A membrane continuous collection system and method of operation thereof

Abstract

The present application relates to the technical field of film material roll-to-roll processing, and particularly relates to a film continuous collection system and a working method thereof, the system comprising: a plurality of process modules and a cooperative control module arranged in sequence along a film material running direction, the cooperative control module comprising a tension acquisition assembly, a driving execution assembly, and a central control assembly; the central control assembly being internally provided with a gradient tension parameter storage unit, a temperature compensation unit, a roll diameter calculation unit, and a cooperative linkage unit; the parameter storage unit being pre-stored with a reference tension value; the temperature compensation unit being used for correcting a tension setting value of a drying module; the roll diameter calculation unit being used for real-time calculation of current roll diameters of a discharge roll and a receiving roll and corresponding adjustment of output torque of the driving execution assembly; and the cooperative linkage unit controlling the driving execution assemblies of adjacent process modules to perform step-by-step buffer adjustment. The present application improves finished product winding quality and production yield, and effectively enhances the reliability of long-time continuous operation of the equipment.

Description

Technical Field

[0001] This invention relates to the field of membrane roll-to-roll processing technology, and more particularly to a continuous membrane collection system and its operating method. Background Technology

[0002] The continuous membrane collection system is a core set of equipment in the post-processing of flexible membrane materials. It is mainly used for the continuous processing and finished product winding of roll materials such as carbon films and functional composite films. By integrating supporting processes such as feeding, surface cleaning, and width slitting, it realizes uninterrupted production line operation from raw material roll material to finished product roll material, which can effectively improve processing efficiency and avoid surface contamination and physical damage during membrane material transportation.

[0003] Existing continuous collection systems for carbon films mostly employ a multi-station linear roll-to-roll architecture, with unloading, washing, drying, slitting, and take-up units sequentially arranged along the film's conveyor belt direction. The entire line uses the main traction roller group as the belt speed reference, and the unwinding and various take-up mechanisms operate synchronously in a speed-following mode, generally adopting a uniform tension control strategy across the entire line. This control method cannot adapt to the differences in the physical state of the film material at different process stages. After impregnation, heating, and slitting, the mechanical strength and elongation characteristics of the film material will change significantly. A single tension setting is prone to problems such as film wrinkles, film breaks, and slitting size deviations. It is difficult to consistently guarantee the neatness of the finished product's rewound end face and the production yield, and the reliability of the equipment during long-term continuous operation is insufficient.

[0004] The information disclosed in this background section is intended only to enhance the understanding of the general background of this disclosure and should not be construed as an admission or in any way implying that the information constitutes prior art known to those skilled in the art. Summary of the Invention

[0005] In view of at least one of the above technical problems, the present invention provides a membrane continuous collection system and its working method, which adopts a segmented gradient tension collaborative control architecture, and is equipped with temperature compensation, dynamic roll diameter adaptation and adjacent process buffer linkage mechanism to adapt to the physical characteristics of the membrane material at different processing stages and achieve precise and stable control of the belt tension throughout the process.

[0006] This invention provides a continuous membrane collection system, comprising multiple process modules arranged sequentially along the membrane material transport direction. These multiple process modules include a feeding module, a cleaning module, a drying module, a slitting module, and a collecting module. It also includes a collaborative control module. The collaborative control module includes a tension acquisition component, a drive execution component, and a central control component, which are respectively arranged in each of the process modules; The central control component has a built-in gradient tension parameter storage unit, temperature compensation unit, roll diameter calculation unit, and collaborative linkage unit. The gradient tension parameter storage unit pre-stores the reference tension values ​​corresponding to each of the process modules, and the reference tension of each process module is set in a gradient-differentiated manner along the conveyor belt direction. The temperature compensation unit is signal-connected to the temperature detection unit of the drying module and is used to correct the tension setting value of the drying module according to the real-time temperature of the drying module. The roll diameter calculation unit is connected to the rotation speed detection unit of the feeding module and the taking-up module respectively, and is used to calculate the current roll diameter of the feeding roll and the taking-up roll in real time and adjust the output torque of the drive execution component accordingly. The coordinated linkage unit is used to control the drive execution components of adjacent process modules to perform step-by-step buffering adjustment when tension in a single segment fluctuates.

[0007] Furthermore, the unwinding module includes an unwinding frame, an unwinding shaft rotatably mounted on the unwinding frame, and a bottom-supporting rewinding shaft. The unwinding shaft is used to release the composite film material, and the bottom-supporting rewinding shaft is used to rewind the peeled bottom-supporting film.

[0008] Furthermore, the cleaning module includes a cleaning tank and traction roller sets respectively located at the inlet and outlet ends of the cleaning tank. The composite film material is guided by the traction roller sets in an immersed conveyor belt within the cleaning tank.

[0009] Furthermore, the drying module includes an oven body, a multi-layer folding guide roller assembly disposed within the oven body, and an adjustment control panel disposed on the top of the oven body; The temperature detection unit is located inside the oven, and the tension acquisition components of the drying module are located at the inlet and outlet of the oven, respectively.

[0010] Furthermore, the slitting module includes a slitting frame, a slitting blade assembly mounted on the slitting frame, and a slitting traction mechanism, wherein the slitting traction mechanism is located on the feeding side of the slitting blade assembly.

[0011] Furthermore, the receiving module includes a winding frame, a film winding shaft rotatably mounted on the winding frame, and an edge-trimming winding shaft. The film winding shaft is used to wind up the finished film material after slitting, and the edge-trimming winding shaft is used to wind up the edge material generated by slitting.

[0012] The present invention also provides a method for operating a membrane continuous collection system, comprising the following steps: Based on the physical state characteristics of the membrane material in each of the process modules, the reference tension value of each process module is preset in the central control component, and the reference tension values ​​of each segment are distributed in a differentiated gradient. The tension acquisition component collects the actual tension value of the corresponding process module in real time, and simultaneously collects the real-time temperature and real-time rotation speed data of the drying module and each roller. Based on the real-time temperature, the thermal elongation of the film material is calculated by the temperature compensation unit, and the tension setting value of the drying module is adjusted accordingly. Based on the real-time rotation speed data of each reel, the current reel diameter of the unloading reel, finished product rewind, bottom support rewind, and edge trimming rewind is calculated in real time by the reel diameter calculation unit, and the output torque of each reel is adjusted accordingly to keep the linear speed of the corresponding process module constant. When the actual tension of a single process module exceeds the preset fluctuation threshold, the collaborative linkage unit controls the drive execution component of the adjacent process module to perform reverse buffer adjustment; During the take-up process, as the winding diameter increases, the winding tension of the take-up module is gradually reduced according to a preset taper curve.

[0013] Furthermore, the reference tension values ​​for the corresponding process modules are set to satisfy the following: reference tension value of the feeding module > reference tension value of the slitting module > reference tension value of the drying module > reference tension value of the cleaning module.

[0014] Furthermore, the tension setting value of the drying module is corrected accordingly, including: The thermal elongation coefficient of the composite membrane material is pre-calibrated. When the real-time temperature of the drying module is higher than the reference temperature, the tension setting value of the drying module is reduced according to the thermal elongation ratio; when the real-time temperature of the drying module is lower than the reference temperature, the tension setting value of the drying module is increased accordingly.

[0015] Furthermore, the adjustment range of the reverse buffer adjustment decreases sequentially along the transmission direction of the tension fluctuation for each of the process modules, and the maximum adjustment amount of a single process module does not exceed 10% of the reference tension of that process module.

[0016] The technical solution of this invention can achieve the following technical effects: Employing a segmented, gradient-differentiated tension control logic, it adapts to the physical state differences of the membrane material under different processing steps, improving the membrane material processing yield and finished product winding quality. Simultaneously, it integrates temperature compensation and real-time roll diameter calculation mechanisms, dynamically adjusting tension parameters and drive outputs based on changes in drying conditions and roll diameter during unwinding and winding, ensuring stable and consistent belt tension and linear speed throughout the entire process. In conjunction with the buffer adjustment linkage mechanism of adjacent processes, it effectively suppresses the transmission of local tension fluctuations along the belt direction, improving the reliability of the equipment during long-term continuous operation.

[0017] The above description is only an overview of the technical solution of this application. In order to better understand the technical means of this application and to implement it in accordance with the contents of the specification, and to make the above and other objects, features and advantages of this application more obvious and understandable, the following are specific embodiments of this application. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in the present invention. 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 diagram of the membrane continuous collection system in an embodiment of the present invention; Figure 2 This is a schematic flowchart illustrating the operation of the membrane continuous collection system in an embodiment of the present invention.

[0020] Reference numerals: 1. Process module; 2. Feeding module; 21. Unwinding frame; 22. Unwinding shaft; 23. Bottom-supporting take-up shaft; 3. Cleaning module; 31. Cleaning tank; 32. Traction roller group; 4. Drying module; 41. Drying oven body; 42. Return guide roller group; 43. Debugging control panel; 5. Slitting module; 51. Slitting frame; 52. Slitting knife group; 53. Slitting traction mechanism; 6. Taking-up module; 61. Taking-up frame; 62. Film take-up shaft; 63. Edge trimming take-up shaft. Detailed Implementation

[0021] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0022] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used in this specification is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0023] This invention provides a method such as Figure 1 The membrane continuous collection system shown includes multiple process modules 1 arranged sequentially along the membrane material transport direction. Each process module 1 includes a feeding module 2, a cleaning module 3, a drying module 4, a slitting module 5, and a collecting module 6. It also includes a collaborative control module. The collaborative control module includes a tension acquisition component, a drive execution component, and a central control component, which are respectively arranged in each process module 1; The central control unit has a built-in gradient tension parameter storage unit, temperature compensation unit, roll diameter calculation unit, and collaborative linkage unit; The gradient tension parameter storage unit pre-stores the reference tension values ​​corresponding to each process module 1, and the reference tension of each process module 1 is set in a gradient-differentiated manner along the belt conveyor direction. The temperature compensation unit is connected to the temperature detection unit of the drying module 4 and is used to correct the tension setting value of the drying module 4 according to the real-time temperature of the drying module 4. The roll diameter calculation unit is connected to the speed detection unit of the feeding module 2 and the taking-up module 6 respectively, and is used to calculate the current roll diameter of the feeding roll and the taking-up roll in real time and adjust the output torque of the drive execution component accordingly. The coordinated linkage unit is used to control the drive execution components of adjacent process modules 1 to perform step-by-step buffering and adjustment when tension fluctuations occur in a single segment.

[0024] The working principle of this invention is as follows: The membrane continuous collection system adopts a horizontal roll-to-roll linear layout. Multiple process modules 1 are arranged sequentially along the membrane material conveyor belt direction. The multiple process modules 1 specifically include a feeding module 2, a cleaning module 3, a drying module 4, a slitting module 5, and a receiving module 6. The entire line is equipped with a collaborative control module to realize the control of the conveyor belt tension throughout the process. The feeding module 2 is used to release the carbon membrane composite roll to be processed and simultaneously peel off the bottom protective film of the winding membrane material. The cleaning module 3 is used to remove dust and processing residues from the surface of the membrane material through immersion cleaning. The drying module 4 is used to remove residual cleaning liquid from the surface of the membrane material through high-temperature drying. The slitting module 5 is used to cut the entire membrane material into finished membrane materials of a set width and remove the rough edges on both sides. The receiving module 6 is used to separately wind up the finished membrane materials after slitting and the trimmed waste.The collaborative control module includes tension acquisition components and drive execution components respectively set in each process module 1, as well as a central control component for unified scheduling and control. The tension acquisition component can be a cantilevered tension detection roller, installed on the film conveyor path on the feeding or discharging side of each process module 1, to collect real-time actual tension data of the film at the corresponding position. The drive execution component is integrated into the drive ends of the traction roller, unwinding shaft 22, and rewinding shaft of each process module 1, used to output corresponding torque to adjust the conveyor tension and transmission line speed. The central control component can be an industrial programmable logic controller (PLC), which internally includes a gradient tension parameter storage unit, a temperature compensation unit, a roll diameter calculation unit, and a collaborative linkage unit. The gradient tension parameter storage unit pre-stores reference tension values ​​corresponding to each process module 1. The reference tension corresponding to each process module 1 is set to a differentiated gradient value along the film conveyor direction according to the physical state of the film in the corresponding process, to adapt to the differences in the mechanical properties of the film at different processing stages. The temperature compensation unit is signal-connected to the temperature detection unit built into the drying module 4. The temperature detection unit can be a platinum resistance temperature sensor, arranged in the drying module. 4. In the intermediate temperature zone inside the oven, the actual working temperature is collected in real time and transmitted to the temperature compensation unit. The temperature compensation unit dynamically corrects the tension setting value corresponding to the drying module 4 based on the collected real-time temperature to offset the tension deviation caused by the deformation of the film material due to heat. The roll diameter calculation unit is connected to the speed detection unit of the feeding module 2 and the take-up module 6 respectively. The speed detection unit can be a rotary encoder, which is installed on the drive shaft end of each roll to collect the rotation speed of the roll in real time. The roll diameter calculation unit combines the main line reference belt speed and the real-time speed of the roll to calculate the current roll diameter of the feeding roll and the take-up roll in real time, and adjusts the output torque of the drive execution component accordingly to ensure the continuous stability of the linear speed and tension throughout the feeding and take-up process. The collaborative linkage unit is used to monitor the tension data of each process module 1 in real time. When the tension of a single process module 1 shows abnormal fluctuations that exceed the preset fluctuation range, the collaborative linkage unit sends adjustment commands to the drive execution components of adjacent process modules 1. The local tension fluctuations are eliminated through step-by-step buffer adjustment to prevent the fluctuations from being transmitted to the entire line along the film material feeding direction, thus ensuring the operational stability of the equipment during long-term continuous production.

[0025] In some embodiments of the present invention, such as Figure 1 As shown, the unwinding module 2 includes an unwinding frame 21, an unwinding shaft 22 rotatably mounted on the unwinding frame 21, and a bottom-supporting rewinding shaft 23. The unwinding shaft 22 is used to release the composite film material, and the bottom-supporting rewinding shaft 23 is used to rewind the peeled bottom film.

[0026] The unwinding module 2 includes a vertically mounted unwinding frame 21, and an unwinding shaft 22 and a bottom-supporting rewinding shaft 23, which are rotatably mounted on the same side wall of the unwinding frame 21. The unwinding frame 21 can be a frame structure welded from carbon steel square tubes, with anti-corrosion spraying treatment on the surface. The bottom of the frame is reserved with an installation reference surface and connection holes for docking with the main frame of the entire line, ensuring that the belt travel reference height of the unwinding station is consistent with that of the subsequent process modules 1. Both the unwinding shaft 22 and the bottom-supporting rewinding shaft 23 can be keyed air expansion shafts, which lock the paper core of the roll material by air inflation. They are easy to install and disassemble and have high coaxiality, which can effectively suppress the axial movement of the roll material during the belt travel. The unwinding shaft 22 is arranged in the lower station and is used to clamp and release the composite film roll material with a bottom-supporting protective film on the surface. The bottom-supporting rewinding shaft 23 is arranged in the upper station and is arranged vertically corresponding to the unwinding shaft 22. It is used to rewind the bottom-supporting film peeled off from the surface of the composite film material.

[0027] In practical applications, the entire roll of composite carbon film is clamped and fixed to the unwinding shaft 22. The end of the roll is manually pulled out and a section of the bottom support film is peeled off. The end of the bottom support film is then pulled and fixed to the bottom support winding shaft 23. During equipment operation, the unwinding shaft 22 releases the composite film at a uniform speed along with the main conveyor belt speed, and the bottom support winding shaft 23 simultaneously winds up the peeled bottom support film, thus achieving continuous automatic separation of the film substrate and the bottom support protective film.

[0028] In some embodiments of the present invention, such as Figure 1 As shown, the cleaning module 3 includes a cleaning tank 31 and traction roller groups 32 respectively located at the inlet and outlet ends of the cleaning tank 31. The composite film material is guided by the traction roller groups 32 and carried in an immersed manner within the cleaning tank 31.

[0029] Cleaning module 3 includes an open cleaning tank 31 and traction roller sets 32 respectively located at the inlet and outlet ends of the cleaning tank 31. The cleaning tank 31 can be formed by bending and welding stainless steel sheet. The inner wall of the tank is passivated and polished to prevent residual hard particles from scratching the surface of the membrane material. An overflow port is reserved on the upper part of the side wall of the tank and a drain port is set at the bottom to facilitate the circulation and replacement of the cleaning fluid and the stable control of the working fluid level. Multiple fixed guide rollers are staggered along the membrane material conveying path inside the tank. The surface of the fixed guide rollers is covered with a corrosion-resistant rubber layer. After the membrane material is introduced into the tank through the traction roller set 32 ​​at the inlet end, it follows a continuously bending immersion conveying path under the guidance of the internal guide rollers. Completely submerged below the cleaning liquid surface, the membrane material is effectively contacted with the cleaning liquid for a longer period, thus thoroughly removing surface contaminants such as dust and processing residue particles adhering to the membrane surface. The traction roller group 32 at both the feed end and the discharge end includes an active traction roller and an elastic pressing roller. The drive end of the active traction roller is connected to the drive execution component of the collaborative control module, providing stable belt-carrying power for the membrane material in the cleaning section. The elastic pressing roller relies on the constant pressing force provided by the cylinder to tightly adhere the membrane material to the surface of the active roller, preventing belt slippage from affecting transmission accuracy and tension stability. After cleaning, the membrane material is smoothly discharged through the discharge end traction roller group 32 and enters the subsequent drying process.

[0030] In some embodiments of the present invention, such as Figure 1 As shown, the drying module 4 includes an oven body 41, a multi-layer folding guide roller group 42 disposed inside the oven body 41, and an adjustment control panel 43 disposed on the top of the oven body 41. The temperature detection unit is located inside the oven body 41, and the tension acquisition components of the drying module 4 are located at the inlet and outlet of the oven, respectively.

[0031] The oven body 41 can adopt a double-layer structure with a stainless steel inner liner and a rock wool insulation layer, which effectively reduces heat loss and ensures a uniform and stable internal temperature field. The multi-layer folding guide roller group 42 is fixed to the inner wall of the oven body 41 in an alternating upper and lower layer arrangement. The surface of the guide rollers is mirror polished to avoid scratching and damaging the surface of the film material. After the film material enters the oven body 41, it is transported back and forth along the multi-layer folding guide roller group 42 in a serpentine path. By extending the high-temperature residence time, the residual cleaning liquid on the surface is fully dried. The adjustment control panel 43 is connected to the central control component. The panel integrates temperature setting buttons, start / stop buttons and operating status display area, which allows operators to directly adjust drying parameters and operating status on-site. In this system, the temperature detection unit can use a platinum resistance temperature sensor, which is arranged in the airflow circulation area in the middle of the oven body 41, avoiding the direct blowing position of the heating element to ensure the accuracy of temperature detection. The real-time oven temperature data detected by the sensor is synchronously transmitted to the temperature compensation unit of the central control component, providing a temperature basis for the dynamic correction of tension in the drying section. Tension acquisition components arranged at the inlet and outlet respectively collect the tension values ​​of the film material before entering the oven and after drying in real time. The two sets of tension data are synchronously uploaded to the central control component to monitor the tension fluctuation in the drying section. This, together with the drive execution component, enables stable control of the belt tension in the drying section, avoiding tension imbalance caused by heat deformation of the film material.

[0032] In some embodiments of the present invention, such as Figure 1 As shown, the slitting module 5 includes a slitting frame 51, a slitting blade assembly 52 mounted on the slitting frame 51, and a slitting traction mechanism 53, with the slitting traction mechanism 53 located on the feeding side of the slitting blade assembly 52.

[0033] The slitting traction mechanism 53 is located on the feeding side of the slitting knife assembly 52. ​​The slitting frame 51 can be a rigid frame structure welded from high-strength carbon steel plates. The bottom of the frame is provided with positioning pin holes and connecting bolt holes. It is fastened to the main frame of the entire line through positioning pins and bolts to ensure that the belt travel reference height of the slitting station is consistent with the preceding and following process modules 1, so as to avoid belt travel deviation and tension change of the film material due to height difference. The slitting traction mechanism 53 can be a combination structure of metal active traction roller and pneumatic pressing roller. The drive end of the active traction roller is coordinated with the control The drive execution components of the module are connected by transmission, and the traction speed can be adjusted according to the tension setting value corresponding to the slitting station. The pneumatic pressing roller relies on constant air pressure to flatly press the film material onto the surface of the active traction roller, avoiding slippage or loosening of the film material belt, and providing a stable tension foundation for subsequent slitting operations. The slitting knife group 52 can adopt multiple sets of circular knife slitting components with adjustable transverse spacing. The knife group spacing can be flexibly adjusted according to the target width of the finished film material. At the same time, trimming knife positions can be set on both sides of the film material width to remove irregular burrs on both sides of the film material while slitting at a fixed width.

[0034] In actual operation, the film material after the drying process first enters the slitting and traction mechanism 53 on the feeding side. Under the traction action, it is flattened and a stable belt tension is established. Then, it is smoothly fed into the slitting knife group 52 on the rear side to complete the fixed width slitting and trimming operation. With the corresponding tension acquisition component, the tension data is fed back in real time to ensure the slitting size accuracy.

[0035] In some embodiments of the present invention, such as Figure 1 As shown, the receiving module 6 includes a winding frame 61, a film winding shaft 62 rotatably mounted on the winding frame 61, and an edge trimming winding shaft 63. The film winding shaft 62 is used to wind up the finished film material after slitting, and the edge trimming winding shaft 63 is used to wind up the edge material generated by slitting.

[0036] The winding frame 61 can be a rigid frame structure welded from carbon steel square tubes. The bottom of the frame is equipped with adjustable horizontal support feet and standardized docking installation positions. After being firmly connected to the main frame of the entire line, it can ensure that the guide plate height of the winding station is aligned with the slitting module 5, avoiding tension fluctuations and uneven winding end faces caused by deviations in the film material entry and exit angles. Both the film take-up shaft 62 and the edge trimming take-up shaft 63 can be keyed air-expansion shafts, which achieve rapid clamping and unloading of the roll material by inflating and tightening the paper core. The clamping coaxiality is high, which can effectively reduce radial runout during the winding process. The film take-up shaft 62 is arranged at the main winding station of the winding frame 61, corresponding to receiving the finished carbon film after slitting. The edge trimming take-up shaft 63 can be set into two sets, respectively arranged on the upper two sides of the film take-up shaft 62, corresponding to the narrow edge material on both sides after winding and slitting, avoiding interference and entanglement between the edge material and the finished film material. The drive ends of the film take-up shaft 62 and the edge trimming take-up shaft 63 are connected to the drive execution component of the collaborative control module. The output torque is dynamically adjusted in conjunction with the roll diameter calculation unit to calculate the current roll diameter data in real time, ensuring that the linear speed and the overall belt speed are accurately matched during the winding process and maintaining stable winding tension.

[0037] In actual operation, the finished film material after being slit by the slitting module 5 is guided by the transition guide roller and then rolled flat onto the film winding shaft 62. The edge materials generated on both sides of the slitting are respectively pulled and fixed to the corresponding edge winding shaft 63. The edge materials are rolled up synchronously with the main line. With the corresponding tension acquisition component, the tension data is fed back in real time, which can effectively ensure that the finished roll material has a neat winding end face and consistent tension between the inner and outer layers, supporting the continuous operation of the equipment for a long time.

[0038] Based on the same inventive concept as the membrane continuous collection system described in the foregoing embodiments, the present invention also provides a method for operating a membrane continuous collection system, such as... Figure 2 As shown, it includes the following steps: Based on the physical state characteristics of the membrane material in each process module 1, the reference tension value of each process module 1 is preset in the central control component, and the reference tension values ​​of each segment are distributed in a differentiated gradient. The tension acquisition component collects the actual tension value of the corresponding process module 1 in real time, and simultaneously collects the real-time temperature and real-time rotation speed data of the drying module 4. Based on the real-time temperature, the thermal elongation of the membrane material is calculated by the temperature compensation unit, and the tension setting value of the drying module 4 is adjusted accordingly. Based on the real-time rotation speed data of each reel, the current reel diameter of the unloading reel, finished product reel, bottom support reel, and edge trimming reel is calculated in real time by the reel diameter calculation unit, and the output torque of each reel is adjusted accordingly to keep the linear speed of the corresponding process module 1 constant. When the actual tension of a single process module 1 exceeds the preset fluctuation threshold, the coordinated linkage unit controls the drive execution components of the adjacent process module 1 to perform reverse buffer adjustment. During the material taking process, as the winding diameter increases, the winding tension of the material taking module 6 is gradually reduced according to the preset taper curve.

[0039] First, based on the physical characteristics of the carbon film to be processed in each process module 1, a reference tension value corresponding to each process module 1 is pre-set in the central control component. A differentiated gradient distribution is set according to the differences in the mechanical strength of the film material at different processing stages, ensuring that the tension at each station matches the film material's load-bearing capacity under the corresponding process. After the equipment starts running, the tension acquisition components arranged in each process module 1 collect the actual tension value of the film material at the corresponding station in real time. Simultaneously, the real-time oven temperature inside the drying module 4 is collected, along with the real-time rotational speed data of the unwinding shaft 22, the film winding shaft 62, the bottom-support winding shaft 23, and the edge-trimming winding shaft 63. All collected data is synchronously uploaded to the central control component as the basis for control decisions. During operation, the temperature compensation unit calculates the thermal elongation of the film material under the current working conditions based on the collected real-time oven temperature and the film material's own thermal deformation characteristics, and accordingly corrects the tension setting value of the drying module 4 to offset the tension fluctuations caused by the thermal elongation of the film material. Simultaneously, the roll diameter gauge... The calculation unit combines the main line reference belt speed and the real-time rotation speed data of each reel to calculate the current roll diameter of the unwinding roll, finished product winding, bottom support winding, and edge trimming winding in real time. Based on the roll diameter changes, it adjusts the output torque of each reel drive execution component accordingly, so that the linear speed of each winding and unwinding station always matches the main line belt speed. The central control component compares the actual tension value of each station with the corresponding reference tension value in real time. When the actual tension of a single process module 1 exceeds the preset fluctuation threshold due to reasons such as the passing of the roll joint or sudden change in roll diameter, the coordination unit immediately issues an adjustment command to the drive execution component of the adjacent process module 1. The local tension disturbance is offset by reverse buffer adjustment to avoid tension fluctuations from being transmitted and spread along the belt direction. During the finished product winding process, as the roll diameter of the film winding reel 62 continues to increase, the system gradually reduces the winding tension of the winding module 6 according to the preset taper curve, so that the tightness of the finished roll from the core to the outer layer remains uniform and consistent, ensuring the quality of the finished product winding.

[0040] In some embodiments of the present invention, the reference tension value of the corresponding process module 1 is set to satisfy: the reference tension value of the feeding module 2 > the reference tension value of the slitting module 5 > the reference tension value of the drying module 4 > the reference tension value of the cleaning module 3.

[0041] The reference tension values ​​set for each process module 1 follow a gradient arrangement rule that matches the processing state of the membrane material. Specifically, the reference tension value of the feeding module 2 is greater than that of the slitting module 5, the reference tension value of the slitting module 5 is greater than that of the drying module 4, and the reference tension value of the drying module 4 is greater than that of the cleaning module 3. This gradient arrangement is set according to the differences in the structural morphology and mechanical properties of the membrane material at each process stage. The membrane material at the feeding module 2 is a composite roll material with a protective film on the surface, which has the strongest overall structural strength and tensile strength. Setting the highest reference tension ensures a smooth and even unwinding process and establishes a stable reference for the entire production line. The slitting module 5 requires the membrane material to remain flat and taut. To ensure slitting dimensional accuracy, the reference tension is set to the second highest level. This satisfies the tension requirements of the slitting operation while avoiding excessive tension that could cause the film material to shrink in width or deviate in size. The film material in the drying module 4 becomes more extensible and brittle after being heated. Excessive tension can easily cause irreversible stretching deformation of the film material or even the risk of film breakage. Therefore, the reference tension is lower than that in the slitting module 5 to ensure smooth conveyor belt movement while avoiding overstretching damage under heat. The film material in the cleaning module 3 is immersed in the cleaning solution. The film surface is highly lubricated and there is no need for high-precision positioning. Setting the lowest level of reference tension is sufficient to maintain smooth conveyor belt movement. At the same time, it can avoid excessive tension that could cause the film material to be pulled and scraped between the guide rollers in the tank, thus protecting the surface quality of the film material.

[0042] In some embodiments of the present invention, the tension setting value corresponding to the correction of the drying module 4 includes: The thermal elongation coefficient of the composite membrane is pre-calibrated. When the real-time temperature of the drying module 4 is higher than the reference temperature, the tension setting value of the drying module 4 is reduced according to the thermal elongation ratio; when the real-time temperature of the drying module 4 is lower than the reference temperature, the tension setting value of the drying module 4 is increased accordingly.

[0043] The thermal elongation coefficient of the membrane material to be processed is pre-calibrated to characterize the degree of length deformation of the membrane material under a unit temperature change. During actual calibration, samples of the membrane material from the current production batch can be taken and tested under simulated drying conditions. Parameters for membrane materials of different thicknesses and porosities can be independently calibrated and stored in the central control unit, ensuring that the temperature compensation calculations accurately match the characteristics of the actual processed membrane material. When the real-time temperature of the drying module 4 is higher than the preset reference temperature, the thermal elongation of the membrane material increases accordingly. Maintaining the original tension setting would cause the actual effective tension of the membrane material to deviate from the reasonable range. In this case, the system adjusts the tension setting value of the drying module 4 proportionally to the thermal elongation, ensuring that the membrane material maintains stable effective tension under thermal elongation. This avoids membrane surface loosening and misalignment, uneven drying, and prevents the membrane material from being passively stretched due to constraints, leading to thermal cracking. When the real-time temperature of the drying module 4 is lower than the preset reference temperature, the thermal elongation of the membrane material decreases accordingly, and the overall rigidity of the membrane material relatively increases. In this case, the system adjusts the tension setting value of the drying module 4 accordingly to maintain the required tension of the conveyor belt, avoiding membrane material slippage and positional deviation due to insufficient tension.

[0044] In some embodiments of the present invention, the adjustment range of the reverse buffer adjustment decreases sequentially along the transmission direction of the tension fluctuation in each process module 1, and the maximum adjustment amount of a single process module 1 does not exceed 10% of the reference tension of that process module 1.

[0045] The amplitude control is set based on the transmission characteristics of tension fluctuations. The intensity of the impact of tension fluctuations will gradually decrease naturally as the transmission distance increases. By adopting a module-by-module decreasing adjustment amplitude, fluctuations at the source workstation can be quickly eliminated while avoiding excessive adjustment at the far-end process, preventing secondary tension oscillations and ensuring the overall stability of the entire conveyor belt.

[0046] In actual execution, the main correction action is performed with the process module 1 where the fluctuation occurs as the core adjustment node. Along the direction of the fluctuation's transmission to the processes before and after, the corresponding adjustment amplitude is gradually reduced according to a preset ratio after each adjacent process module 1. This allows the adjustment intensity to decrease synchronously with the weakening of the fluctuation's influence, taking into account both the response efficiency of fluctuation resolution and the stability of system operation. At the same time, a maximum adjustment limit is set for a single process module 1 to avoid excessively drastic adjustment actions in a single instance, prevent the response amplitude of the drive execution component from being too large and causing new tension impacts, and ensure a smooth transition in the adjustment process.

[0047] The 10% maximum adjustment threshold is a conventional preferred value for tension buffer adjustment in roll-to-roll processing of brittle flexible membrane materials in this field. Its setting comes from general engineering experience in the field of industrial winding control and the need to adapt to the conventional mechanical properties of carbon film materials.

[0048] Although this application has been described in conjunction with specific features and embodiments, it is obvious that various modifications and combinations can be made thereto without departing from the spirit and scope of this application. Accordingly, this specification and drawings are merely exemplary illustrations of the application as defined herein, and are to be considered as covering any and all modifications, variations, combinations, or equivalents within the scope of this application. Clearly, those skilled in the art can make various alterations and modifications to this application without departing from its scope. Thus, if such modifications and modifications fall within the scope of this application and its equivalents, this application intends to include such modifications and modifications.

Claims

1. A continuous membrane collection system, comprising multiple process modules arranged sequentially along the membrane material conveying direction, wherein the multiple process modules include a feeding module, a washing module, a drying module, a slitting module, and a collecting module, characterized in that, It also includes a collaborative control module: The collaborative control module includes a tension acquisition component, a drive execution component, and a central control component, which are respectively arranged in each of the process modules; The central control component has a built-in gradient tension parameter storage unit, temperature compensation unit, roll diameter calculation unit, and collaborative linkage unit. The gradient tension parameter storage unit pre-stores the reference tension values ​​corresponding to each of the process modules, and the reference tension of each process module is set in a gradient-differentiated manner along the conveyor belt direction. The temperature compensation unit is signal-connected to the temperature detection unit of the drying module and is used to correct the tension setting value of the drying module according to the real-time temperature of the drying module. The roll diameter calculation unit is connected to the rotation speed detection unit of the feeding module and the taking-up module respectively, and is used to calculate the current roll diameter of the feeding roll and the taking-up roll in real time and adjust the output torque of the drive execution component accordingly. The coordinated linkage unit is used to control the drive execution components of adjacent process modules to perform step-by-step buffering adjustment when tension in a single segment fluctuates.

2. The membrane continuous collection system according to claim 1, characterized in that, The unwinding module includes an unwinding frame, an unwinding shaft rotatably mounted on the unwinding frame, and a bottom-supporting rewinding shaft. The unwinding shaft is used to release the composite film material, and the bottom-supporting rewinding shaft is used to rewind the peeled bottom-supporting film.

3. The membrane continuous collection system according to claim 1, characterized in that, The cleaning module includes a cleaning tank and traction roller sets respectively located at the inlet and outlet ends of the cleaning tank. The composite film material is guided by the traction roller sets and carried in an immersed manner within the cleaning tank.

4. The membrane continuous collection system according to claim 1, characterized in that, The drying module includes an oven body, a multi-layer folding guide roller assembly disposed inside the oven body, and an adjustment control panel disposed on the top of the oven body. The temperature detection unit is located inside the oven, and the tension acquisition components of the drying module are located at the inlet and outlet of the oven, respectively.

5. The membrane continuous collection system according to claim 1, characterized in that, The slitting module includes a slitting frame, a slitting blade assembly mounted on the slitting frame, and a slitting traction mechanism, wherein the slitting traction mechanism is located on the feeding side of the slitting blade assembly.

6. The membrane continuous collection system according to claim 1, characterized in that, The receiving module includes a winding frame, a film winding shaft rotatably mounted on the winding frame, and an edge trimming winding shaft. The film winding shaft is used to wind up the finished film material after slitting, and the edge trimming winding shaft is used to wind up the edge material generated by slitting.

7. A method for operating a membrane continuous collection system, applied to the membrane continuous collection system according to any one of claims 1 to 6, characterized in that, Includes the following steps: Based on the physical state characteristics of the membrane material in each of the process modules, the reference tension value of each process module is preset in the central control component, and the reference tension values ​​of each segment are distributed in a differentiated gradient. The tension acquisition component collects the actual tension value of the corresponding process module in real time, and simultaneously collects the real-time temperature and real-time rotation speed data of the drying module and each roller. Based on the real-time temperature, the thermal elongation of the film material is calculated by the temperature compensation unit, and the tension setting value of the drying module is adjusted accordingly. Based on the real-time rotational speed data of each reel, the current reel diameter of the unloading reel, finished product rewind, bottom support rewind, and edge trimming rewind is calculated in real time by the reel diameter calculation unit, and the output torque of each reel is adjusted accordingly to keep the linear speed of the corresponding process module constant. When the actual tension of a single process module exceeds the preset fluctuation threshold, the collaborative linkage unit controls the drive execution component of the adjacent process module to perform reverse buffer adjustment; During the take-up process, as the winding diameter increases, the winding tension of the take-up module is gradually reduced according to a preset taper curve.

8. The method of operating the membrane continuous collection system according to claim 7, characterized in that, The reference tension values ​​for the corresponding process modules are set to satisfy the following: reference tension value of the feeding module > reference tension value of the slitting module > reference tension value of the drying module > reference tension value of the cleaning module.

9. The method of operating the membrane continuous collection system according to claim 7, characterized in that, The corresponding adjustment of the tension setting value of the drying module includes: The thermal elongation coefficient of the composite membrane material is pre-calibrated. When the real-time temperature of the drying module is higher than the reference temperature, the tension setting value of the drying module is reduced according to the thermal elongation ratio; when the real-time temperature of the drying module is lower than the reference temperature, the tension setting value of the drying module is increased accordingly.

10. The method of operating the membrane continuous collection system according to claim 7, characterized in that, The adjustment range of the reverse buffer adjustment decreases sequentially along the transmission direction of the tension fluctuation for each of the process modules, and the maximum adjustment amount of a single process module does not exceed 10% of the reference tension of that process module.

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