a high voltage roller for testing the voltage resistance of a metal thin film

Abstract

This application relates to the field of electrical properties technology for thin metal films, and provides a design method and system for a high-pressure roller for testing the pressure resistance of thin metal films. The method involves determining that the negative electrode of the high-pressure roller is a rotatable stainless steel roller, which is coaxially and fixedly connected to a stainless steel shaft; configuring a conductive rubber as the positive electrode, with a thickness set within a preset thickness range and a width narrower than a preset width range of the thin metal film to be tested; wrapping a acetal steel insulating sleeve around the shoulder of the stainless steel shaft and adding another acetal steel insulating sleeve at the mounting plate of the high-pressure roller to block the conductive path between the stainless steel shaft and the mounting plate; setting a brush to contact the stainless steel shaft; configuring a winding motor, connected to the stainless steel shaft via a synchronous belt, so that the winding motor drives the stainless steel roller to rotate, causing the thin metal film to be tested to move at a speed within a preset speed range, thus completing the pressure resistance test and the high-pressure roller design. The acetal steel insulating sleeves at both the shaft shoulder and the mounting plate provide double insulation protection.

Description

Technical Field

[0001] This application relates to the field of electrical properties of metal thin films, and in particular to a design method and system for a high-pressure roller for testing the pressure resistance of metal thin films. Background Technology

[0002] The withstand voltage test of the coating on the surface of a metal thin film is a critical step in the quality inspection of thin film production. Existing withstand voltage testing equipment has several shortcomings: the insulation protection layer between the roller shaft and the mounting frame is insufficient, which easily leads to leakage current during high-voltage testing and poor test stability; the contact parameters of the positive and negative electrodes lack matching design, resulting in poor uniformity of contact between the electrodes and the thin film coating, which easily causes partial discharge and low test accuracy; the high-voltage conduction structure is poorly compatible with the film-moving drive structure, making it impossible to maintain a stable high-voltage output under continuous film-moving conditions, resulting in low continuous testing efficiency. Summary of the Invention

[0003] This application provides a design method and system for a high-pressure roller for testing the withstand voltage of metal films, aiming to solve the problems of insufficient insulation protection between the roller shaft and the mounting frame, easy leakage current during high-pressure testing, and poor test stability.

[0004] In a first aspect, embodiments of this application provide a design method for a high-pressure roller for testing the pressure resistance of a metal thin film, the method comprising: The negative electrode of the high-pressure roller is determined to be a rotatable stainless steel roller. The diameter of the stainless steel roller is set within a preset diameter range, and the stainless steel roller is coaxially and fixedly connected to the stainless steel shaft. A conductive rubber is configured as the positive electrode. The surface roughness of the conductive rubber is set within a preset roughness range, the thickness is set within a preset thickness range, and the width is set to be narrower than the preset width range of the metal film to be tested. A acetal insulating sleeve is wrapped around the shoulder of the stainless steel shaft, and an additional acetal insulating sleeve is added to the mounting plate of the high-pressure roller to form a double insulation protection structure, blocking the conductive path between the stainless steel shaft and the mounting plate; a brush is set to contact the stainless steel shaft to realize the conduction of high voltage to the stainless steel roller. A winding motor is configured, which is connected to a stainless steel shaft via a synchronous belt. The winding motor drives the stainless steel roller to rotate, causing the metal film to be tested to move at a speed within a preset range, thus completing the pressure resistance test and high-pressure roller design.

[0005] In some embodiments, determining that the negative electrode of the high-pressure roller is a rotatable stainless steel roller, setting the diameter of the stainless steel roller within a preset diameter range, and fixing the stainless steel roller and the stainless steel shaft coaxially, includes: selecting the stainless steel roller as the negative electrode, setting the diameter of the stainless steel roller to 100 mm, fixing the stainless steel roller and the stainless steel shaft coaxially, so that the stainless steel roller rotates synchronously with the stainless steel shaft and maintains conductive connection.

[0006] In some embodiments, the conductive rubber configured as the positive electrode has its surface roughness set within a preset roughness range, including: selecting the conductive rubber as the positive electrode, setting the working surface roughness of the conductive rubber to 0.2 micrometers, so that the working surface of the conductive rubber forms a uniform surface contact with the metal coating of the metal thin film to be tested.

[0007] In some embodiments, the thickness is set within a preset thickness range, and the width is set to be narrower than a preset width range of the metal film to be tested, including: setting the thickness of the conductive rubber to 2 to 3 millimeters, and setting the width of the conductive rubber to be 20 to 30 millimeters narrower than the metal film to be tested, so that the contact area of ​​the conductive rubber falls entirely within the metal coating area of ​​the metal film to be tested.

[0008] In some embodiments, the step of wrapping a acetal insulating sleeve around the shoulder of the stainless steel shaft and adding a acetal insulating sleeve at the mounting plate of the high-pressure roller to form a double insulation protection structure and block the conductive path between the stainless steel shaft and the mounting plate includes: wrapping the acetal insulating sleeve around the outside of the shoulder of the stainless steel shaft and adding a acetal insulating sleeve at the mating position between the mounting plate and the stainless steel shaft to form two insulation barriers between the stainless steel shaft and the mounting plate, thereby blocking the conduction of high-voltage current to the mounting plate.

[0009] In some embodiments, the configuration of the winding motor is connected to the stainless steel shaft via a synchronous belt. The winding motor drives the stainless steel roller to rotate, causing the metal film under test to move at a speed within a preset speed range, thereby completing the pressure resistance test and high-pressure roller design. This includes: connecting the output end of the winding motor to the stainless steel shaft via a synchronous belt, adjusting the speed of the winding motor to make the metal film under test move at a speed of two to five meters per minute, continuously applying a test voltage during the movement, and completing the pressure resistance test of the metal film.

[0010] In some embodiments, the method further includes: acquiring current data in the test circuit in real time, comparing the current value with a preset threshold through a breakdown determination algorithm, identifying the withstand voltage breakdown point of the metal film, and recording the film position and corresponding test voltage corresponding to the breakdown point.

[0011] In some embodiments, the method further includes: acquiring coating width data of the metal film to be tested, calculating the appropriate width of the insulating regions on both sides through a parameter matching algorithm, and automatically adjusting the installation position of the acetal sleeve and the pasting position of the right insulating tape to ensure that the insulating region is aligned with the coating boundary.

[0012] In some embodiments, the method further includes: inputting the nominal withstand voltage rating of the metal thin film to be tested, matching the corresponding test voltage and film moving speed through an adaptive adjustment algorithm, generating a test parameter combination suitable for the current sample, automatically loading the parameters and starting the test process.

[0013] Secondly, this application provides a high-pressure roller design system for testing the pressure resistance of metal thin films, the system comprising: The range setting unit is used to determine that the negative electrode of the high-pressure roller is a rotatable stainless steel roller, and sets the diameter of the stainless steel roller within a preset diameter range, so that the stainless steel roller is coaxially and fixedly connected to the stainless steel shaft; a conductive rubber is configured as the positive electrode, and the surface roughness of the conductive rubber is set within a preset roughness range, the thickness is set within a preset thickness range, and the width is set to be narrower than the preset width range of the metal film to be tested. The contact conduction unit is used to wrap a acetal insulating sleeve around the shoulder of the stainless steel shaft and to add a acetal insulating sleeve at the mounting plate of the high-pressure roller, forming a double insulation protection structure to block the conductive path between the stainless steel shaft and the mounting plate; and to set a brush to contact the stainless steel shaft to realize the conduction of high voltage to the stainless steel roller. The pressure resistance test unit is used to configure the winding motor. The winding motor is connected to the stainless steel shaft via a synchronous belt. The winding motor drives the stainless steel roller to rotate, so that the metal film under test moves at a speed within a preset speed range to complete the pressure resistance test and the design of the high-pressure roller.

[0014] This application uses acetal insulating sleeves at both the shaft shoulder and the mounting plate to form double insulation protection, completely blocking the conductive path between the stainless steel shaft and the mounting plate, effectively avoiding high-voltage leakage, and improving the insulation safety and operational stability of the high-voltage testing process.

[0015] The structural parameters of the stainless steel roller negative electrode and the conductive rubber positive electrode are matched to ensure that the positive and negative electrodes form a uniform and stable conductive contact with the metal film under test, eliminate partial discharge interference, and improve the detection accuracy of the withstand voltage test.

[0016] High voltage conduction is achieved by using a brush in contact with a stainless steel shaft. Combined with a winding motor and synchronous belt transmission structure, a stable high voltage output can be maintained during continuous film movement, enabling continuous film-walking pressure resistance testing and improving testing efficiency.

[0017] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and do not limit this application. Attached Figure Description

[0018] To more clearly illustrate the technical solutions of the embodiments of this application, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1 This is a schematic flowchart illustrating the steps of a high-pressure roller design method for testing the pressure resistance of a metal thin film according to an embodiment of this application; Figure 2 This is a schematic diagram of the structure of a high-pressure roller for testing the pressure resistance of a metal thin film according to an embodiment of this application; Figure 3 This is a schematic block diagram of a high-pressure roller design system for testing the pressure resistance of a metal thin film according to an embodiment of this application; Figure 4 This is a schematic block diagram of the structure of a computer device provided in an embodiment of this application.

[0020] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and do not limit this application. Detailed Implementation

[0021] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0022] The flowchart shown in the attached diagram is for illustrative purposes only and does not necessarily include all content and operations / steps, nor does it necessarily have to be performed in the order described. For example, some operations / steps can be broken down, combined, or partially merged, so the actual execution order may change depending on the actual situation.

[0023] It should be understood that, in order to clearly describe the technical solutions of the embodiments of the present invention, the terms "first" and "second" are used in the embodiments of the present invention to distinguish identical or similar items with essentially the same function and effect. Those skilled in the art will understand that the terms "first" and "second" do not limit the quantity or execution order, and the terms "first" and "second" are not necessarily different.

[0024] It should be understood that the terminology used in this specification is for the purpose of describing particular embodiments only and is not intended to limit the scope of the application. As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms unless the context clearly indicates otherwise.

[0025] It should also be understood that the term “and / or” as used in this application specification and the appended claims means any combination of one or more of the associated listed items and all possible combinations, and includes such combinations.

[0026] The withstand voltage test of the coating on the surface of a metal thin film is a critical step in the quality inspection of thin film production. Existing withstand voltage testing equipment has several shortcomings: the insulation protection layer between the roller shaft and the mounting frame is insufficient, which easily leads to leakage current during high-voltage testing and poor test stability; the contact parameters of the positive and negative electrodes lack matching design, resulting in poor uniformity of contact between the electrodes and the thin film coating, which easily causes partial discharge and low test accuracy; the high-voltage conduction structure is poorly compatible with the film-moving drive structure, making it impossible to maintain a stable high-voltage output under continuous film-moving conditions, resulting in low continuous testing efficiency.

[0027] Please refer to Figure 1 and Figure 2 This embodiment provides a high-pressure roller design method for testing the pressure resistance of metal thin films, which can be applied to computer equipment with parameter calculation and equipment control capabilities. The computer equipment can be independently deployed in the local control system of the pressure resistance testing equipment, or it can be deployed on a remote server and establish data interaction with the testing equipment through wired or wireless communication links, adapting to various implementation scenarios such as single-machine deployment, cluster deployment, and terminal embedded deployment. All sample parameters, equipment operation data, and test result data involved in this method are collected, stored, and processed with the formal authorization of the relevant parties, and the entire process complies with relevant data security and privacy protection regulations.

[0028] The following is combined Figure 1 The method and process shown are the same as Figure 2 The apparatus structure shown illustrates the core steps and optional implementation methods of this method in detail.

[0029] The provided design method for a high-pressure roller for testing the pressure resistance of metal thin films includes steps S101 to S103. Details are as follows: Step S101. Determine that the negative electrode of the high-pressure roller is a rotatable stainless steel roller, set the diameter of the stainless steel roller within a preset diameter range, and fix the stainless steel roller and the stainless steel shaft coaxially; configure a conductive rubber as the positive electrode, set the surface roughness of the conductive rubber within a preset roughness range, the thickness within a preset thickness range, and the width to be narrower than the preset width range of the metal film to be tested.

[0030] Specifically, let's first clarify the definition of the high-pressure roller in this application: The core testing component of the high-pressure roller is the stainless steel roller labeled 1 in the attached figure. The overall high-pressure roller assembly includes a stainless steel roller 1 and a stainless steel shaft 2 that is rigidly connected to it on the same axis. The two rotate synchronously and jointly bear the negative high-voltage potential. The negative electrode of the high-pressure roller assembly is determined to be the rotatable stainless steel roller 1. The diameter of the stainless steel roller is set within a preset diameter range, so that the stainless steel roller 1 and the stainless steel shaft 2 are fixedly connected on the same axis.

[0031] This step completes the pressure resistance test and the selection, dimensional parameter setting, and assembly relationship determination of the positive and negative electrodes of the high-pressure roller design circuit. This establishes a stable and low-deviation conductive contact foundation for subsequent continuous film-running pressure resistance tests. First, the structural form of the negative electrode is determined, and a stainless steel roller that can rotate freely around its own axis is selected as the test negative electrode. Stainless steel has excellent conductivity, surface wear resistance, and structural rigidity, which can maintain a stable conductive contact surface and structural accuracy during long-term continuous film-running tests, and is not prone to surface corrosion and wear deformation. The surface of the stainless steel roller is subjected to ultra-mirror polishing and passivation treatment to further reduce surface micro-protrusions, avoid tip discharge, and improve the corrosion resistance of the roller surface. The diameter range of the stainless steel roller is preset to make the roller circumference and film-running speed compatible, ensuring that the pressure time per unit length of film passing through the test area is within the set range. If the roller diameter is too small, the film wrap angle will be too large, resulting in bending damage and stress concentration; if the diameter is too large, the equipment space occupied will be significantly increased, and the uniformity of the roller surface linear speed will decrease. The stainless steel roller and the stainless steel shaft are coaxially fixedly connected. The connection method can be a rigid connection such as heat-fitted interference fit or flat key connection. Before connection, the mating surfaces of the two are precisely ground and coated with a conductive medium to ensure that there is no gap between the contact surfaces. This ensures that there is no relative rotation between the stainless steel roller and the stainless steel shaft. The two can rotate synchronously and maintain a tight metal-to-metal contact, so that high voltage can be evenly conducted through the stainless steel shaft to the entire roller surface of the stainless steel roller, avoiding the problem of uneven circumferential and axial voltage distribution on the roller surface.

[0032] Simultaneously, the positive electrode of the test circuit is configured, using carbon black-filled conductive rubber as the positive electrode contact component. The conductive rubber possesses a certain degree of elastic deformation capability, allowing it to adapt to the microscopic undulations of the metal film surface through minute deformation when in contact, forming a surface-to-surface contact effect and preventing the hard electrode from scratching the film coating. A pressure-equalizing elastic pad is added to the back of the conductive rubber to ensure uniform distribution of contact pressure along the width of the conductive rubber, eliminating the defect of excessive pressure at both ends and insufficient pressure in the middle. The surface roughness range of the conductive rubber is preset to control the flatness of the working surface, ensuring that the contact resistance between the conductive rubber and the metal coating is uniform along the width direction, avoiding excessively high local contact resistance that could generate discharge hotspots and affect the accuracy of the test results. The thickness range of the conductive rubber is preset to provide sufficient elasticity to adapt to film undulations, while avoiding excessive thickness that could lead to insufficient structural rigidity and uneven contact pressure distribution. The width range of the conductive rubber is preset so that the width of the conductive rubber is smaller than the overall width of the metal film to be tested. This ensures that the positive electrode contact area is completely covered by the metal coating of the film during the test, preventing the positive electrode from extending beyond the coating boundary and contacting the film substrate, thus preventing test leakage and result deviation.

[0033] Step S102. Wrap a acetal insulating sleeve around the shoulder of the stainless steel shaft and add a acetal insulating sleeve to the mounting plate of the high-pressure roller to form a double insulation protection structure, blocking the conductive path between the stainless steel shaft and the mounting plate; set a brush to contact the stainless steel shaft to realize the conduction of high voltage to the stainless steel roller.

[0034] Specifically, a acetal insulating sleeve is wrapped around the outer wall of the stainless steel shaft 2 near the shoulder of the stainless steel roller 1 (the shaft step between the stainless steel roller and the mounting plate) as the first layer of insulation. A acetal insulating sleeve 3 (as shown in the attached diagram) is embedded in the shaft hole of the mounting plate of the high-pressure roller assembly as the second layer of insulation. The two acetal insulating sleeves form a double insulation protection structure. A uniform assembly gap is left between the acetal insulating sleeve 3 and the stainless steel shaft 2 to ensure free rotation of the shaft and completely block the conductive path between the stainless steel shaft and the mounting plate. An independent brush assembly is set so that it elastically abuts against the exposed shaft section surface of the stainless steel shaft 2 to form contact and conduction, so as to realize the stable conduction of high voltage to the high-pressure roller assembly.

[0035] This step constructs a double-insulation protection system for the high-voltage circuit and a rotating high-voltage input path to block high-voltage current from flowing into the equipment frame, ensuring the safety and voltage stability of the testing process. First, a double-insulation protection structure is built. The first layer of insulation is located at the shoulder of the stainless steel shaft, with a acetal alloy insulating sleeve wrapped around the outer surface of the shoulder. The inner hole of the acetal alloy insulating sleeve precisely matches the outer diameter of the shoulder, and a positioning boss at the end is embedded in the shoulder groove to prevent axial movement during operation. acetal alloy possesses excellent insulation properties, mechanical strength, and high-voltage resistance, allowing it to stably block the current conduction path while withstanding radial loads on the shaft system. The second layer of insulation is located at the mounting plate of the high-voltage roller. A acetal alloy insulating sleeve with a flange is installed at the mating assembly position between the mounting plate and the stainless steel shaft. The flange fits against the outer end face of the mounting plate, increasing the creepage distance. The stainless steel shaft passes through the inner hole of the insulating sleeve, with a uniform assembly gap between them to ensure free rotation of the shaft. A dry air insulation layer forms within the gap, which, together with the acetal alloy material on both sides, constitutes a composite insulation structure. The double insulation protection structure is formed by two acetal steel insulating sleeves at the shaft shoulder and the mounting plate, creating two independent insulation barriers between the stainless steel shaft and the mounting plate. Combined with the air insulation gap in the middle, a three-level insulation barrier is formed. Even if one insulation layer is worn or damaged, the remaining insulation structure can still maintain its complete insulation performance, completely blocking the conductive path between the stainless steel shaft and the mounting plate, avoiding leakage and current leakage during high-voltage testing, and improving the safety and long-term stability of equipment operation.

[0036] After completing the insulation structure configuration, the brush assembly is installed. The brushes are made of metal graphite and equipped with a constant-pressure spring mechanism, ensuring that the conductive contact ends of the brushes elastically press against the outer circumferential surface of the stainless steel shaft with constant pressure. The brushes are arranged in a parallel dual-brush configuration, with two sets of brushes symmetrically distributed on both sides of the stainless steel shaft. Even if one set of brushes experiences poor contact, the other set can still maintain normal conductivity, reducing contact resistance and improving the reliability of high-voltage conduction. The other end of the brushes is connected to the output terminal of an external high-voltage power supply. When the high-voltage power supply outputs the test voltage, the current is conducted through the stationary brushes to the rotating stainless steel shaft, and then through the stainless steel shaft to the entire surface of the stainless steel roller. This achieves stable high-voltage conduction to the rotating stainless steel roller, ensuring a continuous and stable voltage on the negative electrode during the film-running test, preventing voltage interruptions, fluctuations, or contact sparks due to shaft rotation.

[0037] Step S103. Configure a winding motor, connect the winding motor and the stainless steel shaft through a synchronous belt, and drive the stainless steel roller to rotate so that the metal film to be tested moves at a speed within a preset speed range to complete the pressure resistance test and high pressure roller design.

[0038] Specifically, this step simultaneously completes the design of the transmission system for the high-pressure roller assembly and the execution of continuous film-feeding pressure resistance tests, perfects the complete structural design of the entire high-pressure roller set, and puts it into practical testing.

[0039] First, the design and assembly of the transmission system for the high-pressure roller were completed. As the power component of the entire high-pressure roller structure, a continuously variable speed winding motor was selected as the power source, paired with a precision reducer to output torque. The winding motor was fixedly mounted on the transmission side of the mounting plate, ensuring the output shaft of the winding motor was parallel to the stainless steel shaft. A drive pulley was installed at the output end of the winding motor, and a driven pulley was installed at the end of the stainless steel shaft passing through the mounting plate and located outside the acetal insulating sleeve. A synchronous belt was fitted onto the drive and driven pulleys to form a transmission connection. An adjustable tensioning wheel was configured to press the slack side of the synchronous belt, maintaining stable tension and preventing the belt from loosening and slipping after long-term operation. The synchronous belt drive has the characteristics of accurate transmission ratio and no slippage. Combined with a rotary encoder installed at the end of the stainless steel shaft to form a closed-loop speed feedback, the control deviation of the film feeding speed can be controlled within the set range, ensuring stable and controllable speed of the stainless steel roller. Thus, combining the electrode main structure in step S101 and the insulation protection and high-voltage conduction structure in step S102, the complete structural design of the entire high-pressure roller was completed.

[0040] Subsequently, based on the completed high-pressure roller design, a metal film withstand voltage test was performed: Before the test started, a circuit self-check was performed to check the insulation status between the positive and negative electrodes and the continuity status of the circuit. The test was only started after confirming there were no short circuits or insulation abnormalities. After the test started, the winding motor was driven to rotate, which in turn drove the stainless steel shaft and stainless steel roller to rotate synchronously via a synchronous belt. This pulled the metal film to be tested, which was wrapped around the surface of the stainless steel roller, to move at a constant speed. After the film speed stabilized within the preset speed range, the test voltage was gradually increased to the set value using a stepped voltage increase method to avoid instantaneous high-voltage impact causing non-defective breakdown of the sample. During the test, the metal film to be tested passed through the gap between the stainless steel roller and the conductive rubber at the end of the swing arm at a constant speed. The substrate side of the film contacted the stainless steel roller, which served as the negative electrode, and the metal coating side of the film contacted the conductive rubber, which served as the positive electrode, forming a complete withstand voltage test circuit. During the continuous movement of the film, the test circuit continuously applied a stable withstand voltage test voltage to the film segment passing through the contact area, completing continuous withstand voltage testing of the entire effective area of ​​the roll of metal film, achieving roll-to-roll online withstand voltage quality inspection. When the test is finished, the test voltage should be gradually reduced to zero before stopping the winding motor and film feeding to avoid the sample being subjected to high voltage in a localized area for an extended period of time.

[0041] In some embodiments, the preset speed range is set to two to five meters per minute, and can be adjusted within this range according to the pressure resistance level of the sample: for high pressure resistance level samples, the film feeding speed is reduced to ensure test adequacy, while for low pressure resistance level samples, the film feeding speed is increased to improve detection efficiency; the rotational speed of the winding motor is adjusted in real time by the control system based on encoder feedback in a closed loop to offset speed deviations caused by load fluctuations and ensure film feeding speed stability.

[0042] In some embodiments, determining that the negative electrode of the high-pressure roller is a rotatable stainless steel roller, setting the diameter of the stainless steel roller within a preset diameter range, and fixing the stainless steel roller and the stainless steel shaft coaxially, includes: selecting the stainless steel roller as the negative electrode, setting the diameter of the stainless steel roller to 100 mm, fixing the stainless steel roller and the stainless steel shaft coaxially, so that the stainless steel roller rotates synchronously with the stainless steel shaft and maintains conductive connection.

[0043] This embodiment further defines the negative electrode parameters and assembly method in step S101. A stainless steel roller is selected as the negative electrode for the pressure withstand test, and its diameter is set to 100 millimeters. At this diameter, the contact angle between the roller and the metal film is within a reasonable range. This ensures sufficient contact arc length to improve the effectiveness of the pressure test, allowing the pressure application time per unit length of film to meet the detection sensitivity requirements. It also avoids a significant increase in the overall equipment size due to an excessively large roller, while accommodating film flow speeds of several meters per minute, preventing excessive fluctuations in roller surface linear speed that could affect test stability. The two ends of the stainless steel roller are rounded to eliminate the sharp discharge effect of right-angled edges, preventing localized discharge at the roller edges from interfering with the test results during testing.

[0044] The stainless steel roller and stainless steel shaft are coaxially fixed and assembled. Before assembly, the mating section of the stainless steel shaft and the inner hole of the stainless steel roller are precision ground to ensure that the coaxiality error is controlled within the set tolerance range. The stainless steel roller is fitted onto the corresponding position of the stainless steel shaft using a heat-fit interference fit. The heating temperature is controlled within the material's allowable range. After cooling, a gapless rigid connection is formed. For high-torque applications, a flat key can be added to the mating surface to transmit greater torque. After assembly, a conductive sealing medium is applied to the mating end faces to fill microscopic gaps, ensuring a tight fit between the metal contact surfaces and maintaining a stable conductive connection. Ultimately, the stainless steel roller and stainless steel shaft do not rotate relative to each other and can rotate synchronously with the stainless steel shaft, allowing the high-voltage current to be evenly distributed across the entire roller surface, avoiding localized high or low voltage issues.

[0045] In some embodiments, the conductive rubber configured as the positive electrode has its surface roughness set within a preset roughness range, including: selecting the conductive rubber as the positive electrode, setting the working surface roughness of the conductive rubber to 0.2 micrometers, so that the working surface of the conductive rubber forms a uniform surface contact with the metal coating of the metal thin film to be tested.

[0046] This embodiment further defines the surface roughness parameters and contact effect of the conductive rubber in step S101. The conductive rubber is selected as the positive electrode for the pressure resistance test. It is manufactured using a molding process, and after molding, the working surface undergoes precision grinding and polishing, setting the surface roughness to 0.2 micrometers. At this roughness level, the working surface of the conductive rubber achieves a high degree of flatness, with no obvious protrusions or pits, and the overall surface roughness deviation is controlled within a very small range. The two edges of the conductive rubber are machined with rounded transitions to avoid sharp edges scratching the metal thin film coating.

[0047] When the conductive rubber is pressed onto the metal coating surface of the metal film under test with a set pressure, the contact pressure and contact resistance are evenly distributed across the entire contact surface in conjunction with the equalizing pad layer on the back, preventing localized poor contact or excessively high local current density. During the test, the working surface of the conductive rubber forms a uniform surface contact with the metal coating of the metal film under test, ensuring that the test voltage is applied evenly to the corresponding film area. This avoids phenomena such as partial discharge and micro-sparks caused by uneven contact, eliminates interference from contact factors on the withstand voltage test results, and improves the accuracy of the test results and the repeatability of tests between different batches.

[0048] In some embodiments, the thickness is set within a preset thickness range, and the width is set to be narrower than a preset width range of the metal film to be tested, including: setting the thickness of the conductive rubber to 2 to 3 millimeters, and setting the width of the conductive rubber to be 20 to 30 millimeters narrower than the metal film to be tested, so that the contact area of ​​the conductive rubber falls entirely within the metal coating area of ​​the metal film to be tested.

[0049] This embodiment further limits the thickness and width parameters of the conductive rubber in step S101, setting the thickness of the conductive rubber to two to three millimeters. Conductive rubber within this thickness range possesses moderate elastic deformation capability, and the deformation can cover the microscopic undulations and slight warping of common metal films. When in contact with a metal film, it can adapt to the minute undulations of the film surface through slight deformation, ensuring effective contact across the entire width range. Simultaneously, the conductive rubber at this thickness provides sufficient structural support, preventing excessive deformation due to excessive thickness leading to dispersed contact pressure, and also preventing insufficient elasticity and contact pressure due to insufficient thickness. The appropriate thickness can be selected within this range based on the surface flatness of the film; a thicker conductive rubber is selected for samples with larger surface undulations, while a thinner conductive rubber is selected for samples with flat surfaces.

[0050] The width of the conductive rubber is set to be 20 to 30 millimeters narrower than the metal film under test, meaning that the two sides of the conductive rubber are recessed by 10 to 15 millimeters compared to the two sides of the metal film under test. The recess amount can be adapted to the total width of the film; a smaller recess value is selected for narrow films, and a larger recess value for wide films. Since the two sides of the metal film under test have insulating areas, and the middle area is the effective metal plating layer, this width setting ensures that the contact area of ​​the conductive rubber falls entirely within the metal plating layer of the metal film under test, while maintaining a safe distance from the plating boundary. This prevents the sides of the conductive rubber from extending beyond the plating boundary and contacting the film substrate or edge insulating areas, thus preventing leakage in the test circuit and incomplete test voltage application, ensuring the integrity of the test circuit and the validity of the test results.

[0051] In some embodiments, the step of wrapping a acetal insulating sleeve around the shoulder of the stainless steel shaft and adding a acetal insulating sleeve at the mounting plate of the high-pressure roller to form a double insulation protection structure and block the conductive path between the stainless steel shaft and the mounting plate includes: wrapping the acetal insulating sleeve around the outside of the shoulder of the stainless steel shaft and adding a acetal insulating sleeve at the mating position between the mounting plate and the stainless steel shaft to form two insulation barriers between the stainless steel shaft and the mounting plate, thereby blocking the conduction of high-voltage current to the mounting plate.

[0052] The first insulating barrier is formed by tightly wrapping the acetal insulating sleeve around the outer shoulder of the stainless steel shaft 2 near the stainless steel roller 1. The second insulating barrier is formed by installing the acetal insulating sleeve 3 (as shown in the attached diagram) at the mating shaft hole position between the mounting plate and the stainless steel shaft. The outer ring of the insulating sleeve is interference-fitted to the shaft hole of the mounting plate, and the inner ring is left with a rotational clearance to the stainless steel shaft. Two independent insulating barriers are formed between the stainless steel shaft and the mounting plate to block the high voltage current from being conducted to the mounting plate.

[0053] This embodiment further defines the setting method and function of the double insulation protection structure in step S102. The acetal insulating sleeve is wrapped around the outside of the shoulder of the stainless steel shaft. The shoulder is located at the step where the diameter of the stainless steel shaft changes. The inner diameter of the acetal insulating sleeve is adapted to the outer diameter of the shoulder. After being fitted, it fits tightly against the surface of the shoulder. The end face of the insulating sleeve abuts against the inner end face of the stainless steel roller, which has the dual functions of axial positioning and insulation barrier, forming the first insulation barrier to block the high voltage current from being conducted along the axial direction of the stainless steel shaft towards the mounting plate.

[0054] A acetal insulating sleeve is installed at the mating position between the mounting plate and the stainless steel shaft. This acetal insulating sleeve is embedded in the shaft hole of the mounting plate, with its outer ring interference-fitted to the shaft hole. The stainless steel shaft passes through the inner hole of the insulating sleeve, leaving a uniform assembly clearance between them to ensure free rotation of the stainless steel shaft. The dry air within this clearance forms an auxiliary insulating layer. A radial flange is provided at the outer end of the acetal insulating sleeve, fitting against the outer end face of the mounting plate, effectively extending the surface creepage distance and forming a second insulating barrier, blocking the conductive path between the stainless steel shaft and the metal substrate of the mounting plate.

[0055] Two acetal steel insulating sleeves at the shaft shoulder and the mounting plate, along with an air gap in between, form a multi-layered barrier between the stainless steel shaft and the mounting plate, consisting of two solid insulation layers and one air gap insulation layer. This constitutes a highly reliable double-insulation protection structure. Even if one insulating sleeve develops wear, scratches, or other defects after long-term operation, the other insulating sleeve and the air gap can still maintain complete insulation performance, completely blocking the path of high-voltage current conduction to the mounting plate, preventing the equipment frame from becoming energized, and ensuring the safety of testing personnel and the stable operation of the equipment.

[0056] In some embodiments, the configuration of the winding motor is connected to the stainless steel shaft via a synchronous belt. The winding motor drives the stainless steel roller to rotate, causing the metal film under test to move at a speed within a preset speed range, thereby completing the pressure resistance test and high-pressure roller design. This includes: connecting the output end of the winding motor to the stainless steel shaft via a synchronous belt, adjusting the speed of the winding motor to make the metal film under test move at a speed of two to five meters per minute, continuously applying a test voltage during the movement, and completing the pressure resistance test of the metal film.

[0057] This embodiment further defines the transmission connection method and test execution process in step S103. The winding motor is fixedly installed at the corresponding position on the mounting plate, ensuring that the output shaft of the winding motor is parallel to the stainless steel shaft. A drive pulley is installed at the output end of the winding motor, and a driven pulley is installed at the corresponding end of the stainless steel shaft. A synchronous belt is fitted onto the drive and driven pulleys, and an adjustable tensioner is used to press the slack side of the synchronous belt, forming a synchronous belt drive structure. The synchronous belt drive has the characteristics of accurate transmission ratio and no slippage, which can ensure that the rotational speed of the winding motor is accurately transmitted to the stainless steel shaft, thereby precisely controlling the film's movement speed. A rotary encoder is installed at the end of the stainless steel shaft to collect the shaft rotational speed in real time and feed it back to the control system, forming a speed closed-loop control, automatically correcting the motor output speed, and offsetting the speed deviation caused by load fluctuations.

[0058] During the test, the output speed of the winding motor is adjusted to ensure the metal film under test moves at a constant speed of two to five meters per minute. This speed range balances testing efficiency and accuracy; excessive speed will result in insufficient testing time at a single point, failing to effectively detect withstand voltage defects; excessive speed will reduce the testing efficiency of the entire roll of film. The speed can be adjusted within this range according to the withstand voltage rating of the sample. For high withstand voltage rating samples, the film speed is reduced to ensure sufficient testing, while for low withstand voltage rating samples, the film speed is increased to improve detection efficiency. During the film's movement, a stable test voltage is continuously applied to the film in the contact area through the positive and negative electrodes, completing withstand voltage loading for each segment of the film passing through the contact area, thus achieving continuous online withstand voltage testing of the entire roll of metal film.

[0059] In some embodiments, the method further includes: acquiring current data in the test circuit in real time, comparing the current value with a preset threshold through a breakdown determination algorithm, identifying the withstand voltage breakdown point of the metal film, and recording the film position and corresponding test voltage corresponding to the breakdown point.

[0060] This embodiment adds automatic breakdown point identification and recording function to the core method. A high-precision current acquisition module is connected in series in the test circuit to collect current data in the test circuit in real time. The acquisition frequency is matched and set according to the film walking speed to ensure that a current sampling is completed every 0.5 mm of film movement, ensuring that even tiny breakdown defects can be captured.

[0061] The system pre-stores dual-threshold rules for breakdown determination, including a transient peak threshold and a duration threshold. When a breakdown occurs at a location on the metal thin film, the current in the test circuit will instantaneously increase and exceed the normal leakage current range. The breakdown determination algorithm compares the real-time current value with the preset threshold. When the current value exceeds the transient peak threshold and the duration reaches the set time, a breakdown is determined to have occurred at the current test location. Interference pulses that only momentarily exceed the peak value but quickly fall back will not trigger the determination, effectively avoiding false judgments caused by electromagnetic interference.

[0062] After identifying the breakdown point, the system combines the encoder's pulse count and the film travel speed to calculate the film travel length corresponding to the current breakdown point, and then calculates the position information of the breakdown point on the entire roll of film, with a positioning accuracy of millimeters. Simultaneously, it records the applied test voltage value and the current waveform at the moment of breakdown. The algorithm can classify defects based on the waveform characteristics of the breakdown current, distinguishing between pinhole-type breakdown, scratch-type breakdown, and breakdown due to poor coating uniformity. The location, voltage, defect type, and waveform data of all breakdown points can be stored in the local storage unit for subsequent quality inspection analysis and production process traceability and improvement.

[0063] In some embodiments, the method further includes: acquiring coating width data of the metal film to be tested, calculating the appropriate width of the insulating regions on both sides through a parameter matching algorithm, and automatically adjusting the installation position of the acetal sleeve and the pasting position of the right insulating tape to ensure that the insulating region is aligned with the coating boundary.

[0064] This embodiment adds an automatic adaptation function for the insulation area to the core method. Before testing, the clamped roll is scanned in the width direction by the linear array vision acquisition module to obtain the coating width data and total width data of the metal film to be tested. The boundary position of the metal coating and the two side edges is automatically identified with an accuracy of 0.1 mm. The corresponding parameters can also be entered manually.

[0065] By using a parameter matching algorithm, combining the width parameters of the conductive rubber, the installation position parameters, and the axial movement of the film, the appropriate width of the insulation area on both sides is calculated. This ensures that the width of the insulation area is sufficient to cover the edge installation deviation of the electrode and the film movement deviation, while not occupying too much effective coating test area, thus maximizing the use of the effective test area.

[0066] For the left insulation area, the system automatically adjusts the axial installation position of the acetal sleeve on the stainless steel shaft through the electric slide mechanism based on the calculated fitting width, so that the inner edge of the acetal sleeve is precisely aligned with the left boundary of the coating; for the right insulation area, the system outputs the sticking position parameters of the insulating tape to guide the manual sticking operation, or controls the axial position of the automatic sticking mechanism to ensure that the inner edge of the insulating tape is precisely aligned with the right boundary of the coating.

[0067] Through the above automatic adjustment, the insulation areas on both sides are precisely aligned with the coating boundary, which avoids leakage at the electrode edge due to the insulation area being too narrow, and also avoids wasting the effective coating test area due to the insulation area being too wide. It is suitable for thin film samples of different widths and does not require manual adjustment of the component position.

[0068] In some embodiments, the method further includes: inputting the nominal withstand voltage rating of the metal thin film to be tested, matching the corresponding test voltage and film moving speed through an adaptive adjustment algorithm, generating a test parameter combination suitable for the current sample, automatically loading the parameters and starting the test process.

[0069] This embodiment adds an adaptive matching function for test parameters to the core method. Before testing, the nominal withstand voltage rating, coating material, and substrate type of the metal thin film to be tested are entered. The nominal withstand voltage rating corresponds to the standard withstand voltage performance index of the thin film coating. The system has a built-in parameter mapping database trained with a large amount of test data, which stores the optimal combination of test parameters for different withstand voltage ratings and different materials.

[0070] Using an adaptive adjustment algorithm, the corresponding test voltage value is calculated based on the input sample information and the preset test coefficients. At the same time, according to the defect detection sensitivity requirements corresponding to the nominal withstand voltage level, the corresponding film moving speed is matched. The higher the withstand voltage level of the film, the higher the matched test voltage, and the film moving speed is appropriately reduced to ensure the sufficiency of the test. At the same time, the current threshold for breakdown judgment is adjusted accordingly to adapt to the normal leakage current level of different samples.

[0071] After the algorithm completes its calculations, it generates a combination of test parameters adapted to the current sample, including test voltage, film travel speed, current threshold, and boost rate. The system automatically performs safety checks on the generated parameters to ensure they are within the equipment's rated operating range. Once the checks are successful, the parameters are automatically loaded into the corresponding control module of the test equipment. After loading, the test process starts automatically, eliminating the need for manual parameter setting and improving the efficiency of changeover testing. It also avoids test failures caused by manual parameter setting errors. Parameter combinations for different sample specifications can be saved as independent formulas, which can be directly called up for subsequent samples of the same specification.

[0072] In some embodiments, this embodiment constructs a multi-parameter closed-loop dynamic testing system based on the core method to achieve real-time optimization and safety monitoring of the testing process. First, multiple sets of sensing and acquisition units are deployed on the testing equipment, including an insulation resistance acquisition unit, a film tension acquisition unit, a contact resistance acquisition unit, and an ambient temperature and humidity acquisition unit. The insulation resistance acquisition unit is connected to the stainless steel shaft and the mounting plate, employing a high-voltage insulation detection circuit to acquire the actual insulation resistance value of the double-insulated structure once per second. The film tension acquisition unit uses a tension roller sensor, positioned on the feed side of the film path, to acquire the film tension value of the metal film in real time. The contact resistance acquisition unit is connected to the test circuit to acquire the total contact resistance value between the positive and negative electrodes and the film in real time. The ambient temperature and humidity acquisition unit is located near the test area to acquire temperature and humidity data of the test environment.

[0073] After the test starts, multiple sets of sensor acquisition units continuously collect corresponding data at a set sampling frequency and transmit the data to the closed-loop optimization algorithm module in real time. The closed-loop optimization algorithm first performs a safety priority check to verify the effectiveness of the double insulation. It compares the real-time collected insulation resistance value with the preset safety insulation threshold. When the insulation resistance value is lower than the safety threshold, it is determined that the insulation performance has deteriorated. The algorithm immediately outputs a control command to cut off the high voltage and pause the test, and at the same time generates an insulation abnormality alarm message to avoid high-voltage leakage safety accidents.

[0074] Under the premise that the insulation performance meets the safety requirements, the closed-loop optimization algorithm combines real-time collected contact resistance value, film tension value and ambient temperature and humidity data, and dynamically corrects the current test parameters through a multi-parameter coupled correction model: when the contact resistance increases, the algorithm appropriately reduces the film speed and extends the pressure application time of single-point test to compensate for the effective test voltage drop caused by the increase in contact resistance; when the film tension fluctuates, the algorithm synchronously adjusts the output torque of the winding motor and the unwinding mechanism to maintain the film tension stability and avoid changes in the contact state between the film and the electrode caused by tension changes; when the ambient temperature and humidity exceed the standard range, the algorithm correspondingly corrects the test voltage and current judgment thresholds to eliminate the interference of ambient temperature and humidity changes on leakage current and breakdown voltage, and ensure the comparability of test results.

[0075] Meanwhile, the algorithm dynamically adjusts the operating parameters of subsequent test sections based on the breakdown detection results of the tested sections: if no breakdown defects are detected within a continuous distance, the algorithm appropriately increases the film-walking speed within a safe range to improve the overall testing efficiency; if breakdown defects are detected continuously, the algorithm automatically reduces the film-walking speed and increases the current sampling frequency to perform fine retesting of areas with dense defects, accurately locate the position and breakdown voltage of each breakdown point, and avoid missing small defects during high-speed film-walking.

[0076] The algorithm also features equipment health management, accumulating equipment runtime and the working time of brushes, conductive rubber, and insulating sleeves. Combined with a wear model, it predicts the remaining lifespan of components and provides early reminders for replacement and maintenance. Through the aforementioned multi-source data acquisition and closed-loop optimization algorithm, this embodiment can adjust operating parameters in real time during testing, balancing test safety, accuracy, and efficiency. Simultaneously, it achieves full online monitoring of insulation status and equipment health management, improving the intelligence level and long-term operational reliability of the entire high-pressure roller testing system.

[0077] In some embodiments, this embodiment provides a detailed description of the physical device structure corresponding to the aforementioned high-pressure roller design method for testing the pressure resistance of metal thin films. The overall structure of the device is as follows: Figure 2 As shown, the complete working process of this device is as follows: the winding motor 4 is started, which drives the stainless steel shaft and stainless steel roller to rotate synchronously through the synchronous belt, pulling the metal film to be tested to move at a constant speed along the set path; the external high voltage power supply applies a stable high voltage negative potential to the stainless steel shaft and stainless steel roller through an independent brush assembly; the swing amplitude of the clamping arm is adjusted so that the conductive rubber fixed at the end of the arm presses against the coating surface of the moving metal film with a preset pressure, and the conductive rubber, as the high voltage positive electrode, forms a closed withstand voltage test circuit with the negative electrode high voltage roller assembly; during the continuous movement of the film, the test circuit continuously applies a test voltage to the film section passing through the area where the conductive rubber and stainless steel roller are in contact, completing the continuous withstand voltage test of the entire roll of metal film; the acetal steel insulating sleeve at the shoulder of the stainless steel roller and the acetal steel insulating sleeve in the shaft hole of the mounting plate form double insulation protection, blocking the high voltage current from flowing to the mounting plate throughout the entire process, ensuring safe and stable operation throughout the test.

[0078] The high-pressure roller device described in this embodiment uses a vertical mounting plate as the overall mounting base. The mounting plate is made of aluminum alloy with an anodized surface, combining lightweight and surface insulation properties. All functional components are assembled on the same side of the mounting plate for easy debugging and maintenance. Support feet are provided at the bottom to ensure the stability of the device. The core of the device includes five parts: a negative electrode roller assembly, a double insulation assembly, a high-voltage conduction assembly, a transmission drive assembly, and a positive electrode contact assembly. The corresponding numbers and specific structures of each part in the figure are as follows: Stainless steel roller 1 is the main body of the negative electrode for withstand voltage testing. It is made of a single piece of stainless steel. The outer circular surface of the roller is precision ground and ultra-mirror polished, resulting in a smooth and defect-free surface. The diameter is set at 100 mm, and the edges at both ends are rounded to avoid sharp discharge. Stainless steel roller 1 is coaxially fixedly mounted on the extended section of stainless steel shaft 2. The two are rigidly connected by a thermostatic interference fit. After assembly, there is no relative rotation, and they can rotate synchronously around the axis. The metal surfaces of the two are tightly fitted, maintaining a stable conductive connection. During the test, the metal film to be tested is wrapped around the outer surface of the stainless steel roller 1, and the substrate side of the film is in direct contact with the roller surface of the stainless steel roller 1, so that the stainless steel roller 1 serves as the negative electrode of the test and carries a high voltage potential.

[0079] The stainless steel shaft 2 is the core shaft component that simultaneously performs transmission and conductivity functions. It is horizontally inserted into the shaft hole of the mounting plate, with one end extending outward to mount the stainless steel roller 1, and the other end extending to the transmission side of the mounting plate for connecting to power and high voltage. A shoulder structure is provided on the side of the stainless steel shaft 2 near the stainless steel roller 1. The outer side of the shoulder is wrapped with a acetal steel insulating sleeve. This acetal steel insulating sleeve constitutes the physical carrier of the left-side insulation area. The design of using a acetal steel sleeve in the corresponding side insulation area can both axially position the stainless steel roller 1 and prevent high-voltage current from being conducted along the shoulder towards the mounting plate.

[0080] The acetal insulating sleeve 3 is embedded in the inner wall of the shaft hole of the mounting plate, featuring an outer flange structure. It is fitted around the outer circumference of the stainless steel shaft 2, with a uniform assembly gap between it and the stainless steel shaft 2 to ensure free rotation of the shaft. This acetal insulating sleeve 3, together with the acetal insulating sleeve at the shaft shoulder, forms a double insulation protection structure, creating two independent insulating barriers between the stainless steel shaft 2 and the mounting plate. Combined with the intermediate air gap, this completely blocks the conductive path between the stainless steel shaft 2 and the metal substrate of the mounting plate, preventing the mounting plate from becoming energized during high-voltage testing and ensuring safe equipment operation.

[0081] The take-up motor 4 is fixedly mounted on the transmission side of the mounting plate, serving as the power source for the film feeding action. Its output shaft is arranged parallel to the stainless steel shaft 2, and a precision reducer is fitted at the output end. A synchronous belt is fitted between the output pulley of the take-up motor 4 and the driven pulley at the end of the stainless steel shaft 2, and a tensioning pulley mechanism is configured to form a synchronous belt drive structure. The rotational power output by the take-up motor 4 is precisely transmitted to the stainless steel shaft 2 through the synchronous belt, thereby driving the stainless steel roller 1 to rotate synchronously, pulling the metal film under test to move at a uniform speed of two to five meters per minute, realizing continuous film feeding pressure resistance testing. The synchronous belt drive is slip-free and has an accurate transmission ratio. Combined with encoder closed-loop control, it can ensure that the film movement speed is stable and controllable, avoiding speed fluctuations from affecting the consistency of test results.

[0082] The clamping arm 5, which can reciprocate around the fulcrum, is an adjustable mounting bracket for the conductive rubber. The independent brush assembly is fixedly installed on the upper bracket of the mounting plate. It adopts a parallel arrangement of two brushes, with two sets of brushes symmetrically distributed on both sides of the stainless steel shaft 2. It is equipped with a constant pressure spring mechanism to maintain a constant contact pressure. The conductive end of the brush elastically abuts against the exposed surface of the outer circumference of the stainless steel shaft. The brush terminal is connected to the negative output terminal of an external high-voltage power supply, which can stably transmit high-voltage electricity while the shaft is rotating continuously.

[0083] In addition to the components marked in the above figure, the device is also equipped with a conductive rubber as the positive electrode. The conductive rubber is fixedly installed at the end of the clamping swing arm 5 (i.e., the adjustable bracket mentioned above) in the attached figure. The working surface of the conductive rubber faces the outer circular roller surface of the stainless steel roller 1. The swing arm can adjust the clamping force and contact position of the conductive rubber relative to the stainless steel roller by swinging around the fulcrum. The working surface roughness of the conductive rubber is 0.2 micrometers, the thickness is 2 to 3 millimeters, and the width is 20 to 30 millimeters narrower than the metal film to be tested. During the test, the conductive rubber is pressed against the metal coating side of the metal film to be tested with a set pressure. The metal film to be tested is clamped between the conductive rubber and the roller surface of the stainless steel roller, forming a complete test circuit with the negative electrode high-pressure roller assembly. The width of the conductive rubber is smaller than the width of the film, which can ensure that the positive electrode contact area falls completely within the metal coating area in the middle of the film. Insulation areas are set on both sides of the metal film to be tested. The left insulation area is achieved by the acetal insulating sleeve at the shaft end, and the right insulation area is achieved by pasting insulating tape at the corresponding position of the film, so as to prevent the test voltage from flowing to the side of the film and ensure that the test area only covers the effective metal coating.

[0084] The complete working process of this device is as follows: the winding motor 4 is started, which drives the stainless steel shaft 2 and stainless steel roller 1 to rotate via the synchronous belt, pulling the metal film to be tested to move at a constant speed along the set path; the external high-voltage power supply applies a high-voltage test potential to the stainless steel shaft 2 and stainless steel roller 1 through the brush, serving as the test negative electrode; the conductive rubber is pressed onto the metal coating surface of the film as the positive electrode, forming a withstand voltage test circuit between it and the negative electrode; during the continuous movement of the film, the test circuit continuously applies a test voltage to the film segment passing through the contact area, completing the continuous withstand voltage test of the entire roll of metal film; the two acetal steel insulating sleeves at the shaft shoulder and the mounting plate form double insulation protection, blocking the high-voltage current from being conducted to the mounting plate throughout the process, ensuring the safety and stability of the test process.

[0085] Please see Figure 3 As shown, Figure 3 This is a schematic diagram of the high-pressure roller design system 200 for testing the pressure resistance of metal thin films provided in this application embodiment. The high-pressure roller design system 200 for testing the pressure resistance of metal thin films is used to execute the steps of the high-pressure roller design method for testing the pressure resistance of metal thin films shown in the above embodiments. The high-pressure roller design system 200 for testing the pressure resistance of metal thin films can be a single server or a server cluster, or it can be a terminal, such as a handheld terminal, a laptop computer, a wearable device, or a robot.

[0086] like Figure 3 As shown, the high-pressure roller design system 200 for testing the pressure resistance of metal thin films includes: The range setting unit 201 is used to determine that the negative electrode of the high pressure roller is a rotatable stainless steel roller, set the diameter of the stainless steel roller within a preset diameter range, and fix the stainless steel roller and the stainless steel shaft coaxially; and configure a conductive rubber as the positive electrode, set the surface roughness of the conductive rubber within a preset roughness range, the thickness within a preset thickness range, and the width within a preset width range of the metal film to be tested. The contact conduction unit 202 is used to wrap a acetal insulating sleeve around the shoulder of the stainless steel shaft and to add a acetal insulating sleeve at the mounting plate of the high-pressure roller to form a double insulation protection structure, blocking the conductive path between the stainless steel shaft and the mounting plate; and to set a brush to contact the stainless steel shaft to realize the conduction of high voltage to the stainless steel roller. The pressure resistance test unit 203 is used to configure a winding motor. The winding motor is connected to the stainless steel shaft via a synchronous belt. The winding motor drives the stainless steel roller to rotate, so that the metal film to be tested moves at a speed within a preset speed range to complete the pressure resistance test and the design of the high pressure roller.

[0087] In some embodiments, determining that the negative electrode of the high-pressure roller is a rotatable stainless steel roller, setting the diameter of the stainless steel roller within a preset diameter range, and fixing the stainless steel roller and the stainless steel shaft coaxially, includes: selecting the stainless steel roller as the negative electrode, setting the diameter of the stainless steel roller to 100 mm, fixing the stainless steel roller and the stainless steel shaft coaxially, so that the stainless steel roller rotates synchronously with the stainless steel shaft and maintains conductive connection.

[0088] In some embodiments, the conductive rubber configured as the positive electrode has its surface roughness set within a preset roughness range, including: selecting the conductive rubber as the positive electrode, setting the working surface roughness of the conductive rubber to 0.2 micrometers, so that the working surface of the conductive rubber forms a uniform surface contact with the metal coating of the metal thin film to be tested.

[0089] In some embodiments, the thickness is set within a preset thickness range, and the width is set to be narrower than a preset width range of the metal film to be tested, including: setting the thickness of the conductive rubber to 2 to 3 millimeters, and setting the width of the conductive rubber to be 20 to 30 millimeters narrower than the metal film to be tested, so that the contact area of ​​the conductive rubber falls entirely within the metal coating area of ​​the metal film to be tested.

[0090] In some embodiments, the step of wrapping a acetal insulating sleeve around the shoulder of the stainless steel shaft and adding a acetal insulating sleeve at the mounting plate of the high-pressure roller to form a double insulation protection structure and block the conductive path between the stainless steel shaft and the mounting plate includes: wrapping the acetal insulating sleeve around the outside of the shoulder of the stainless steel shaft and adding a acetal insulating sleeve at the mating position between the mounting plate and the stainless steel shaft to form two insulation barriers between the stainless steel shaft and the mounting plate, thereby blocking the conduction of high-voltage current to the mounting plate.

[0091] In some embodiments, the configuration of the winding motor is connected to the stainless steel shaft via a synchronous belt. The winding motor drives the stainless steel roller to rotate, causing the metal film under test to move at a speed within a preset speed range, thereby completing the pressure resistance test and high-pressure roller design. This includes: connecting the output end of the winding motor to the stainless steel shaft via a synchronous belt, adjusting the speed of the winding motor to make the metal film under test move at a speed of two to five meters per minute, continuously applying a test voltage during the movement, and completing the pressure resistance test of the metal film.

[0092] In some embodiments, the method further includes: acquiring current data in the test circuit in real time, comparing the current value with a preset threshold through a breakdown determination algorithm, identifying the withstand voltage breakdown point of the metal film, and recording the film position and corresponding test voltage corresponding to the breakdown point.

[0093] In some embodiments, the method further includes: acquiring coating width data of the metal film to be tested, calculating the appropriate width of the insulating regions on both sides through a parameter matching algorithm, and automatically adjusting the installation position of the acetal sleeve and the pasting position of the right insulating tape to ensure that the insulating region is aligned with the coating boundary.

[0094] In some embodiments, the method further includes: inputting the nominal withstand voltage rating of the metal thin film to be tested, matching the corresponding test voltage and film moving speed through an adaptive adjustment algorithm, generating a test parameter combination suitable for the current sample, automatically loading the parameters and starting the test process.

[0095] It should be noted that those skilled in the art will understand that, for the sake of convenience and brevity, the specific working process of the high-pressure roller design system for testing the pressure resistance of metal thin films described above and each module can be referred to the corresponding content in the various embodiments of the high-pressure roller design method for testing the pressure resistance of metal thin films, and will not be repeated here.

[0096] The aforementioned design method for a high-pressure roller for testing the pressure resistance of metal films can be implemented as a computer program, which can be used in various applications such as... Figure 3 It runs on the system shown.

[0097] Please see Figure 4 , Figure 4 This is a schematic block diagram of the structure of a computer device provided in an embodiment of this application. The computer device includes a processor, a memory, and a network interface connected via a device bus, wherein the memory may include a storage medium and internal memory.

[0098] The storage medium can store operating devices and computer programs. The computer program includes program instructions that, when executed, cause the processor to perform any design method for a high-pressure roller for testing the pressure resistance of a thin metal film.

[0099] The processor provides computing and control capabilities, supporting the operation of the entire computer device.

[0100] The internal memory provides an environment for the execution of computer programs in non-volatile storage media. When the computer program is executed by the processor, it enables the processor to execute any high-pressure roller design method for testing the pressure resistance of metal thin films.

[0101] This network interface is used for network communication, such as sending assigned tasks. Those skilled in the art will understand that... Figure 4 The structure shown is merely a block diagram of a portion of the structure related to the present application and does not constitute a limitation on the terminal to which the present application is applied. Specific computer devices may include more or fewer components than those shown in the figure, or combine certain components, or have different component arrangements.

[0102] It should be understood that the processor can be a Central Processing Unit (CPU), but it can also be other general-purpose processors, digital signal processors (DSPs), application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc. Among these, a general-purpose processor can be a microprocessor or any conventional processor.

[0103] In one embodiment, the processor is configured to run a computer program stored in memory to perform the following steps: The negative electrode of the high-pressure roller is determined to be a rotatable stainless steel roller. The diameter of the stainless steel roller is set within a preset diameter range, and the stainless steel roller is coaxially and fixedly connected to the stainless steel shaft. A conductive rubber is configured as the positive electrode. The surface roughness of the conductive rubber is set within a preset roughness range, the thickness is set within a preset thickness range, and the width is set to be narrower than the preset width range of the metal film to be tested. A acetal insulating sleeve is wrapped around the shoulder of the stainless steel shaft, and an additional acetal insulating sleeve is added to the mounting plate of the high-pressure roller to form a double insulation protection structure, blocking the conductive path between the stainless steel shaft and the mounting plate; a brush is set to contact the stainless steel shaft to realize the conduction of high voltage to the stainless steel roller. A winding motor is configured, which is connected to a stainless steel shaft via a synchronous belt. The winding motor drives the stainless steel roller to rotate, causing the metal film to be tested to move at a speed within a preset range, thus completing the pressure resistance test and high-pressure roller design.

[0104] In some embodiments, determining that the negative electrode of the high-pressure roller is a rotatable stainless steel roller, setting the diameter of the stainless steel roller within a preset diameter range, and fixing the stainless steel roller and the stainless steel shaft coaxially, includes: selecting the stainless steel roller as the negative electrode, setting the diameter of the stainless steel roller to 100 mm, fixing the stainless steel roller and the stainless steel shaft coaxially, so that the stainless steel roller rotates synchronously with the stainless steel shaft and maintains conductive connection.

[0105] In some embodiments, the conductive rubber configured as the positive electrode has its surface roughness set within a preset roughness range, including: selecting the conductive rubber as the positive electrode, setting the working surface roughness of the conductive rubber to 0.2 micrometers, so that the working surface of the conductive rubber forms a uniform surface contact with the metal coating of the metal thin film to be tested.

[0106] In some embodiments, the thickness is set within a preset thickness range, and the width is set to be narrower than a preset width range of the metal film to be tested, including: setting the thickness of the conductive rubber to 2 to 3 millimeters, and setting the width of the conductive rubber to be 20 to 30 millimeters narrower than the metal film to be tested, so that the contact area of ​​the conductive rubber falls entirely within the metal coating area of ​​the metal film to be tested.

[0107] In some embodiments, the step of wrapping a acetal insulating sleeve around the shoulder of the stainless steel shaft and adding a acetal insulating sleeve at the mounting plate of the high-pressure roller to form a double insulation protection structure and block the conductive path between the stainless steel shaft and the mounting plate includes: wrapping the acetal insulating sleeve around the outside of the shoulder of the stainless steel shaft and adding a acetal insulating sleeve at the mating position between the mounting plate and the stainless steel shaft to form two insulation barriers between the stainless steel shaft and the mounting plate, thereby blocking the conduction of high-voltage current to the mounting plate.

[0108] In some embodiments, the configuration of the winding motor is connected to the stainless steel shaft via a synchronous belt. The winding motor drives the stainless steel roller to rotate, causing the metal film under test to move at a speed within a preset speed range, thereby completing the pressure resistance test and high-pressure roller design. This includes: connecting the output end of the winding motor to the stainless steel shaft via a synchronous belt, adjusting the speed of the winding motor to make the metal film under test move at a speed of two to five meters per minute, continuously applying a test voltage during the movement, and completing the pressure resistance test of the metal film.

[0109] In some embodiments, the method further includes: acquiring current data in the test circuit in real time, comparing the current value with a preset threshold through a breakdown determination algorithm, identifying the withstand voltage breakdown point of the metal film, and recording the film position and corresponding test voltage corresponding to the breakdown point.

[0110] In some embodiments, the method further includes: acquiring coating width data of the metal film to be tested, calculating the appropriate width of the insulating regions on both sides through a parameter matching algorithm, and automatically adjusting the installation position of the acetal sleeve and the pasting position of the right insulating tape to ensure that the insulating region is aligned with the coating boundary.

[0111] In some embodiments, the method further includes: inputting the nominal withstand voltage rating of the metal thin film to be tested, matching the corresponding test voltage and film moving speed through an adaptive adjustment algorithm, generating a test parameter combination suitable for the current sample, automatically loading the parameters and starting the test process.

[0112] This application also provides a computer-readable storage medium storing a computer program that, when executed by a processor, causes the processor to implement the steps of the high-pressure roller design method for testing the pressure resistance of metal thin films as provided in any embodiment of this application.

[0113] The computer-readable storage medium may be an internal storage unit of the computer device described in the foregoing embodiments, such as the hard disk or memory of the computer device. The computer-readable storage medium may also be an external storage device of the computer device, such as a plug-in hard disk, SmartMediaCard (SMC), SecureDigital (SD) card, or FlashCard equipped on the computer device.

[0114] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any person skilled in the art can easily conceive of various equivalent modifications or substitutions within the technical scope disclosed in this application, and these modifications or substitutions should all be covered within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A design method for a high-pressure roller for testing the pressure resistance of a metal thin film, characterized in that, include: The negative electrode of the high-pressure roller is determined to be a rotatable stainless steel roller. The diameter of the stainless steel roller is set within a preset diameter range, and the stainless steel roller is coaxially and fixedly connected to the stainless steel shaft. A conductive rubber is configured as the positive electrode. The surface roughness of the conductive rubber is set within a preset roughness range, the thickness is set within a preset thickness range, and the width is set to be narrower than the preset width range of the metal film to be tested. A acetal insulating sleeve is wrapped around the shoulder of the stainless steel shaft, and an additional acetal insulating sleeve is added to the mounting plate of the high-pressure roller to form a double insulation protection structure, blocking the conductive path between the stainless steel shaft and the mounting plate; a brush is set to contact the stainless steel shaft to realize the conduction of high voltage to the stainless steel roller. A winding motor is configured, which is connected to a stainless steel shaft via a synchronous belt. The winding motor drives the stainless steel roller to rotate, causing the metal film to be tested to move at a speed within a preset range, thus completing the pressure resistance test and high-pressure roller design.

2. The method according to claim 1, characterized in that, The determination that the negative electrode of the high-pressure roller is a rotatable stainless steel roller, with the diameter of the stainless steel roller set within a preset diameter range, and the stainless steel roller and stainless steel shaft coaxially and fixedly connected, includes: A stainless steel roller is selected as the negative electrode, and the diameter of the stainless steel roller is set to 100 mm. The stainless steel roller is coaxially fixed and assembled with the stainless steel shaft so that the stainless steel roller rotates synchronously with the stainless steel shaft and maintains electrical continuity.

3. The method according to claim 1, characterized in that, The conductive rubber configured as the positive electrode has its surface roughness set within a preset roughness range, including: A conductive rubber was selected as the positive electrode, and the surface roughness of the conductive rubber was set to 0.2 micrometers to ensure that the working surface of the conductive rubber forms a uniform surface contact with the metal coating of the metal thin film to be tested.

4. The method according to claim 3, characterized in that, The thickness is set within a preset thickness range, and the width is set to be narrower than a preset width range for the metal film to be tested, including: The thickness of the conductive rubber is set to 2 to 3 mm, and the width of the conductive rubber is set to be 20 to 30 mm narrower than the metal film to be tested, so that the contact area of ​​the conductive rubber falls completely within the metal coating area of ​​the metal film to be tested.

5. The method according to claim 1, characterized in that, The method of wrapping a acetal insulating sleeve around the shoulder of the stainless steel shaft and adding a acetal insulating sleeve at the mounting plate of the high-pressure roller to form a double insulation protection structure, thereby blocking the conductive path between the stainless steel shaft and the mounting plate, includes: The acetal insulating sleeve is wrapped around the outside of the shoulder of the stainless steel shaft. The acetal insulating sleeve is installed at the mating position between the mounting plate and the stainless steel shaft, forming two insulating barriers between the stainless steel shaft and the mounting plate, blocking the high voltage current from being conducted to the mounting plate.

6. The method according to claim 1, characterized in that, The configured take-up motor is connected to the stainless steel shaft via a synchronous belt. The take-up motor drives the stainless steel roller to rotate, causing the metal film under test to move at a speed within a preset range, completing the pressure resistance test and high-pressure roller design, including: The output end of the winding motor is connected to the stainless steel shaft drive via a synchronous belt. The speed of the winding motor is adjusted so that the metal film under test moves at a speed of two to five meters per minute. During the movement, the test voltage is continuously applied to complete the pressure resistance test of the metal film.

7. The method according to claim 1, characterized in that, The method further includes: The current data in the test circuit is collected in real time. The current value is compared with the preset threshold by the breakdown judgment algorithm to identify the withstand voltage breakdown point of the metal film and record the film position and corresponding test voltage of the breakdown point.

8. The method according to claim 1, characterized in that, The method further includes: The coating width data of the metal film to be tested is obtained, and the appropriate width of the insulation area on both sides is calculated by the parameter matching algorithm. The installation position of the acetal sleeve and the pasting position of the right insulating tape are automatically adjusted to ensure that the insulation area is aligned with the coating boundary.

9. The method according to claim 1, characterized in that, The method further includes: Enter the nominal withstand voltage rating of the metal thin film to be tested, match the corresponding test voltage and film moving speed through an adaptive adjustment algorithm, generate a combination of test parameters suitable for the current sample, automatically load the parameters and start the test process.

10. A high-pressure roller design system for testing the pressure resistance of metal thin films, used to implement the method as described in any one of claims 1-9, characterized in that, include: The range setting unit is used to determine that the negative electrode of the high-pressure roller is a rotatable stainless steel roller, and sets the diameter of the stainless steel roller within a preset diameter range, so that the stainless steel roller is coaxially and fixedly connected to the stainless steel shaft; a conductive rubber is configured as the positive electrode, and the surface roughness of the conductive rubber is set within a preset roughness range, the thickness is set within a preset thickness range, and the width is set to be narrower than the preset width range of the metal film to be tested. The contact conduction unit is used to wrap a acetal insulating sleeve around the shoulder of the stainless steel shaft and to add a acetal insulating sleeve at the mounting plate of the high-pressure roller, forming a double insulation protection structure to block the conductive path between the stainless steel shaft and the mounting plate; and to set a brush to contact the stainless steel shaft to realize the conduction of high voltage to the stainless steel roller. The pressure resistance test unit is used to configure the winding motor. The winding motor is connected to the stainless steel shaft via a synchronous belt. The winding motor drives the stainless steel roller to rotate, so that the metal film under test moves at a speed within a preset speed range to complete the pressure resistance test and the design of the high-pressure roller.

Images