A segmented pressure tension regulation method based on limit value determination of aluminum foil slitting machine

Abstract

The present application relates to the technical field of aluminum foil production, and particularly relates to a segmented pressure tension regulation method based on limit value determination of an aluminum foil slitting machine, to solve the problems of unified parameter control, low precision of manual adjustment and poor running stability of the aluminum foil slitting machine, which easily leads to aluminum foil breakage, interlayer layering, foil surface wrinkling, surface indentation and end face blackening. The method splits the whole process of slitting into process segments, sets tension and pressure roller pressure upper and lower limit thresholds for each independent segment, collects actual values of pressure and tension of each segment in real time during equipment operation and compares them through closed loop feedback, when the operating parameters touch the limit thresholds, the control system completes automatic fine adjustment according to the preset regulation logic, thereby realizing segmented adaptive matching of pressure and tension of different working conditions and material segments, the control logic is clear, the parameter setting is simple, the slitting production of aluminum foil with different thickness and width can be adapted, the foil breakage rate is significantly reduced, and the winding forming quality and the stability of equipment operation are improved.

Description

Technical Field

[0001] This invention relates to the field of aluminum foil production technology, and specifically to a method for segmented pressure and tension control based on the determination of the limit value of an aluminum foil slitting machine. Background Technology

[0002] Aluminum foil slitting is a core and critical process in the deep processing of aluminum foil. Slitting machines, through the coordinated action of unwinding tension, guide roller pressure, cutter holder holding pressure, and winding tension, complete the slitting of large-size master rolls and the precise winding of finished small rolls. Currently, the mainstream production method in the industry is to set uniform parameters for the entire machine, with the same set of tension and pressure parameters used throughout the unwinding zone, cutter shaft slitting zone, guide roller transition zone, and winding zone. In actual production conditions, the stress state of aluminum foil varies significantly during equipment start-up, uniform speed operation, high-speed production, winding and finishing, and dynamic changes in roll diameter: Sudden tension changes at equipment start-up can easily break ultra-thin aluminum foil; excessive roller pressure during high-speed uniform speed production can easily create indentations and squeezing defects on the foil surface; and as the roll diameter continues to decrease in the later stages of winding, constant tension can easily cause problems such as loose inner rolls and tight outer rolls, uneven end faces, and interlayer separation. Meanwhile, traditional processes rely on operators manually fine-tuning parameters segment by segment, which suffers from drawbacks such as slow response, low adjustment accuracy, poor stability, and high labor intensity. This makes it impossible to achieve long-term continuous and stable production, and the void ratio of the rolls is difficult to control precisely. Existing slitting control technologies mostly focus on single constant tension control and basic roll diameter compensation control, and have not yet formed a mature control scheme that integrates segmented management of the entire process and the linkage of pressure and tension dual-parameter limit thresholds. This results in poor adaptability to operating conditions, a high failure rate, and insufficient stability in finished product quality. Summary of the Invention

[0003] This invention provides a segmented pressure and tension control method based on the limit value determination of an aluminum foil slitting machine, in order to solve the problems existing in the background mentioned above.

[0004] To achieve the above objectives, the present invention adopts the following technical solution: A method for segmented pressure and tension control based on the limit value determination of an aluminum foil slitting machine includes the following steps: Step 1, Process Section Division: Along the aluminum foil feeding direction, the slitting equipment is divided into four independent functional control sections: uncoiling section, cutter shaft slitting section, intermediate transition section and rewinding section. Each section is equipped with an independent tension and pressure gradient control system, which do not interfere with each other and can be independently controlled.

[0005] Step 2: Preset limit parameters for each section: The operator enters the upper and lower limit parameters of tension and pressure for each section through the human-machine interface of the slitting machine, according to the process requirements of aluminum foil thickness, material characteristics and finished product width. After the parameters are saved and locked, a standard process reference range is formed.

[0006] Step 3, Equipment Start-up and Routine Monitoring: After the equipment starts up and enters the fully automatic operation mode, the control system continuously collects real-time data on tension and pressure in each section at a fixed sampling frequency, and simultaneously collects the winding length and real-time roll diameter parameters. Under the constant speed operation state of the equipment, the system relies on the preset limit threshold range to stably output pressure and tension, ensuring that the material roll void ratio is constant and maintaining continuous and stable production conditions.

[0007] Step 4, Automatic Adjustment Process When Exceeding Limits: Tension over-limit adjustment process: When the real-time tension is less than or equal to the lower limit of the tension, it is determined that the tension is insufficient, the material belt is loose and deviates. The system will increase the tension output slightly with a preset fine-tuning step size until the parameters return to the standard range and then stop adjusting and run at a constant speed.

[0008] When the real-time tension exceeds the upper limit of the tension: it is determined to be a tension overload, which poses a risk of stretching deformation and foil breakage. The system will automatically reduce the tension output slightly and gradually reduce the material feeding force to eliminate the hidden dangers of aluminum foil stretching and strip breakage.

[0009] Pressure over-limit adjustment process: When the real-time pressure is less than or equal to the lower limit of the pressure: it is determined that the pressure roller is not pressing enough, which is prone to material slippage and cutting deviation. The system will automatically replenish the pressure and gradually increase the pressure roller pressure to the process standard range.

[0010] When the real-time pressure exceeds the upper limit of the pressure: it is determined that the pressure is too high and may damage the foil surface. The system will automatically release the pressure and reduce the pressure to a safe range to prevent indentation and squeezing defects.

[0011] Dual-parameter linkage adjustment rules: Pressure and tension within the same section are coordinated and linked for correction: when a single parameter exceeds the limit multiple times, the system automatically matches and fine-tunes another parameter to ensure stable aluminum foil feeding posture and balanced tension and pressure matching. Different sections are independently controlled and do not interfere with each other, ensuring the stability of the entire process.

[0012] Step 5: Full-condition adaptive operation and safe shutdown protection: During the equipment start-up and acceleration phases: parameters in each section are dynamically and adaptively adjusted according to the operating speed, and fine-tuning is performed immediately when parameters reach the limit threshold to prevent foil breakage during the start-up phase.

[0013] During the dynamic change phase of the roll diameter: as the winding roll diameter changes from small to large, the tension and pressure of the winding section are adaptively corrected in real time according to the roll diameter variable, thereby avoiding the phenomenon of parameter mismatch before and after winding, and ensuring that the material roll is dense, flat and with regular end face.

[0014] Furthermore, the tension limit threshold is mainly used to avoid problems such as aluminum foil loosening and deviation, stacking misalignment, excessive stretching, thickness reduction, and strip breakage; the pressure limit threshold is mainly used to solve defects such as insufficient pressure roller bonding, material slippage, slitting misalignment, and foil surface indentation and aluminum foil extrusion caused by pressure overload.

[0015] Furthermore, the system supports the storage of process formulas for multiple specifications of aluminum foil, and parameters can be called up with one click when changing production lines, adapting to flexible production.

[0016] The present invention has the following beneficial effects: This invention relates to the field of aluminum foil production technology, specifically to a segmented pressure and tension control method based on the limit value determination of aluminum foil slitting machines. This method addresses the problems of low precision and poor operational stability caused by the current unified parameter control and manual adjustment of aluminum foil slitting machines during operation, which easily leads to aluminum foil breakage, interlayer displacement, foil wrinkling, surface indentation, and end-face blackening. The method divides the entire slitting process into process segments, setting upper and lower limit thresholds for tension and pressure roller pressure for each independent segment. During equipment operation, the actual pressure and tension values ​​of each segment are collected in real time and compared using closed-loop feedback. When the operating parameters reach the limit thresholds, the control system automatically fine-tunes according to preset control logic, thereby achieving segmented adaptive matching of pressure and tension for different working conditions and material segments. The control logic is clear, parameter tuning is simple, and it can adapt to the slitting production of aluminum foils of different thicknesses and widths, significantly reducing foil breakage rate and improving winding and forming quality and equipment operational stability.

[0017] This invention breaks away from the traditional unified parameter control mode of the whole machine. It independently sets the pressure and tension limit thresholds according to the material feeding function zone, realizes precise parameter control of the zone, and specifically solves the stress defect problem of different process sections. It ensures the control of the independent limit thresholds of each section, significantly reduces quality defects such as foil breakage, delamination, wrinkling, and indentation, significantly improves the slitting yield of aluminum foil, and stably controls the void ratio of the material roll, providing a good process foundation for subsequent annealing, degreasing and other processes.

[0018] This invention uses parameter limit values ​​as the basis for control and judgment, and combines dynamic changes in roll diameter to achieve automatic fine-tuning throughout the entire process, replacing the traditional manual repeated adjustments. It has a fast response speed and high process consistency, and realizes fully automatic closed-loop adjustment triggered by limit thresholds. The limit thresholds are used as process boundary control parameters throughout the process, so that the equipment always operates stably within the standard process range, and the stability of material conveying and equipment operation is significantly improved.

[0019] This invention simultaneously controls two core process parameters: pressure of the pressure roller and tension of the feed material. It achieves linkage and matching of the two parameters, taking into account both the stability of equipment operation and the surface forming quality of aluminum foil, and ensuring the coordinated control of the two parameters of pressure and tension.

[0020] This invention only requires setting the limit parameters of each section once in the early stage, and then the entire process is automated. It greatly reduces the dependence on the experience and skills of the operators, is suitable for large-scale, standardized mass production operations, and is easy to operate and highly practical. Attached Figure Description

[0021] Figure 1 This is a schematic diagram illustrating the change in the defective quantity of the aluminum foil slitting process in this invention. Detailed Implementation

[0022] The present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0023] Taking the slitting and production of ultra-thin aluminum foil with a thickness of 6μm and a width of 1200mm as an example, the specific application process of this method is as follows: 1. Equipment Pre-inspection: Before starting the machine, check the working status of all sensors, actuators, tension detection components, and pressure adjustment mechanisms in the unwinding section, cutter shaft slitting section, intermediate transition section, and winding section to ensure that the equipment's sensing, acquisition, and parameter execution mechanisms are normal and usable.

[0024] 2. Setting partition limit parameters Operators complete the input and locking of process parameters for each section on the equipment's human-machine interface: Unwinding section: Relying on the roll diameter sensor to collect the maximum roll diameter data in real time, and manually enter the minimum roll diameter parameters, the system background automatically calculates and matches the tension output according to the roll diameter change, so as to realize the adaptive control of unwinding tension.

[0025] Cutting transmission section of the cutter shaft: The tension limit reference value is set to 13N.

[0026] The intermediate guide roller transition section has a tension limit reference value set at 7N.

[0027] Rewinding section: Upper and lower tension settings: winding tension 40N / mm 2 The winding tension is set to 40 N / mm. 2 Input the tension ratio value using the minimum roll diameter of 76mm, from 100% to the maximum roll diameter of 1000mm, and set the limit ratio to 90%.

[0028] Pressure setting: The pressure setting mainly involves the pressure of the four rubber rollers. The pressure of the four rollers is set according to the thickness, width, and crown of different products. Under normal circumstances, the pressure roller is 0.55N and the support roller is 2.22N. The pressure of the rubber rollers gradually increases with the increase of the roll diameter. The limit ratio value is controlled from 37% to a maximum of 100%.

[0029] Save the parameter recipe and switch to the limit value segmented automatic adjustment mode.

[0030] Start the aluminum foil slitting machine; the equipment will accelerate to its rated speed; if the speed exceeds the limit, the automatic adjustment process will continue. Tension over-limit adjustment process: When the real-time tension is less than or equal to the lower limit of the tension, it is determined that the tension is insufficient, the material belt is loose and deviates. The system will increase the tension output slightly with a preset fine-tuning step size until the parameters return to the standard range and then stop adjusting and run at a constant speed.

[0031] When the real-time tension exceeds the upper limit of the tension: it is determined to be a tension overload, which poses a risk of stretching deformation and foil breakage. The system will automatically reduce the tension output slightly and gradually reduce the material feeding force to eliminate the hidden dangers of aluminum foil stretching and strip breakage.

[0032] Pressure over-limit adjustment process: When the real-time pressure is less than or equal to the lower limit of the pressure: it is determined that the pressure roller is not pressing enough, which is prone to material slippage and cutting deviation. The system will automatically replenish the pressure and gradually increase the pressure roller pressure to the process standard range.

[0033] When the real-time pressure exceeds the upper limit of the pressure: it is determined that the pressure is too high and may damage the foil surface. The system will automatically release the pressure and reduce the pressure to a safe range to prevent indentation and squeezing defects.

[0034] Dual-parameter linkage adjustment rules: Within the same section, pressure and tension are coordinated and adjusted: when a single parameter repeatedly exceeds its limit, the system automatically matches and fine-tunes another parameter to ensure stable aluminum foil feeding and balanced tension and pressure. Different sections are independently controlled without interference, ensuring the stability of the entire process. Step 5: Full-condition adaptive operation and safe shutdown protection: During the equipment start-up and acceleration phases: parameters in each section are dynamically and adaptively adjusted according to the operating speed, and fine-tuning is performed immediately when parameters reach the limit threshold to prevent foil breakage during the start-up phase.

[0035] During the dynamic change phase of the roll diameter: as the winding roll diameter changes from small to large, the tension and pressure of the winding section are adaptively corrected in real time according to the roll diameter variable, thereby avoiding the phenomenon of parameter mismatch before and after winding, and ensuring that the material roll is dense, flat and with regular end face.

[0036] The real-time parameters of each section remain stable within the limit range. The system monitors, fine-tunes, and corrects for exceeding limits in real time throughout the entire process according to the aforementioned zone limit thresholds, ensuring stable parameter control. This effectively solves quality problems such as strip breakage, indentation, delamination, and uneven end faces during the slitting of ultra-thin wide aluminum foil, significantly improving the pass rate and production stability of finished aluminum foil products. The defective quantity in the aluminum foil slitting process is significantly reduced. Figure 1 As shown.

Claims

1. A method for segmented pressure and tension control based on the limit value determination of an aluminum foil slitting machine, characterized in that, Includes the following steps: Step 1, Process Section Division: Along the aluminum foil feeding direction, the slitting equipment is divided into four independent functional control sections: uncoiling section, cutter shaft slitting section, intermediate transition section and rewinding section. Each section is equipped with an independent tension and pressure gradient control system, which do not interfere with each other and can be independently controlled. Step 2: Preset limit parameters for each section: The operator enters the upper and lower limit parameters of tension and pressure for each section through the human-machine interface of the slitting machine, according to the process requirements of aluminum foil thickness, material characteristics and finished product width. After the parameters are saved and locked, a standard process reference range is formed. Step 3, Equipment Start-up and Routine Monitoring: After the equipment starts up and enters the fully automatic operation mode, the control system continuously collects real-time data of tension and pressure in each section at a fixed sampling frequency, and simultaneously collects the winding length and real-time roll diameter parameters. Under the constant speed operation state of the equipment, the system stably outputs pressure and tension based on the preset limit threshold range to ensure that the material roll void ratio is constant and maintains continuous and stable production conditions. Step 4, Automatic Adjustment Process When Exceeding Limits: Tension over-limit adjustment process: When the real-time tension is less than or equal to the lower limit of the tension: it is determined that the tension is insufficient, the material belt is loose and deviates. The system will increase the tension output slightly with a preset fine-tuning step size until the parameter returns to the standard range and then stop adjusting and run at a constant speed. When the real-time tension exceeds the upper limit of the tension: it is determined to be a tension overload, which poses a risk of stretching deformation and foil breakage. The system will automatically reduce the tension output slightly and gradually reduce the material feeding force to eliminate the hidden dangers of aluminum foil stretching and strip breakage. Pressure over-limit adjustment process: When the real-time pressure is less than or equal to the lower limit of the pressure: it is determined that the pressure roller is not pressing enough, which is prone to material slippage and cutting deviation. The system will automatically replenish the pressure and gradually increase the pressure roller pressure to the process standard range. When the real-time pressure exceeds the upper limit of the pressure: it is determined that the pressure is too high and may damage the foil surface. The system will automatically release the pressure and reduce the pressure to a safe range to prevent indentation and crushing defects. Dual-parameter linkage adjustment rules: Pressure and tension within the same section are coordinated and linked for correction: when a single parameter exceeds the limit multiple times, the system automatically matches and fine-tunes another parameter to ensure stable aluminum foil feeding posture and balanced tension and pressure matching. Different sections are independently controlled and do not interfere with each other, ensuring the stability of the entire process. Step 5: Full-condition adaptive operation and safe shutdown protection: During the equipment start-up and acceleration phases: the parameters of each section are dynamically and adaptively adjusted according to the operating speed, and the parameters are finely adjusted immediately when they touch the limit threshold to prevent foil breakage during the start-up phase. During the dynamic change phase of the roll diameter: as the winding roll diameter changes from small to large, the tension and pressure of the winding section are adaptively corrected in real time according to the roll diameter variable, thereby avoiding the phenomenon of parameter mismatch before and after winding, and ensuring that the material roll is dense, flat and with regular end face.

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