Method and system for regulating uniformity of anodized aluminum foil surface

Abstract

The present application relates to the technical field of electric field distribution regulation, specifically to a formation aluminum foil surface uniformity regulation method and system, comprising the following steps: obtaining formation process state data and historical control response data, determining a region to be regulated and an electric field regulation unit state, establishing a region influence relationship, spatially mapping the formation process state data to form an electric field state, a distribution reference and a region deviation, determining a control sensitivity and generating a collaborative control quantity based on the historical control response data, determining an estimated region response, obtaining an actual region response and comparing the response difference, and correcting the region influence relationship or the control sensitivity. The present application forms a closed-loop correlation between the region influence relationship, the control sensitivity and the region response, so that the collaborative control quantity reflects the region effect and corrects the control basis according to the actual formation response, reduces the associated region electric field linkage caused by regulation, and keeps the formation aluminum foil surface region in coordinated control.

Description

Technical Field

[0001] This invention relates to the field of electric field distribution control technology, and in particular to a method and system for controlling the surface uniformity of electroformed aluminum foil. Background Technology

[0002] The field of electric field distribution control technology mainly involves the design, adjustment, and control of the electric field intensity, direction, and distribution in a specific space, medium, or material interface. Related technologies typically revolve around electrode structure, electrode spacing, power supply method, conductive path, insulating boundary, electrolyte conditions, and process parameters, and are applied in industries such as electrochemical treatment, electrolytic capacitor manufacturing, metal surface treatment, electroplating, and electronic material processing. Among these, the traditional method for controlling the surface uniformity of aluminum foil refers to adjusting the formation state and electrochemical reaction distribution in different regions of the aluminum foil surface during the aluminum foil formation process. This is usually achieved by controlling and managing the formation conditions corresponding to each region of the aluminum foil surface by setting the electrode arrangement, aluminum foil running position, power supply method, current path, electrolyte state, and formation process parameters.

[0003] Traditional methods mainly rely on preset formation parameters and fixed electrode arrangement to adjust the aluminum foil surface as a whole. During the control process, there is a lack of unified characterization of the electric field relationship between different surface areas and the mutual influence between areas. Adjustment of parameters in a single area will cause synchronous changes in the electric field state of adjacent areas. The fixed control relationship will also deviate with changes in the aluminum foil operating state and formation conditions, resulting in an unstable correspondence between the local adjustment results and the actual regional response, making it difficult to maintain consistent control of the formation state of each area. Summary of the Invention

[0004] The purpose of this invention is to provide a method and system for controlling the surface uniformity of formed aluminum foil. Addressing the issue that different surface regions are affected to varying degrees by different electric field adjustment units during the formation process, and that local control changes have a synergistic effect on related regions, this invention establishes a regional influence relationship between the electric field adjustment units and the regions to be controlled. It combines formation process state data and historical control response data to determine regional deviations and control sensitivity, performs coordinated control of multiple electric field adjustment units, and corrects the control criteria based on the response difference between the actual and predicted regional responses, thereby forming a closed-loop control process corresponding to the electric field distribution on the surface of the formed aluminum foil.

[0005] To achieve the above objectives, the present invention provides a method for controlling the surface uniformity of formed aluminum foil, comprising the following steps: S1: Acquire formation process status data and historical control response data, and determine multiple controllable regions and electric field adjustment unit status on the surface of the formed aluminum foil based on the formation process status data; S2: Based on the spatial correspondence between each electric field adjustment unit and each region to be controlled, and the state of each electric field adjustment unit, determine the degree of influence of each electric field adjustment unit on each region to be controlled, and establish the regional influence relationship; S3: Based on the regional influence relationship, spatially map the formation process state data to determine the electric field state of each region to be controlled, form a distribution benchmark based on the electric field state, and determine the regional deviation of each region to be controlled relative to the distribution benchmark. S4: Determine the control sensitivity between the control change of each electric field adjustment unit and the state change of each region to be controlled based on the historical control response data, and generate a cooperative control quantity based on the region deviation, the region influence relationship and the control sensitivity; S5: Determine the estimated region response based on the coordinated control quantity and the control sensitivity, control each of the electric field adjustment units and obtain the actual region response, compare the actual region response with the estimated region response, when the response difference exceeds the allowable deviation, correct the region influence relationship or the control sensitivity based on the response difference, when the response difference does not exceed the allowable deviation, maintain the region influence relationship and the control sensitivity.

[0006] Furthermore, the formation process status data is collected from the current control cycle of the formation equipment, and the historical control response data is read from the stored data of the historical control cycle; based on the spatial correspondence between the surface area of ​​the formed aluminum foil and the preset action range of each electric field adjustment unit, the surface area of ​​the formed aluminum foil corresponding to the preset action range of each electric field adjustment unit is determined as the area to be controlled, and the operating state corresponding to each electric field adjustment unit is extracted from the formation process status data as the electric field adjustment unit state.

[0007] Furthermore, the spatial correspondence is determined based on the relative position and range of action between each electric field adjustment unit and each region to be controlled, and the spatial correspondence is corrected based on the state of the electric field adjustment unit to obtain the degree of action of each electric field adjustment unit for each region to be controlled; the regional influence relationship is organized according to the multiple degrees of action corresponding to each region to be controlled, so that the regional influence relationship characterizes the correlation effect of each electric field adjustment unit on different regions to be controlled within the same control cycle.

[0008] Furthermore, according to the spatial correspondence between each of the regions to be regulated and each of the electric field adjustment units, the corresponding data in the formation process state data corresponding to each of the regions to be regulated is determined as region state data, and the state contribution of the region state data to the region to be regulated is determined according to the degree of each effect, thus forming the electric field state of each of the regions to be regulated; the distribution benchmark is determined according to the distribution relationship between the multiple electric field states, and the degree of deviation of each electric field state from the distribution benchmark is determined as the region deviation of the region to be regulated.

[0009] Furthermore, according to the control cycle, the control changes of each electric field adjustment unit and the state changes of the region to be controlled are extracted from the historical control response data. A control response correspondence is established between the direction and amplitude of the control change and the direction and amplitude of the state change. The control sensitivity of each electric field adjustment unit when acting on each region to be controlled is determined according to the control response correspondence. When the control response correspondence corresponding to a continuous control cycle changes, the control response correspondence is re-determined using the continuous historical control response data before the current control cycle, and the control sensitivity is updated.

[0010] Further, the corresponding adjustment direction and deviation degree are determined according to the regional deviation of each region to be controlled, and the adjustment direction and deviation degree corresponding to each region to be controlled are converted into candidate control quantities for the corresponding electric field adjustment unit according to the regional influence relationship and the control sensitivity; when the same electric field adjustment unit corresponds to multiple candidate control quantities, the multiple candidate control quantities are combined according to the degree of action in the regional influence relationship to obtain the cooperative control quantity for the corresponding electric field adjustment unit.

[0011] Further, the state change amount of each region to be regulated is determined according to the control change corresponding to the coordinated control amount and the control sensitivity, and the state change amount is determined as the estimated region response; after each electric field adjustment unit completes the control of the coordinated control amount, the state data of the formation process after control is reacquired, the electric field state of each region to be regulated after control is determined according to the regional influence relationship, the electric field state after control is compared with the electric field state before control to obtain the state change, and the state change is determined as the actual region response.

[0012] Furthermore, the actual region response and the estimated region response are compared one by one according to each of the regions to be controlled, and the response difference is determined based on the comparison results. When the actual region response and the estimated region response are inconsistent in their directions of change and the response difference exceeds the allowable deviation, the degree of influence of the electric field adjustment unit on the region to be controlled in the region influence relationship is corrected. When the actual region response and the estimated region response are consistent in their directions of change and the response difference exceeds the allowable deviation, the control sensitivity of the electric field adjustment unit acting on the region to be controlled is corrected.

[0013] Furthermore, after correcting the regional influence relationship or the control sensitivity, the corrected regional influence relationship or the control sensitivity is used in the next control cycle to determine the cooperative control quantity and the estimated regional response, and the actual regional response of the next control cycle is obtained; the actual regional response of the next control cycle is compared with the estimated regional response and the response difference is determined. When the response difference exceeds the allowable deviation, the regional influence relationship or the control sensitivity is further corrected based on the actual regional response of the next control cycle. When the response difference does not exceed the allowable deviation, the correction is stopped.

[0014] Furthermore, the present invention also provides a surface uniformity control system for formed aluminum foil, which is applied to the surface uniformity control method of formed aluminum foil. The system includes a state acquisition module, a region relationship construction module, an electric field state determination module, a collaborative control module, and a feedback correction module. The state acquisition module acquires the formation process state data and historical control response data, and determines multiple controllable areas and electric field adjustment unit states on the surface of the formed aluminum foil based on the formation process state data. The regional relationship construction module determines the degree of influence of each electric field adjustment unit on each region to be controlled based on the spatial correspondence between each electric field adjustment unit and each region to be controlled, as well as the state of the electric field adjustment unit, and establishes regional influence relationships. The electric field state determination module performs spatial mapping on the formation process state data based on the regional influence relationship, determines the electric field state of each region to be controlled, forms a distribution benchmark based on the electric field state, and determines the regional deviation of each region to be controlled relative to the distribution benchmark. The collaborative control module determines the control sensitivity between the control changes of each electric field adjustment unit and the state changes of each region to be regulated based on the historical control response data, and generates a collaborative control quantity based on the region deviation, the region influence relationship and the control sensitivity. The feedback correction module determines the estimated region response based on the cooperative control quantity and the control sensitivity, controls each of the electric field adjustment units and obtains the actual region response, compares the actual region response with the estimated region response, and when the response difference exceeds the allowable deviation, corrects the region influence relationship or the control sensitivity based on the response difference; when the response difference does not exceed the allowable deviation, maintains the region influence relationship and the control sensitivity.

[0015] The beneficial effects of the technical solutions provided in the embodiments of the present invention include at least the following: By determining the controllable region and electric field adjustment unit state on the surface of the aluminum foil based on the formation process state data, and establishing regional influence relationships based on spatial correspondence, the degree of influence of different electric field adjustment units on different surface regions of the aluminum foil forms a calculable control basis. Based on the regional influence relationships, a spatial mapping of the electric field state on the aluminum foil surface is completed, forming regional deviations. Then, combined with historical control response data, the control sensitivity and cooperative control quantities are determined, ensuring that the control quantities are simultaneously constrained by the aluminum foil regional deviation, regional influence relationships, and historical responses. By comparing the actual regional response with the predicted regional response, the regional influence relationships or control sensitivity are corrected when the response difference exceeds the allowable deviation. This allows subsequent control to be corrected according to the actual response of the formed aluminum foil, and reduces the electric field linkage caused by local adjustments to related regions of the aluminum foil. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 A schematic diagram of the module interaction of the aluminum foil surface uniformity control system. Figure 2 This is a schematic diagram showing the spatial correspondence between the electric field adjustment unit and the region to be controlled. Figure 3 This is a schematic diagram of the regional influence relationship and the state-space mapping of the electric field; Figure 4 A schematic diagram illustrating the formation of coordinated control quantities and predicted regional responses; Figure 5 This is a schematic diagram of regional response comparison and feedback correction. Detailed Implementation

[0018] The specific embodiments of the present invention will be described below with reference to the accompanying drawings. The following description is based on the technical solution described in the application documents and is used to illustrate the data sources, processing order, and feedback relationships between formation process state data, historical control response data, the region to be controlled, the state of the electric field adjustment unit, spatial correspondence, regional influence relationship, electric field state, distribution benchmark, regional deviation, control sensitivity, cooperative control quantity, estimated regional response, and actual regional response during the control of the uniformity of the formed aluminum foil surface. Formation process state data refers to the set of data collected by the formation equipment within the current control cycle and used to describe the formation operation state. Historical control response data refers to the correlation records formed and stored in previous control cycles between the control changes of the electric field adjustment unit and the corresponding state changes of the region to be controlled. The region to be controlled refers to the surface area defined based on the spatial correspondence between the surface of the formed aluminum foil and the effective range of the electric field adjustment unit. The electric field adjustment unit refers to a controllable execution object in the formation equipment that can change the electric field state within its corresponding effective range according to the cooperative control quantity. The regional influence relationship is used to represent the degree of influence of different electric field adjustment units on different regions to be controlled. Control sensitivity is used to describe the response of the controlled region to a state change when the electric field control unit undergoes a control change. The above terms will maintain a consistent meaning in the following implementation.

[0019] Example 1

[0020] Please see Figures 1 to 5 This embodiment provides a method for controlling the surface uniformity of formed aluminum foil. The continuous control cycle of the forming equipment serves as the time basis for data organization and feedback correction. Within each control cycle, the current forming process state data is acquired, and historical control response data from previous control cycles is retrieved. A regional influence relationship is established based on the spatial interaction between the formed aluminum foil surface area and multiple electric field adjustment units. This regional influence relationship is then used to organize the electric field state of different areas to be controlled, forming a regional deviation. The control sensitivity is determined based on the historical control response data. The regional deviation, regional influence relationship, and control sensitivity together form a coordinated control quantity. After the coordinated control quantity is issued, the forming process state data is reacquired. The difference between the actual regional response and the estimated regional response is used as the basis for whether to correct the regional influence relationship or the control sensitivity, thus forming a continuous feedback chain between the current control cycle and the next control cycle.

[0021] S1: Acquire formation process status data and historical control response data, and determine multiple controllable regions and electric field adjustment unit statuses on the surface of the formed aluminum foil based on the formation process status data.

[0022] S11: After the start of the current control cycle, the existing acquisition link of the formation equipment generates the formation process status data for the current control cycle. The formation process status data uses the control cycle as the time boundary, ensuring that data within the same control cycle corresponds to the same control action. The formation process status data should at least reflect the surface spatial state used to determine the area to be controlled and the current operating state of each electric field adjustment unit. For data generated consecutively within the same control cycle, the correspondence is maintained according to the data formation sequence, and data from the later control cycle is not used as the control input for the current control cycle.

[0023] S12: Retrieves historical control response data from the stored data of historical control cycles. Historical control response data is stored according to control cycles. Each control cycle's record maintains at least the identity of the electric field regulation unit, the corresponding controlled area, the pre-control state, the control change, and the post-control state. Historical control response data is not recorded using isolated control quantities or isolated area states as the unit of recording. Instead, it uses the control response relationship formed by an electric field regulation unit for a controlled area within the same control cycle as the basis for subsequent retrieval, enabling the traceability of the corresponding source between control changes and changes in area state.

[0024] S13: Please refer to Figure 2 The region to be regulated is determined based on the spatial correspondence between the surface area of ​​the formed aluminum foil and the preset operating range of each electric field adjustment unit. The preset operating range represents the surface area of ​​the formed aluminum foil that the corresponding electric field adjustment unit can directly act on under a given arrangement and operating condition of the forming equipment. The surface area of ​​the formed aluminum foil that spatially corresponds to the preset operating range of at least one electric field adjustment unit is divided into regions to be regulated, so that each region to be regulated can be traced back to one or more electric field adjustment units.

[0025] S14: Extract the operating state corresponding to each electric field regulating unit from the formation process state data of the current control cycle, and determine the extraction result as the electric field regulating unit state. The electric field regulating unit state is used to characterize whether the corresponding electric field regulating unit maintains the action conditions consistent with the preset action range in the current control cycle. If the electric field regulating unit state indicates that the current action conditions have changed from the preset state, the change is used to correct the spatial correspondence in the subsequent S2, and is not directly used to generate cooperative control quantities in S1, thereby maintaining the processing order between region determination, relationship construction and control generation.

[0026] S2: Based on the spatial correspondence between each electric field adjustment unit and each region to be controlled, and the state of the electric field adjustment unit, determine the degree of influence of each electric field adjustment unit on each region to be controlled, and establish the regional influence relationship.

[0027] S21: Using the region to be controlled and the electric field control unit obtained in S1 as two objects with spatial correspondence, please refer to [link / reference]. Figure 2 The basic spatial correspondence is determined based on the relative position between the preset range of each electric field adjustment unit and each region to be adjusted. When a region to be adjusted falls within the range of an electric field adjustment unit, a correspondence is established between them; when a region to be adjusted is simultaneously acted upon by multiple electric field adjustment units, a correspondence is established between the region to be adjusted and each of the multiple electric field adjustment units separately, without merging multiple electric field adjustment units into a single virtual execution object.

[0028] S22: Correct the basic spatial correspondence based on the state of the electric field adjustment unit in the current control cycle. The correction process only changes the degree of influence of the corresponding electric field adjustment unit on the corresponding region to be controlled in the current control cycle, without changing the spatial identity of the region to be controlled itself. For electric field adjustment units whose current operating state is consistent with the preset action state, the basic action relationship corresponding to the preset action range is retained; for electric field adjustment units whose current operating state has changed relative to the preset state, adjust their degree of influence on the corresponding region to be controlled according to the current action state reflected by the electric field adjustment unit state, so that the regional influence relationship corresponds to the actual action conditions of the current control cycle.

[0029] S23: Please refer to Figure 3 The influence of each electric field adjustment unit on each region to be controlled is organized according to the correspondence between the electric field adjustment unit and the region to be controlled, forming a regional influence relationship. The regional influence relationship does not represent a single numerical result, but rather the correlation structure between multiple electric field adjustment units and multiple regions to be controlled. For the same region to be controlled, the regional influence relationship can indicate which electric field adjustment units have an effect on that region and the relative relationship between the degree of influence of different electric field adjustment units; for the same electric field adjustment unit, the regional influence relationship can indicate which regions to be controlled are simultaneously associated with that electric field adjustment unit. Therefore, when generating subsequent coordinated control quantities, the linkage effect of an adjustment of one electric field adjustment unit on multiple regions to be controlled can be identified.

[0030] S24: After the regional influence relationship is completed, it is bound to the current control cycle and used as the basis for spatial mapping in S3 and coordinated control in S4. The regional influence relationship remains stable within the current control cycle unless S5 detects that the difference between the actual regional response and the predicted regional response exceeds the allowable deviation and triggers a correction. This avoids unfounded changes in the regional influence relationship before and after the control quantity is generated within the same control cycle.

[0031] S3: Based on the regional influence relationship, spatial mapping is performed on the state data of the formation process to determine the electric field state of each region to be controlled, a distribution benchmark is formed according to the electric field state, and the regional deviation of each region to be controlled relative to the distribution benchmark is determined.

[0032] S31: Please refer to Figure 3 Using regional influence relationships as an index to map the formation process state data to the spatial regions of the formed aluminum foil surface, data in the formation process state data that can be correlated with the regions to be controlled are assigned to the corresponding regions to be controlled, forming regional state data. The technical identity of the regional state data is determined by the corresponding region to be controlled. The regional state data of different regions to be controlled are stored separately to avoid merging data belonging to different surface regions before making an overall judgment.

[0033] S32: For a region to be regulated that is simultaneously affected by multiple electric field regulation units, the state contribution in the corresponding region state data is determined according to the degree of influence of each electric field regulation unit on the region to be regulated in the regional influence relationship. The state contribution represents the degree of participation of the corresponding electric field regulation unit in the formation of the electric field state of the region to be regulated under the current spatial interaction relationship. Its purpose is to establish a spatial correspondence between the transformation process state data and the specific region to be regulated, and not to directly use the state contribution as the final cooperative control quantity.

[0034] S33: The electric field state of the region to be controlled is determined based on the regional state data corresponding to the same region to be controlled and the state contribution of each electric field control unit. The electric field state serves as a regional-level intermediate result reflecting the current electric field distribution state of the region to be controlled. Its data source is limited to the formation process state data of the current control cycle and the regional influence relationships of the current control cycle. Corresponding electric field states are re-formed for different control cycles to avoid replacing the real-time state of the current control cycle with the electric field state of the previous control cycle.

[0035] S34: After obtaining the electric field states of multiple regions to be controlled, a distribution benchmark is formed based on the distribution relationship between the multiple electric field states. The distribution benchmark is used to characterize the reference distribution state jointly formed by multiple regions to be controlled within the current control cycle. Its formation object is multiple electric field states within the same control cycle; therefore, the electric field state of a single region to be controlled is not directly used as the judgment benchmark for all regions. The distribution benchmark is re-formed with the electric field state of the current control cycle, so that the deviation of subsequent regions corresponds to the current formation state.

[0036] S35: Compare the electric field state of each region to be regulated with the distribution reference to determine the direction and degree of deviation of the region relative to the distribution reference, and define the comparison result as the region deviation. The region deviation retains the identity of the corresponding region to be regulated, enabling S4 to determine the adjustment direction for different regions. The region deviation does not directly correspond to the control quantity of a specific electric field regulation unit; it needs to be converted into a coordinated control quantity after considering the regional influence relationship and control sensitivity.

[0037] S4: Determine the control sensitivity between the control changes of each electric field regulation unit and the state changes of each region to be regulated based on historical control response data, and generate a coordinated control quantity based on regional deviation, regional influence relationship and control sensitivity.

[0038] S41: Extract the control changes of the same electric field regulation unit and the state changes of the region to be regulated that have a regional influence relationship with the electric field regulation unit from the historical control response data according to the control cycle. Each set of historical records keeps the control change preceding the regional state change and ensures that they belong to the same control cycle, thereby avoiding the incorrect combination of control changes and state changes from different control cycles.

[0039] S42: For the same electric field control unit and the same region to be controlled, compare the direction, magnitude, state change direction, and state change magnitude in continuous historical control cycles to establish a control response correspondence. This correspondence describes the corresponding changes in the direction and degree of response of the region to be controlled after a control change by the electric field control unit. If historical control response data is insufficient to establish a continuous correspondence, the existing regional influence relationship is retained, and the insufficient data is not used to form a new control sensitivity. The data is updated only after a new actual regional response is formed and incorporated into the historical control response data.

[0040] S43: Determine the control sensitivity based on the control response correspondence. The control sensitivity is based on the combination of the electric field adjustment unit and the region to be controlled, and the same control sensitivity is not set for all regions to be controlled by the same electric field adjustment unit. When the control response correspondence remains consistent in consecutive control cycles, the corresponding control sensitivity is used; when the control response correspondence changes in consecutive control cycles, the control response correspondence is reconstructed by reading the continuous historical control response data before the current control cycle, and the corresponding control sensitivity is updated accordingly.

[0041] S44: Determine the corresponding adjustment direction and degree of deviation based on the regional deviations of each region to be controlled obtained in S3. The adjustment direction is determined based on the deviation direction of the region to be controlled relative to the distribution reference, and the degree of deviation is determined based on the deviation relationship between the electric field state of the region to be controlled and the distribution reference. Thus, the regional deviation provides the direction and degree of adjustment required, the regional influence relationship provides the electric field adjustment unit that can act on the region to be controlled and the degree of its action, and the control sensitivity provides the response relationship between the control change of the corresponding electric field adjustment unit and the state change of the region to be controlled.

[0042] S45: Please refer to Figure 4The adjustment direction and deviation degree of each region to be controlled are allocated to the corresponding electric field control unit according to the regional influence relationship. Then, based on the corresponding control sensitivity, the adjustment demand of the region to be controlled is converted into the candidate control quantity of the corresponding electric field control unit. The candidate control quantity corresponds one-to-one with the electric field control unit, while retaining the region to be controlled from which the candidate control quantity originates, so that the source of multiple candidate control quantities can be identified when the same electric field control unit corresponds to multiple regions to be controlled.

[0043] S46: When the same electric field control unit corresponds to only one candidate control quantity, that candidate control quantity is used as the cooperative control quantity for the current control cycle of the electric field control unit. When the same electric field control unit corresponds to multiple candidate control quantities, the multiple candidate control quantities are combined according to the degree of influence of the electric field control unit on multiple regions to be controlled in the regional influence relationship. Regions to be controlled with a higher degree of influence maintain the control contribution corresponding to the influence relationship during the combination process, while regions to be controlled with a lower degree of influence maintain a correspondingly lower control contribution. After combination, a single cooperative control quantity for the corresponding electric field control unit is formed, thereby avoiding the issuance of multiple independent control actions to the same electric field control unit in the same control cycle.

[0044] S47: When multiple candidate control variables correspond to inconsistent adjustment directions, instead of directly issuing candidate control variables in opposite directions simultaneously, the combined result of the current control cycle is formed based on the degree of influence represented by the regional influence relationship and the deviation degree of each region to be regulated. This ensures that the same electric field regulation unit receives only one coordinated control variable with a clear control direction in the current control cycle. This process unifies the cross-actions between an electric field regulation unit and multiple regions to be regulated during the control variable generation stage.

[0045] S5: Determine the estimated region response based on the coordinated control quantity and control sensitivity, control each electric field adjustment unit and obtain the actual region response, compare the actual region response with the estimated region response, when the response difference exceeds the allowable deviation, correct the region influence relationship or control sensitivity based on the response difference, when the response difference does not exceed the allowable deviation, maintain the region influence relationship and control sensitivity.

[0046] S51: Please refer to Figure 4 Based on the control changes corresponding to the coordinated control quantities of each electric field regulation unit and the control sensitivity of each electric field regulation unit to each region to be regulated, the expected state change of each region to be regulated after the execution of the coordinated control quantity is determined, and the state change is defined as the estimated region response. When a region to be regulated is acted upon by multiple electric field regulation units, the estimated region response of the region to be regulated is formed by the multiple coordinated control quantities associated with the region to be regulated and their corresponding control sensitivities, and the response of a single electric field regulation unit is not used to replace the entire region response.

[0047] S52: The coordinated control quantity generated in S4 is sent to the corresponding electric field adjustment unit, which then completes the adjustment action for the current control cycle according to the corresponding coordinated control quantity. The specific electrical quantity form of the coordinated control quantity is determined by the original electric field adjustment method of the formation equipment. After the adjustment action is completed, the post-control status acquisition stage begins.

[0048] S53: Reacquire the formation process state data after control, using the same controlled region identity and applicable regional influence relationship as before control, and perform regional mapping on the controlled formation process state data to obtain the post-control electric field state of each controlled region. Compare the post-control electric field state with the electric field state of the corresponding controlled region before control to obtain the state change of the controlled region under this coordinated control action, and determine the state change as the actual regional response.

[0049] S54: Please refer to Figure 5 For each region to be regulated, the actual response is compared with the predicted response. The comparison includes the direction and degree of response change. The response difference is determined based on the differences in the direction and degree of change between the actual and predicted responses. The allowable deviation represents the boundary of the response difference between the actual and predicted responses that can be maintained without triggering parameter corrections. The allowable deviation is determined by the predetermined control accuracy of the formation equipment and the configuration supported by the application documents.

[0050] S55: When the actual regional response and the predicted regional response change directions are inconsistent and the response difference exceeds the allowable deviation, the current deviation is primarily attributed to a deviation in the interaction relationship between the electric field adjustment unit and the region to be controlled. The degree of influence of the corresponding electric field adjustment unit on the region to be controlled is corrected in the regional influence relationship. The corrected degree of influence is used for spatial mapping and cooperative control quantity generation in the next control cycle, without rewriting the historical records of the completed control cycle.

[0051] S56: When the actual regional response and the predicted regional response change in the same direction and the response difference exceeds the allowable deviation, maintain the spatial interaction relationship between the current electric field adjustment unit and the region to be controlled, correct the control sensitivity of the electric field adjustment unit acting on the region to be controlled, so that the corrected response relationship is used when the predicted regional response is estimated by the cooperative control quantity in the next control cycle.

[0052] S57: When the response difference does not exceed the allowable deviation, the regional influence relationship or control sensitivity correction is not triggered, and the current regional influence relationship and control sensitivity are maintained. The cooperative control quantity, pre-control state, post-control state, actual regional response, and the correlation record between the corresponding electric field adjustment unit and the region to be controlled formed in the current control cycle are written into the historical control response data, so that subsequent control cycles can determine whether the control response correspondence has changed based on the newly added historical records.

[0053] S58: After correction is triggered in S55 or S56, the corrected regional influence relationship or control sensitivity is used to determine the cooperative control quantity and predict the regional response in the next control cycle, and the actual regional response of the next control cycle is obtained again according to S53. A new response difference is formed by comparing the actual regional response and the predicted regional response in the next control cycle; if the new response difference still exceeds the allowable deviation, the regional influence relationship or control sensitivity is further corrected based on the actual regional response formed in this control cycle; if the new response difference does not exceed the allowable deviation, the current correction is stopped, and the corrected regional influence relationship and control sensitivity are used as the current control basis for subsequent control cycles. Therefore, each correction uses the already executed cooperative control quantity and the corresponding actual regional response as the feedback source, and does not use subsequent responses that have not yet been generated as the current correction basis.

[0054] Example 2

[0055] Please see Figure 1 This embodiment provides a system for controlling the surface uniformity of formed aluminum foil. This embodiment uses system modules and the data transmission relationships between modules to carry out the surface uniformity control process of formed aluminum foil as described in Embodiment 1. The system includes a state acquisition module, a region relationship construction module, an electric field state determination module, a collaborative control module, and a feedback correction module. Each module interacts with data according to the formation order of the formed process state data and historical control response data. The feedback correction module then returns the corrected region influence relationship or control sensitivity to subsequent control cycles.

[0056] The status acquisition module establishes a data connection with the data acquisition source of the formation equipment to acquire formation process status data in the current control cycle and read historical control response data from the historical control cycle storage data. Based on the spatial correspondence between the surface area of ​​the formed aluminum foil and the preset operating range of the electric field adjustment unit, the status acquisition module determines multiple controllable regions and obtains the operating status of each electric field adjustment unit from the formation process status data, forming the electric field adjustment unit status. The output of the status acquisition module includes the controllable region, the electric field adjustment unit status, the formation process status data, and the historical control response data. The controllable region and the electric field adjustment unit status are sent to the region relationship construction module, the formation process status data is sent to the electric field status determination module, and the historical control response data is sent to the collaborative control module.

[0057] The regional relationship construction module receives the states of the regions to be regulated and the electric field regulation units. Based on the relative positions and ranges of influence of each electric field regulation unit and each region to be regulated, it establishes spatial correspondences and corrects the degree of influence in these spatial correspondences according to the states of the electric field regulation units. This module organizes the degree of influence between multiple electric field regulation units and multiple regions to be regulated into regional influence relationships. These regional influence relationships are simultaneously sent to the electric field state determination module, the collaborative control module, and the feedback correction module, enabling these three modules to respectively complete regional state mapping, collaborative control quantity generation, and feedback correction.

[0058] The electric field state determination module receives the formation process state data and regional influence relationships from the current control cycle. Based on these regional influence relationships, it associates the formation process state data with the corresponding regions to be controlled, forming regional state data. Then, it determines the state contribution based on the degree of influence of each electric field adjustment unit on the region to be controlled, thus obtaining the electric field state of each region. The electric field state determination module forms a distribution benchmark based on the distribution relationship between the electric field states of multiple regions to be controlled, and determines the deviation of the electric field state of each region from the distribution benchmark as the regional deviation. The regional deviation is output to the collaborative control module, and the electric field state before control is retained for the feedback correction module to use when forming the actual regional response.

[0059] The collaborative control module receives historical control response data, regional influence relationships, and regional deviations. It extracts the control changes of the electric field regulating unit and the corresponding state changes of the region to be regulated according to the historical control cycle, constructs a control response correspondence, and determines the control sensitivity based on this correspondence. The collaborative control module determines the regulation direction and degree of deviation based on the regional deviation of each region to be regulated, identifies the electric field regulating unit that can act on the corresponding region based on the regional influence relationship, and then forms candidate control quantities based on the control sensitivity. When the same electric field regulating unit corresponds to multiple candidate control quantities, these multiple candidate control quantities are combined according to the degree of influence in the regional influence relationship to form the collaborative control quantity of that electric field regulating unit. The collaborative control module sends the collaborative control quantity to the corresponding electric field regulating unit, and simultaneously sends the collaborative control quantity and control sensitivity to the feedback correction module to form the predicted regional response.

[0060] The feedback correction module receives the cooperative control quantity, control sensitivity, regional influence relationship, and pre-control electric field state, and determines the estimated regional response of each region to be regulated based on the cooperative control quantity and control sensitivity. After each electric field regulation unit executes the cooperative control quantity, the feedback correction module receives the post-control formation process state data, forms the post-control electric field state based on the regional influence relationship, and compares the post-control electric field state with the pre-control electric field state to obtain the actual regional response. The feedback correction module compares the actual regional response with the estimated regional response. When the direction of change is inconsistent and the response difference exceeds the allowable deviation, it corrects the degree of influence in the regional influence relationship; when the direction of change is consistent and the response difference exceeds the allowable deviation, it corrects the control sensitivity; when the response difference does not exceed the allowable deviation, it maintains the current regional influence relationship and control sensitivity. The correction result is returned to the regional relationship construction module or cooperative control module corresponding to the next control cycle, and the next control cycle continues to form a new cooperative control quantity and estimated regional response.

[0061] Please continue reading. Figure 1 The data flow between system modules is as follows: the state acquisition module outputs the current state data to the region relationship construction module and the electric field state determination module; the region relationship construction module outputs the region influence relationship to the electric field state determination module and the collaborative control module; the electric field state determination module outputs the region deviation to the collaborative control module; the collaborative control module outputs the collaborative control quantity to the electric field adjustment unit; after execution, the electric field adjustment unit generates new formation process state data; the feedback correction module generates the actual region response based on the new formation process state data and feeds back the correction result to the direction structure of subsequent control cycles.

[0062] The handling of insufficient historical data in this system is consistent with that in Implementation Example 1. That is, when historical control response data is insufficient to establish a continuous control response correspondence, the system does not reconstruct control sensitivity based on the insufficient data. Instead, it maintains the currently established regional influence relationships and control relationships that can be supported by existing historical control response data. Only after new actual regional responses are generated in subsequent control cycles and historical control response data is supplemented, is it determined whether the control response correspondence has changed. This process avoids data without a control response foundation directly entering the control sensitivity update stage.

[0063] This system also has a clear termination state for handling feedback that does not meet the correction conditions. When the response difference between the actual regional response and the estimated regional response does not exceed the allowable deviation, the feedback correction module does not output new regional influence relationship correction results or control sensitivity correction results, and the current regional influence relationship and control sensitivity continue to serve as the control basis for subsequent control cycles; when the response difference exceeds the allowable deviation, the feedback correction module only corrects the relationship objects that can be determined by the direction of change, without unconditionally modifying the regional influence relationship and control sensitivity at the same time, thereby maintaining the correspondence between the correction object and the feedback cause.

[0064] Through the aforementioned module relationships, the system implementation process and method implementation process form a consistent data and control chain. The state acquisition module provides the input for the current control cycle, the regional relationship construction module provides the spatial action basis, the electric field state determination module generates regional-level states and regional deviations, the collaborative control module converts the regional deviations into collaborative control quantities corresponding to the electric field adjustment unit, and the feedback correction module generates the actual regional response based on the states before and after control, and uses the response differences to select and correct regional influence relationships or control sensitivity. Each output of the system is received by the subsequent module, and the feedback correction results re-enter the next control cycle, forming a complete collaborative closed loop.

[0065] The specific processes, data organization relationships, control cycle connection relationships, module correspondence relationships, and feedback correction rules described in the above embodiments are used to illustrate that the technical solutions recorded in this invention can form an executable process for controlling the surface uniformity of formed aluminum foil, and are not intended to limit this invention to a specific equipment structure, specific electrical parameters, or specific numerical configurations. Without departing from the scope of the technical solutions recorded in this invention, those skilled in the art can make equivalent substitutions or adjustments to the data carrying format, module carrying body, data field names with equivalent functions, data organization methods of the control cycle, and execution receiving forms that maintain the same input-output relationship. The changes adopted do not alter the technical relationships between the region to be controlled, the regional influence relationship, the electric field state, the regional deviation, the control sensitivity, the cooperative control quantity, the estimated regional response, the actual regional response, and the feedback correction, nor do they extend to other independent technical topics not recorded in the application documents.

Claims

1. A method for controlling the surface uniformity of electrolytically formed aluminum foil, characterized in that, The method includes: Acquire formation process status data and historical control response data, and determine multiple controllable regions and electric field adjustment unit status on the surface of the formed aluminum foil based on the formation process status data; Based on the spatial correspondence between each electric field adjustment unit and each region to be controlled, and the state of each electric field adjustment unit, the degree of influence of each electric field adjustment unit on each region to be controlled is determined, and regional influence relationships are established. Based on the regional influence relationship, the formation process state data is spatially mapped to determine the electric field state of each region to be controlled. A distribution benchmark is formed based on the electric field state, and the regional deviation of each region to be controlled relative to the distribution benchmark is determined. The control sensitivity between the control change of each electric field adjustment unit and the state change of each region to be regulated is determined based on the historical control response data, and a cooperative control quantity is generated based on the region deviation, the region influence relationship and the control sensitivity. The estimated regional response is determined based on the coordinated control quantity and the control sensitivity. Each of the electric field adjustment units is controlled and the actual regional response is obtained. The actual regional response is compared with the estimated regional response. When the response difference exceeds the allowable deviation, the regional influence relationship or the control sensitivity is corrected based on the response difference. When the response difference does not exceed the allowable deviation, the regional influence relationship and the control sensitivity are maintained.

2. The method for controlling the surface uniformity of formed aluminum foil according to claim 1, characterized in that, The current control cycle of the formation equipment collects the formation process status data, and the historical control response data is read from the stored data of the historical control cycle; Based on the spatial correspondence between the surface area of ​​the formed aluminum foil and the preset operating range of each electric field adjustment unit, the surface area of ​​the formed aluminum foil corresponding to the preset operating range of each electric field adjustment unit is determined as the region to be controlled, and the operating state corresponding to each electric field adjustment unit is extracted from the formation process state data as the state of the electric field adjustment unit.

3. The method for controlling the surface uniformity of formed aluminum foil according to claim 1, characterized in that, The spatial correspondence is determined based on the relative position and range of action between each electric field adjustment unit and each region to be controlled, and the spatial correspondence is corrected based on the state of the electric field adjustment unit to obtain the degree of action of each electric field adjustment unit for each region to be controlled. The regional influence relationships are organized according to the multiple degrees of influence corresponding to each of the aforementioned regions to be regulated, so that the regional influence relationships characterize the correlation effect of each electric field adjustment unit on different regions to be regulated within the same control cycle.

4. The method for controlling the surface uniformity of electroformed aluminum foil according to claim 3, characterized in that, According to the spatial correspondence between each region to be controlled and each electric field adjustment unit, the corresponding data in the formation process state data corresponding to each region to be controlled is determined as region state data, and the contribution of the region state data to the state of the region to be controlled is determined according to the degree of each effect, thus forming the electric field state of each region to be controlled. The distribution reference is determined based on the distribution relationship between the multiple electric field states, and the degree of deviation of each electric field state relative to the distribution reference is determined as the region deviation of the region to be controlled.

5. The method for controlling the surface uniformity of formed aluminum foil according to claim 1, characterized in that, According to the control cycle, the control changes of each electric field adjustment unit and the state changes of the region to be controlled are extracted from the historical control response data. The control response correspondence between the control change direction and control change amplitude and the state change direction and state change amplitude is established, and the control sensitivity of each electric field adjustment unit when acting on each region to be controlled is determined according to the control response correspondence. When the control response correspondence changes in a continuous control cycle, the control response correspondence is re-determined using the continuous historical control response data before the current control cycle, and the control sensitivity is updated.

6. The method for controlling the surface uniformity of electroformed aluminum foil according to claim 5, characterized in that, The corresponding adjustment direction and deviation degree are determined according to the regional deviation of each region to be controlled, and the adjustment direction and deviation degree of each region to be controlled are converted into candidate control quantities of the corresponding electric field adjustment unit based on the regional influence relationship and the control sensitivity. When the same electric field adjustment unit corresponds to multiple candidate control quantities, the multiple candidate control quantities are combined according to the degree of influence in the regional influence relationship to obtain the cooperative control quantity corresponding to the electric field adjustment unit.

7. The method for controlling the surface uniformity of electroformed aluminum foil according to claim 1, characterized in that, The state change amount of each region to be regulated is determined based on the control change corresponding to the coordinated control amount and the control sensitivity, and the state change amount is determined as the estimated region response; After each of the electric field adjustment units completes the control of the coordinated control quantity, the state data of the formation process after control is reacquired, the electric field state of each region to be regulated is determined according to the regional influence relationship, the electric field state after control is compared with the electric field state before control to obtain the state change, and the state change is determined as the actual regional response.

8. The method for controlling the surface uniformity of electroformed aluminum foil according to claim 7, characterized in that, The actual response and the predicted response are compared one by one in each of the regions to be regulated, and the response difference is determined based on the comparison results. When the actual regional response and the predicted regional response are not in the same direction of change and the difference in response exceeds the allowable deviation, the degree of effect of the electric field adjustment unit on the region to be controlled in the regional influence relationship is corrected. When the actual regional response and the estimated regional response change in the same direction and the response difference exceeds the allowable deviation, the control sensitivity of the electric field adjustment unit acting on the region to be controlled is corrected.

9. The method for controlling the surface uniformity of electroformed aluminum foil according to claim 7, characterized in that, After correcting the regional influence relationship or the control sensitivity, the corrected regional influence relationship or the control sensitivity is used in the next control cycle to determine the cooperative control quantity and the estimated regional response, and the actual regional response in the next control cycle is obtained. The actual regional response of the next control cycle is compared with the estimated regional response, and the response difference is determined. When the response difference exceeds the allowable deviation, the regional influence relationship or the control sensitivity is further corrected based on the actual regional response of the next control cycle. When the response difference does not exceed the allowable deviation, the correction is stopped.

10. A system for controlling the surface uniformity of formed aluminum foil, said system being used to implement the method for controlling the surface uniformity of formed aluminum foil as described in any one of claims 1-9, characterized in that, The system includes a state acquisition module, a region relationship construction module, an electric field state determination module, a collaborative control module, and a feedback correction module. The state acquisition module acquires the formation process state data and historical control response data, and determines multiple controllable areas and electric field adjustment unit states on the surface of the formed aluminum foil based on the formation process state data. The regional relationship construction module determines the degree of influence of each electric field adjustment unit on each region to be controlled based on the spatial correspondence between each electric field adjustment unit and each region to be controlled, as well as the state of the electric field adjustment unit, and establishes regional influence relationships. The electric field state determination module performs spatial mapping on the formation process state data based on the regional influence relationship, determines the electric field state of each region to be controlled, forms a distribution benchmark based on the electric field state, and determines the regional deviation of each region to be controlled relative to the distribution benchmark. The collaborative control module determines the control sensitivity between the control changes of each electric field adjustment unit and the state changes of each region to be regulated based on the historical control response data, and generates a collaborative control quantity based on the region deviation, the region influence relationship and the control sensitivity. The feedback correction module determines the estimated region response based on the cooperative control quantity and the control sensitivity, controls each of the electric field adjustment units and obtains the actual region response, compares the actual region response with the estimated region response, and when the response difference exceeds the allowable deviation, corrects the region influence relationship or the control sensitivity based on the response difference; when the response difference does not exceed the allowable deviation, maintains the region influence relationship and the control sensitivity.

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