A down coiling tension control system
By using the mechanical structure of the slip ring and elastic energy storage components, the stability and accuracy deviation problems of the lower winding tension control system are solved, achieving fast response and high stability tension control, adapting to changes in winding diameter and external interference, ensuring the quality of green ceramic tape, and reducing the impact of motor heating and wear.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- KUNSHAN KAIKE ELECTRONIC MACHINERY EQUIPMENT CO LTD
- Filing Date
- 2025-09-28
- Publication Date
- 2026-07-31
AI Technical Summary
In the existing technology, the lower winding tension control system has problems of poor stability and accuracy deviation during the winding process of green ceramic tape for multilayer ceramic capacitors. In particular, the motor speed adjustment has a lag, making it difficult to quickly adapt to changes in roll diameter and external interference, resulting in large tension fluctuations and affecting the quality of green ceramic tape.
The mechanical structure employs a differential ring, a sliding ring, a fixed ring, and an elastic energy storage component. Tension is limited by frictional torque. The differential ring and the winding shaft rotate synchronously within the frictional torque range. When the frictional torque is exceeded, the differential ring slips, automatically limiting the tension. The elastic energy storage component sets the maximum tension limit, and the power source provides the basic speed and torque.
It achieves fast response and stable tension control, reduces the impact of motor heating and wear on tension control, improves system robustness and long-term accuracy retention, has a simple structure and controllable cost, adapts to changes in roll diameter and external interference, and avoids breakage or excessive stretching of green ceramic tape.
Smart Images
Figure CN224577731U_ABST
Abstract
Description
Technical Field
[0001] This utility model belongs to the technical field of special equipment for ceramic capacitor manufacturing, specifically relating to a winding tension control system, which is suitable for winding green ceramic tape of multilayer ceramic capacitors (MLCCs). Background Technology
[0002] Multilayer ceramic chip capacitors (MLCCs) are core passive components of modern electronic devices, and their manufacturing process significantly impacts product performance. The preparation of the green ceramic tape is a crucial step, typically employing a casting process: ceramic slurry is coated onto a PET carrier film using a casting machine, dried to form a uniform and dense ceramic film, and then wound into a roll using a roll-up system for subsequent processes such as lamination, cutting, and electrode printing.
[0003] During the unwinding and rewinding process, the stability of tension control directly affects the quality of the green ceramic tape. Excessive tension can cause the diaphragm to stretch, deform, or even break, damaging its microstructure. Insufficient tension, on the other hand, can easily lead to diaphragm loosening, wrinkling, or uneven winding, affecting subsequent processing accuracy. Therefore, precise and stable tension control is crucial for ensuring consistent MLCC performance and high yield.
[0004] Currently, common unwinding tension control schemes mainly rely on motors (such as servo motors or torque motors) to drive the reel and achieve winding through belt transmission. Although tension can be indirectly controlled by adjusting the motor speed, motor speed adjustment has a lag and is difficult to adapt quickly to changes in reel diameter or external interference, resulting in tension fluctuations. During long-term operation, problems such as motor overheating, mechanical wear, or belt loosening may further exacerbate tension drift.
[0005] Therefore, there is an urgent need for a simple and cost-controllable unwinding tension control system to solve the problems of poor stability and accuracy deviation in the existing technology, and to meet the high-quality production requirements of MLCC green ceramic tape. Utility Model Content
[0006] The purpose of this invention is to provide a winding tension control system.
[0007] To achieve the above objectives, the technical solution specifically provided by this utility model is as follows:
[0008] A winding tension control system includes a take-up shaft, a drive belt, and a power source, and further includes:
[0009] A differential ring is fitted onto the winding shaft, and one end of the drive belt is fitted onto the differential ring, while the other end is connected to the power source.
[0010] A sliding ring is coaxially sleeved on the take-up shaft and can slide along the axis of the take-up shaft.
[0011] A fixed ring is fixedly installed on the take-up shaft and is located at both ends of the differential ring, respectively, along with the sliding ring.
[0012] And an elastic energy storage component, which is disposed on the winding shaft and is used to apply a force to the sliding ring along the axis of the winding shaft so that the sliding ring abuts against the end face of the differential ring.
[0013] The working principle of this utility model is as follows:
[0014] The power source drives the differential ring to rotate via a belt. The thrust generated by the elastic energy storage component causes the sliding ring to press against the differential ring, generating a frictional torque (M) at the contact surface. f When the torque (M) required for winding is less than or equal to the frictional torque (M) f When there is no relative sliding (static friction) between the differential ring and the take-up shaft, the torque is fully transmitted, and the take-up shaft rotates synchronously with the differential ring. When the torque (M) required for winding is greater than the frictional torque (Mf), f When the slip ring and the take-up shaft are in motion, relative sliding (dynamic friction) occurs. At this time, the actual torque transmitted to the take-up shaft is limited to the frictional torque (M). f The level of excess torque (mm). f The loss is consumed by the slip ring, which manifests as the slip ring rotating faster than the winding shaft.
[0015] The winding tension (T) of the green ceramic tape is directly related to the winding shaft torque (M) (T≈M / R, where R is the roll diameter).
[0016] The frictional torque (M) set for the elastic energy storage component f The maximum torque limit that the take-up shaft can achieve is actually set, which indirectly sets the maximum tension limit that the green ceramic tape can withstand. When the actual tension attempts to exceed this limit, the torque (M) required for winding will exceed (M). f This triggers slippage, limiting the transmitted torque and thus automatically preventing the tension from exceeding the set value. When the actual tension is below the upper limit, there is no slippage, the torque is transmitted normally, and the tension is maintained.
[0017] Based on the aforementioned solution, this utility model effectively solves the problems of tension fluctuation (response lag) and accuracy deviation (long-term stability).
[0018] Slippage is an instantaneous, passive mechanical response process. When tension increases instantaneously (such as a sudden change in roll diameter, speed fluctuation, or slight material jamming), resulting in M > Mslip, it occurs. f Slippage occurs immediately, limiting the increase in torque / tension. There's no need to wait for the motor controller to detect, calculate, and adjust the speed. The response speed far exceeds that of motor speed control systems. Similarly, when the tension decreases instantaneously, as long as M... <M f Once the slippage disappears, the rewind shaft immediately catches up with the drive speed, and the tension is restored.
[0019] The core tension setting is determined by the thrust F of the elastic energy storage component. As long as a suitable elastic element (such as a high-quality spring) is selected, its force characteristics (force-displacement curve) are very stable during long-term operation, with minimal impact from temperature and time. The power source does not need frequent speed adjustments to follow tension changes; it only needs to provide a relatively constant base speed and torque to drive the differential ring. This significantly reduces the impact of motor heat and wear on tension control accuracy. The belt primarily transmits the base torque driving the differential ring, and its slight slack has a far smaller impact on the upper tension limit than the slack caused by the belt directly transmitting the winding torque in existing technologies.
[0020] As the roll diameter increases, the torque required to maintain the same tension T increases linearly. In existing technologies, this requires the control system to calculate the roll diameter in real time and adjust the motor torque / speed. In this solution, when M increases beyond the current M... f At this time, slippage will automatically occur, limiting the tension to within the set upper limit. The system does not need to know the current roll diameter to automatically adapt to changes in roll diameter and keep the tension below the safe value. Although the average tension will change slightly as the roll diameter increases (because M... f (It is fixed), but fluctuations are strictly limited to the upper limit, avoiding the risk of excessive tension. In addition, external speed fluctuations are first absorbed and buffered by the slip element, and will not directly impact the tension of the green ceramic belt.
[0021] Advantages of this utility model compared to the prior art:
[0022] Mechanical slip responds to tension changes in milliseconds, far faster than the response speed of motor speed control systems (typically hundreds of milliseconds or more), effectively suppressing instantaneous tension spikes and fluctuations. It has a natural buffering and adaptability to changes in roll diameter, speed fluctuations, and minor mechanical disturbances, significantly improving system robustness. The upper tension limit is set by mechanical elastic force, making it less susceptible to factors such as motor temperature drift, wear, and belt slack, resulting in better long-term tension control consistency. Based on the original motor drive and belt transmission, it mainly adds a slip ring, sliding ring, fixed ring, and elastic energy storage component, without adding complex sensors (such as tension sensors) or expensive precision servo control systems, resulting in a relatively simple structure and lower manufacturing and maintenance costs. Mechanical components operate reliably with fewer potential failure points, making maintenance relatively simple. A clearly defined upper tension limit prioritizes slippage under abnormal operating conditions (such as material jamming), effectively protecting the green ceramic belt from breakage or excessive stretching deformation. The power source only needs to provide basic driving force, eliminating the need for high-dynamic-performance precise torque or speed control, reducing the performance requirements of the motor and driver.
[0023] Furthermore, the elastic energy storage component includes a clamping block and a compression spring; the clamping block is fixed to the winding shaft, and one end of the compression spring abuts against the clamping block and the other end abuts against the sliding ring.
[0024] Furthermore, the clamping block is ring-shaped and is sleeved on the winding shaft and is threadedly connected to the winding shaft or fixedly connected by bolts.
[0025] Furthermore, the compression spring is a cylindrical helical spring or a wave spring.
[0026] Furthermore, both ends of the differential ring are provided with flange edges.
[0027] Furthermore, friction plates are provided on the opposite end faces of the two flanges.
[0028] Furthermore, the power source includes a drive motor and a pulley located at the output end of the drive motor for the transmission belt to be fitted onto.
[0029] This utility model has the following beneficial effects:
[0030] This invention utilizes a simple passive mechanical slip clutch structure to transform the key aspect of tension control from relying on active, lagging, and drift-prone electrical speed regulation to relying on passive, fast, and stable mechanical friction limiting. This fundamentally solves the problems of large tension fluctuations and poor stability caused by response lag and long-term drift during the unwinding process of MLCC green ceramic tape. Its advantages include rapid response, high stability, simple structure, controllable cost, and excellent long-term precision retention, perfectly meeting the tension control requirements of high-quality MLCC green ceramic tape production. Attached Figure Description
[0031] Figure 1 This is a schematic diagram of the lower winding tension control system in Embodiment 1 of this utility model;
[0032] Figure 2 This is a (partial) structural schematic diagram of the lower winding tension control system in Embodiment 1 of this utility model;
[0033] Figure 3 This is a (partial) structural schematic diagram of the lower winding tension control system in Embodiment 2 of this utility model;
[0034] Figure 4 This is a schematic diagram of the compression spring in Embodiment 2 of this utility model.
[0035] Explanation of reference numerals in the attached figures:
[0036] 1. Rewinding shaft; 11. Bearing; 2. Drive belt; 3. Drive motor; 31. Pulley; 4. Slip ring; 41. Flange edge; 5. Sliding ring; 6. Fixed ring; 7. Compression spring; 8. Clamping block; 9. Friction plate. Detailed Implementation
[0037] To enable those skilled in the art to better understand the technical solutions of this utility model, the present application will be further described in detail below with reference to the accompanying drawings.
[0038] Example 1:
[0039] A winding tension control system, referring to Figure 1 and Figure 2 This includes a winding shaft 1 for winding up the raw porcelain tape.
[0040] Reference Figure 1 and Figure 2 In this embodiment, the take-up shaft 1 is an air-expanding shaft, the main body of which is used to wind up the green ceramic tape, and one end is connected to the drive unit. A differential ring 4 is coaxially sleeved at the end connected to the drive unit. The differential ring 4 is cylindrical, with flange edges 41 at both ends, and is I-shaped in general, for mounting the drive belt 2. A bearing 11 is provided on the side of the take-up shaft 1 that is biased towards the differential ring 4, for mounting the take-up shaft 1 on the equipment frame.
[0041] Reference Figure 1 and Figure 2 The drive unit includes a drive motor 3 and a transmission belt 2. The drive end of the drive motor 3 is equipped with a pulley 31, and one end of the transmission belt 2 is sleeved on the pulley 31 and the other end is sleeved on the differential ring 4. When the drive motor 3 is energized, it transmits torque through the pulley 31, the transmission belt 2 and the differential ring 4.
[0042] Reference Figure 1 and Figure 2 The winding shaft 1 is equipped with a sliding ring 5 and a fixed ring 6 located at both ends of the differential ring 4. The sliding ring 5 can move axially along the winding shaft 1, while the fixed ring 6 is fixedly connected to the winding shaft 1. Friction plates 9 are fixedly installed on the opposite end faces of the two flange edges 41. The friction plates 9 can be made of plastic to increase friction with the sliding ring 5 / fixed ring 6.
[0043] Reference Figure 1 and Figure 2A ring-shaped clamping block 8 is fitted near the end of the take-up shaft 1, and the clamping block 8 is fixedly connected to the take-up shaft 1 by bolts. In other embodiments, the clamping block 8 and the take-up shaft 1 can also be directly threaded together. The clamping block 8 and the sliding ring 5 are both located on the same side of the differential ring 4, and are spaced apart from each other. A compression spring 7 is fitted on the take-up shaft 1 between the clamping block 8 and the sliding ring 5. In this embodiment, the compression spring 7 is a cylindrical helical spring, with one end abutting against the clamping block 8 and the other end abutting against the sliding ring 5. When the compression spring 7 is in a compressed state, it applies a thrust along the axis of the take-up shaft 1 to the sliding ring 5, and the thrust causes the sliding ring 5 to press against the differential ring 4 and generate a frictional torque at the contact surface. According to actual needs, a suitable specification of compression spring 7 can be selected and the distance between the clamping block 8 and the sliding ring 5 can be reasonably set so that the magnitude of the thrust of the compression spring 7 on the sliding ring 5 meets the actual needs.
[0044] The working principle of this embodiment is as follows: when the tension increases instantaneously (such as a sudden change in roll diameter, speed fluctuation, or slight material jamming) causing the winding torque to exceed the frictional torque, slippage immediately occurs, limiting the increase in torque / tension. There is no need to wait for the motor controller to detect, calculate, and adjust the speed. The response speed far exceeds that of a motor speed control system. Similarly, when the tension decreases instantaneously, the slippage disappears, and the winding shaft 1 immediately catches up with the drive speed, restoring the tension. This solves the problem of large tension fluctuations and poor stability caused by response lag and long-term drift during the unwinding process of existing MLCC green ceramic tape.
[0045] Example 2:
[0046] This embodiment is based on Embodiment 1, and refers to... Figure 3 and Figure 4 The only difference is that a wave spring is used instead of a cylindrical helical spring. During compression, the wave spring stores and releases energy through deformation at its crests and troughs, providing the same axial load and deformation as a regular cylindrical helical spring. Through optimized design, the free height of the wave spring under the same load is only 1 / 3 to 1 / 2 that of a cylindrical spring, making it more suitable for applications with limited installation space.
[0047] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.
Claims
1. A down winding tension control system comprising a winding shaft (1), a transmission belt (2) and a power source, characterized in that Also includes: A differential ring (4) is fitted onto the winding shaft (1), and one end of the transmission belt (2) is fitted onto the differential ring (4), while the other end is connected to the power source. The sliding ring (5) is coaxially sleeved on the take-up shaft (1) and can slide along the axis of the take-up shaft (1); The fixed ring (6) is fixedly set on the winding shaft (1) and is located at both ends of the slip ring (4) along with the sliding ring (5); And an elastic energy storage component, which is disposed on the winding shaft (1) and is used to apply a force to the sliding ring (5) along the axial direction of the winding shaft (1) so that the sliding ring (5) abuts against the end face of the differential ring (4).
2. A downweb tension control system according to claim 1, wherein: The elastic energy storage component includes a clamping block (8) and a compression spring (7); the clamping block (8) is fixed to the winding shaft (1), and one end of the compression spring (7) abuts against the clamping block (8) and the other end abuts against the sliding ring (5).
3. A downweb tension control system according to claim 2, wherein: The clamping block (8) is ring-shaped and is sleeved on the winding shaft (1) and is threadedly connected to the winding shaft (1) or fixedly connected by bolts.
4. The downweb tension control system of claim 2, wherein: The compression spring (7) is a cylindrical helical spring or a wave spring.
5. A downweb tension control system according to any one of claims 1 to 4, wherein: Both ends of the slip ring (4) are provided with flange edges (41).
6. A downweb tension control system according to claim 5, wherein: Friction plates (9) are provided on the opposite end faces of the two flange edges (41).
7. A downweb tension control system according to any one of claims 1 to 4, wherein: The power source includes a drive motor (3) and a pulley (31) located at the output end of the drive motor (3) for the transmission belt (2) to be fitted.