Roll press machine, method for adjusting the roll gap of a roll press machine and correcting the deflection of the pressure rolls.

Abstract

To provide a roll press machine capable of high-precision press processing even during long-term continuous processing. [Solution] A roll press machine comprising: a pair of pressure rolls that continuously press-process a sheet, having a pressure roll shaft supported and rotated by a rolling bearing; a press mechanism for adjusting the roll gap of the pressure rolls; a bend mechanism for correcting the deflection of the pressure rolls; a thickness gauge for measuring the thickness of the thin film sheet compressed by the pressure rolls; a laser distance sensor for measuring the shape of the outer surface of the pressure rolls; a calculation unit that calculates the amount of adjustment of the roll gap in the press mechanism and the amount of deflection correction in the bend mechanism based on the thickness measurement from the thickness gauge and the measurement from the laser distance sensor; and a control unit that controls the press mechanism and the bend mechanism based on the amount of adjustment of the roll gap and the amount of deflection correction calculated by the calculation unit.

Description

Technical Field

[0001] The present invention relates to a roll press machine, a method for adjusting the roll gap of a roll press machine, and a method for correcting the deflection of a pressure roll.

Background Art

[0002] In the compression process of a lithium-ion secondary battery electrode material, a coiled electrode material (also referred to as a "material sheet" because it is in sheet form) is unwound and continuously compressed by a roll press machine. The thickness accuracy of the material sheet after compression is severe, about ±1 to 2 μm in both the width direction and the flow direction. Also, the length of one coil tends to be long, and the continuous processing time tends to be long. During continuous processing, due to minute temperature changes inside the roll caused by heat generated by roll rotation, compression processing, etc., minute shape changes of the roll occur.

[0003] When the continuous processing time becomes long, a change of several μm occurs in the thickness of the compressed material sheet, and the compressed thickness may deviate from the target thickness range (tolerance value). For this reason, in Patent Document 1, the thickness is measured by a thickness gauge at a plurality of locations in the width direction of the pressed material sheet, and according to the state of the difference between the thickness measurement values at the plurality of locations and the target thickness so that the thickness within the entire width range of the material is within the target thickness range, a method of performing feedback control of a press mechanism for adjusting the roll gap and a bend mechanism for correcting the deflection of the roll has been proposed (a mechanism for adjusting the thickness of a material sheet such as a press mechanism for adjusting the roll gap and a bend mechanism for correcting the deflection of the roll is collectively referred to as an "alignment mechanism", and its adjustment is referred to as "alignment adjustment").

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] In a roll press machine, as continuous processing progresses, the temperature of the pressure rolls rises due to friction, increasing the deflection of the pressure rolls. Additionally, wear on the pressure rolls changes the roll gap, altering the pressure conditions. Therefore, simply correcting the roll gap and roll deflection based solely on the measurement results of the material sheet thickness after roll pressing has limitations in improving the accuracy of the material sheet thickness.

[0006] The object of the present invention is to provide a roll press machine capable of high-precision press working even during long-term continuous processing, a method for adjusting the roll gap of the roll press machine, and a method for correcting the deflection of the pressure roll. [Means for solving the problem]

[0007] The configuration of the present invention for achieving the above objective is as follows. A roll press machine comprising: a pressure roll shaft supported and rotated by rolling bearings, a pair of pressure rolls for continuously pressurizing a sheet; a press mechanism for adjusting the roll gap of the pressure rolls; a bend mechanism for correcting the deflection of the pressure rolls; a thickness gauge for measuring the thickness of the thin film sheet compressed by the pressure rolls; a laser distance sensor for accurately measuring the shape of the outer surface of the pressure rolls; a calculation unit for calculating the amount of roll gap adjustment in the press mechanism and the amount of deflection correction in the bend mechanism based on the thickness measurement from the thickness gauge and the measurement from the laser distance sensor; and a control unit for controlling the press mechanism and the bend mechanism based on the roll gap adjustment amount and the deflection correction amount calculated by the calculation unit.

[0008] Furthermore, the roll press machine is characterized by comprising: a pressure roll shaft supported and rotated by rolling bearings, a pair of pressure rolls for continuously pressurizing a sheet; a press mechanism for adjusting the roll gap of the pressure rolls; a bend mechanism for correcting the deflection of the pressure rolls; a thickness gauge for measuring the thickness of the thin film sheet compressed by the pressure rolls; a temperature sensor for detecting the temperature of the surface of the pressure rolls; a calculation unit for calculating the amount of adjustment of the roll gap in the press mechanism and the amount of deflection correction in the bend mechanism based on the thickness measurement from the thickness gauge and the measurement from the temperature sensor; and a control unit for controlling the press mechanism and the bend mechanism based on the amount of adjustment of the roll gap and the amount of deflection correction calculated by the calculation unit.

[0009] Furthermore, a method for adjusting the roll gap and correcting the deflection of a pressure roll in a roll press machine, comprising: a pair of pressure rolls having a pressure roll shaft supported and rotating by a rolling bearing for continuously press-processing a sheet; a press mechanism for adjusting the roll gap of the pressure rolls; a bend mechanism for correcting the deflection of the pressure rolls; a thickness gauge for measuring the thickness of the thin film sheet compressed by the pressure rolls; and a laser distance sensor for measuring the shape of the outer surface of the pressure rolls, the method comprising: a calculation step for calculating the amount of roll gap adjustment in the press mechanism and the amount of deflection correction in the bend mechanism based on the thickness measurement from the thickness gauge and the measurement from the laser distance sensor; and a control step for controlling the press mechanism and the bend mechanism based on the amount of roll gap adjustment and the amount of deflection correction calculated in the calculation step.

[0010] Furthermore, a method for adjusting the roll gap and correcting the deflection of a roll press machine, comprising: a pair of pressure rolls having a pressure roll shaft supported and rotating by a rolling bearing for continuously press-processing a sheet; a press mechanism for adjusting the roll gap of the pressure rolls; a bend mechanism for correcting the deflection of the pressure rolls; a thickness gauge for measuring the thickness of the thin film sheet compressed by the pressure rolls; and a temperature sensor for detecting the temperature of the surface of the pressure rolls, the method comprising: a calculation step for calculating the amount of adjustment of the roll gap in the press mechanism and the amount of deflection correction in the bend mechanism based on the thickness measurement from the thickness gauge and the measurement from the temperature sensor; and a control step for controlling the press mechanism and the bend mechanism based on the amount of adjustment of the roll gap and the amount of deflection correction calculated in the calculation step. [Effects of the Invention]

[0011] According to the present invention, it is possible to provide a roll press machine capable of high-precision press working even during long-term continuous processing, a method for adjusting the roll gap of the roll press machine, and a method for correcting the deflection of the pressure roll. [Brief explanation of the drawing]

[0012] [Figure 1] A schematic diagram of the roll press machine to which the present invention applies. [Figure 2] Front view of the roll press machine to which the present invention applies. [Figure 3] A cross-sectional view of the workpiece to be processed by the roll press machine that is the subject of this invention. [Figure 4] An example of an adjustment mechanism for the gap between pressure rolls and the load applied to the pressure rolls of a roll press machine targeted by the present invention. [Figure 5] A diagram illustrating the placement of sensors installed on a roll press machine. [Figure 6] A diagram illustrating the detailed placement of sensors installed on a roll press machine. [Figure 7] A diagram illustrating examples of output values ​​from various sensors and alignment settings. [Figure 8]Flowchart of learning and generation of condition map. [Figure 9] Diagram showing an example of an optimal condition map. [Figure 10] Flowchart of automatic alignment control.

Embodiments for Carrying Out the Invention

[0013] Hereinafter, embodiments of the present invention will be described with reference to the drawings.

Embodiment

[0014] FIG. 1 is an overall schematic configuration diagram of a roll press machine in which a pressure roll according to an embodiment of the present invention is used. The roll press machine 1 is, for example, as shown in FIG. 3, a facility for continuously compression-processing a sheet 11 having a coating portion 11a in which an active material is coated on both sides of a base material 11b made of a conductive metal foil such as an aluminum foil or a copper foil, so as to increase the density of the active material and achieve a uniform thickness. Note that the roll press machine 1 is not limited to a facility for compression-processing a sheet 11 having a coating portion 11a in which an active material is coated on both sides of a base material 11b made of a conductive metal foil such as an aluminum foil or a copper foil. For example, it is also used as a facility for compression-processing a thin film-like sheet such as laminating an adhesive-free aramid paper on both sides of a polyester film. That is, the roll press machine 1 according to an embodiment of the present invention is suitably used for the compression-processing of any thin film-like sheet.

[0015] As shown in FIG. 1, the roll press machine 1 includes, from the upstream side, for example, an unwinder 4 that winds up an unwinding coil of a sheet 11 having a length of about 500 m, an upstream-side conveying mechanism 6 that conveys the sheet 11 sent out from the unwinder 4, a preheating roll 10 for preheating the sheet 11, a pair of pressure rolls (upper pressure roll 2A, lower pressure roll 2B) for compression-processing the sheet 11, a downstream-side conveying mechanism 7 that conveys the compression-processed sheet 11, and a winder 5 that winds up the compression-processed sheet 11 to generate a winding coil.

[0016] The upstream transport mechanism 6 is equipped with multiple guide rolls 8 and a dancer roll 9. The dancer roll 9 is configured so that its axis of rotation can be displaced vertically along an arc-shaped trajectory around a support point. As the dancer roll 9 displaces vertically along the arc-shaped trajectory, it applies a predetermined tension (appropriate tension) to the sheet 11 and, in cooperation with the guide rolls 8, transports the sheet 11 to the preheating roll 10.

[0017] The downstream conveying mechanism 7 also includes a plurality of guide rolls 8, a dancer roll 9, and a thickness gauge 3. The dancer roll 9 displaces up and down along an arc-shaped trajectory, applying a predetermined tension to the sheet 11. The thickness gauge 3, installed between two guide rolls, measures the thickness of the sheet 11 as it passes through the thickness gauge 3, under the predetermined tension applied by the dancer roll 9.

[0018] Note that in Figure 1, the number of guide rolls 8 is shown as few as possible for illustrative purposes. For example, the configuration may include 10 to 30 guide rolls 8 in both the upstream conveying mechanism 6 and the downstream conveying mechanism 7, rather than being limited to the number shown in this figure. Also, in Figure 1, the dancer rolls 9 and preheating rolls 10 are shown separately from the guide rolls 8, but these dancer rolls 9 and preheating rolls 10 may also be referred to as the guide rolls 8.

[0019] Figure 2 shows a front view of a pair of pressure rolls (upper pressure roll 2A, lower pressure roll 2B) (front view of area A in Figure 1). The pressure rolls 2A and 2B, which are positioned opposite each other vertically, are rotatable by rolling bearings 22 that support the respective pressure roll shafts 20 at both ends, bearing housings 23 that hold the rolling bearings 22, and a housing 21 that holds the bearing housings 23. Furthermore, a press cylinder 24, for example, composed of a hydraulic cylinder, is positioned between the bearing housings 23 that hold the rolling bearings 22 that support both ends of the pressure roll shaft 20 of the lower pressure roll 2B, and the lower part of the housing 21. The press cylinder 24 moves up and down to adjust the gap between the pressure rolls 2A and 2B and the load applied to the pressure rolls based on the thickness of the sheet 11 measured by the thickness gauge 3 mentioned above.

[0020] Furthermore, the pressure rolls 2A and 2B in this embodiment are, for example, solid metal rolls with a roll diameter of 300 to 800 mmφ, with a typical example being a roll with a roll diameter of 500 mmφ.

[0021] In Figures 1 and 2, the sheet 11 is transported at a conveying speed of approximately 100 m / min and continuously compressed by pressure rolls 2A and 2B. The thickness Tb of the base material 11b shown in Figure 3 is, for example, about 15 μm, and the thickness including the coated portion 11a on both sides of the base material 11b, i.e., the thickness Ta of the sheet 11, is about 150 μm before compression. The sheet 11, which has a thickness of about 150 μm, is compressed to about 100 μm by compression processing with pressure rolls 2A and 2B. As a result, the density of the coated portion 11a on both sides, i.e., the active material, is improved. On the other hand, as mentioned above, a compression processing accuracy of ±1.0 to 2.0 μm is required.

[0022] Next, the details of the gap between the pressure rolls 2A and 2B and the mechanism for adjusting the load applied to the pressure rolls 2A and 2B will be explained using Figure 4.

[0023] The roll press machine 1 in the roll press equipment includes a bearing housing 23 that houses rolling bearings 22 supporting a pair of pressure rolls (upper pressure roll 2A and lower pressure roll 2B), and a press cylinder 24 that applies a load to the bearing housing 23 of the lower pressure roll 2B, generating a press load on the material sheet 11 between the upper pressure roll 2A and the lower pressure roll 2B. The bearing housing 23 of the upper pressure roll 2A and the press cylinder are supported by a housing (reference numeral 21 in Figure 2, not shown in Figure 4). The upper pressure roll 2A and the lower pressure roll 2B are each provided with a roll drive mechanism (not shown). The roll press machine body also includes a bending mechanism that corrects the deflection of the rolls, consisting of a bending cylinder 47 and a bending bearing housing 46 that houses a bending bearing.

[0024] The press cylinder 24 is the main component of the press mechanism that adjusts the roll gap. The press cylinder 24 is configured to be position-controllable by control commands from a control panel, which will be described later. The press cylinder 24 has a position detection device such as a magnetar scale (not shown) inside or outside, and is configured to be position-controllable using a servo valve in the hydraulic system.

[0025] The bending cylinder 47 allows the pressure to be set by a control command from a control panel, which will be described later. A proportional control valve (solenoid valve) is used for pressure setting in the bending cylinder 47. The bending bearing housing 46 is provided on both outer sides of the bearing housing 23. In this embodiment, the bending mechanism that corrects the deflection of the roll has a bending cylinder 47 provided between the bending bearing housing of the upper pressure roll 2A and the bending bearing housing 46 of the lower pressure roll 2B. It corrects the deflection of the roll by applying a load to the roll in the opposite direction to the roll deflection caused by the processing load on the material. The arrows in the figure represent the direction and magnitude of the load from each cylinder. Each cylinder uses hydraulics. Hydraulic cylinders can handle high loads and stable processing can be performed by using an incompressible fluid (hydraulic oil).

[0026] Figure 5 extracts only the parts directly related to the control of alignment mechanisms such as roll gap control and pressure control from the line of the roll press equipment in Figure 1, simplifies the flow shape of the sheet 11 into a linear shape, and then shows the arrangement of various sensors, which is a characteristic of this embodiment.

[0027] An unwinding machine 4 is provided at the input end of the roll press machine body to attach a pre-press coil 78, in which a material sheet 11 such as lithium-ion secondary battery electrode material is wound into a coil shape. A winding machine 5 is provided at the output end of the roll press machine body to wind the pressed material into a post-press coil 79. In addition, a thickness gauge 3 is installed at the output end of the roll press machine body to measure the thickness of the pressed material sheet 11.

[0028] The thickness gauge 3 only needs to be capable of measuring at least two points in the width direction, but it is preferable to measure the thickness at three points. That is, it is preferable to be configured to measure the thickness at three points (three regions or three locations) in the width direction: the operating side (the side without the roll drive mechanism), the center, and the driving side (the side with the roll drive mechanism). The thickness measurement points may be set by fixing the measuring instrument at three locations and measuring the thickness, or by moving the measuring instrument in the width direction and measuring the thickness. When measuring continuously in the width direction, three regions may be set: the operating side, the center, and the driving side, and the average value of the measured values ​​within these ranges may be used for control.

[0029] Furthermore, there are no restrictions on the measurement method for the thickness gauge 3, as long as it can continuously or intermittently measure the material thickness during line operation. For example, possible measurement methods for the thickness gauge include detecting the position of the upper surface of the material on the guide roll using a laser sensor, detecting the position of the guide roll using a magnetic sensor, and measuring the material thickness from their relative positions, or measuring the positions of both sides of the material using laser sensors and measuring the material thickness from their relative positions.

[0030] Furthermore, in addition to the thickness gauge 3, this embodiment is equipped with various sensors as shown in Figure 6. The pressure roll 2 shown in Figure 6 is a solid metal roll. Heat is generated between the rolling bearings 22 and both ends of the pressure roll shaft 20 of the pressure roll 2, which rotates at high speed, due to the aforementioned mechanical friction. The heat generated in the rolling bearings 22 is conducted to the pressure roll 2 from both sides via the pressure roll shaft 20. As a result, the temperature distribution inside the body of the pressure roll 2 is highest at both ends along the direction of the pressure roll shaft 20, and decreases towards the center. This creates a temperature bias inside the pressure roll 2, causing deformation due to thermal expansion in the direction of the pressure roll shaft 20, and the amount of deformation or the distribution of deformation depends on the temperature distribution (referred to as a "thermal crown"). As a result, the shape of the outer surface 25 of the pressure roll 2 after thermal deformation is as shown by the dashed line in Figure 6. The shape of the outer surface 25 of the pressure roll 2 due to this thermal deformation is measured by the laser distance sensor 72.

[0031] By combining the data obtained from the laser distance sensor 72 with the thickness information of the sheet 11 obtained from the thickness gauge 3, more precise alignment adjustment becomes possible. The laser distance sensor 72 accurately measures the distance from the surface of the pressure roll 2 and monitors the surface position of the pressure roll 2. Based on the acquired distance data, it analyzes how much the surface position of the pressure roll 2 deviates from the reference value.

[0032] Furthermore, a pressure sensor 73 was installed inside the pressure roll 2 to measure the stress applied to the pressure roll 2. The pressure sensor 73 may also be placed near the contact surface of the pressure roll shaft 20 or the pressure roll 2, rather than inside the pressure roll 2.

[0033] Furthermore, a vibration sensor 74 is provided in the bearing housing 23 of the pressure roll shaft 20 to detect vibrations of the pressure roll 2. The vibration sensor 74 may also be provided around the pressure roll bearing housing 23 or in the housing 21.

[0034] Furthermore, a temperature sensor 75 is provided near or around the surface of the pressure roll 2 to detect the surface temperature of the pressure roll 2. While an infrared thermometer capable of non-contact temperature measurement is preferred for the temperature sensor 75, a thermocouple may also be provided inside the pressure roll 2.

[0035] Based on the thickness measurement from the thickness gauge 3, and the measurement values ​​from the laser distance sensor 72, pressure sensor 73, vibration sensor 74, and temperature sensor 75, the control panel 71 calculates control values ​​(correction amounts) for alignment control, such as adjusting the gap between the upper pressure roll 2A and the lower pressure roll 2B and the load applied to the upper pressure roll 2A and the lower pressure roll 2B, as explained using Figure 4. The control values ​​are output to each adjustment mechanism, and the alignment is adjusted according to these control values. Although the signal lines from each sensor on the upper pressure roll 2A to the control panel 71 are omitted in Figure 5, signal lines similar to those from each sensor on the lower pressure roll 2B to the control panel 71 are also provided for the sensors on the upper pressure roll 2A. The control panel 71 may be composed of a control computer (PC) or a dedicated circuit board equipped with a CPU.

[0036] Data from the thickness gauge 3, laser distance sensor 72, pressure sensor 73, vibration sensor 74, and temperature sensor 75 are collected in real time and transmitted to the data acquisition unit of the control panel 71. The data acquisition unit analyzes the data from each sensor and extracts the information necessary for alignment control.

[0037] Next, we will explain how the data acquisition unit of the control panel 71 analyzes data from each sensor and how it calculates control values ​​for alignment control.

[0038] <Method for analyzing data from laser distance sensors and alignment control> The laser distance sensor 72 accurately measures the distance from the surface of the pressure roll 2 and monitors the surface position of the pressure roll 2. Based on the acquired distance data, it analyzes how much the surface position of the pressure roll 2 deviates from the reference value. As continuous processing continues, the temperature of the pressure roll 2 rises due to friction with the sheet 11 and heat generated by friction at the rolling bearings 22 of the pressure roll 2, which is then transferred to the pressure roll 2. When the temperature of the pressure roll 2 rises, the pressure roll 2 expands due to thermal expansion. If the temperature rises due to friction at the rolling bearings 22 of the pressure roll 2, the temperature of both ends of the pressure roll 2 (the sides closer to the bearings), which are closer to the pressure roll shaft 20, becomes higher. As a result, both ends of the pressure roll 2 expand more than the center, causing it to deform into a drum shape when viewed from a direction perpendicular to the pressure roll shaft 20.

[0039] In this case, the bending cylinder 47 shown in Figure 4 is raised to reduce the amount of deflection of the pressure roll 2, thereby adjusting the alignment so that the roll gap in the width direction of the pressure roll 2 becomes uniform. Also, if the temperature of the pressure roll 2 rises due to friction with the sheet 11, the central part of the pressure roll 2 will be hotter than the ends, and the thermal expansion of the central part will be greater than that of the ends, causing it to deform into a barrel shape. In this case, the bending cylinder 47 is lowered to increase the amount of deflection of the pressure roll 2, thereby adjusting the alignment so that the roll gap in the width direction of the pressure roll 2 becomes uniform.

[0040] Furthermore, because the roll gap narrows due to the thermal expansion of the pressure roll 2, the roll gap is increased by moving the pressure roll shaft 20 downward using the press cylinder 24 shown in Figure 4. Conversely, if the temperature of the pressure roll 2 decreases, the pressure roll 2 will thermally contract and the roll gap will widen, so the alignment is adjusted to decrease the roll gap by raising the position of the press cylinder 24. To enable the above, it is desirable to provide a total of three laser distance sensors 72 at both ends and in the center. Alternatively, a continuous profile of the surface of the pressure roll 2 in the longitudinal direction can be obtained by moving one laser distance sensor 72 parallel to the pressure roll shaft 20, or by rotating the laser distance sensor 72 in the longitudinal direction of the pressure roll shaft 20.

[0041] Furthermore, one side of the pressure roll 2 may be higher (the pressure roll shaft 20 is tilted relative to the horizontal) due to a malfunction in the rolling bearing 22 of the pressure roll 2, but such tilting of the pressure roll shaft 20 can also be detected based on the measurement results of the laser distance sensor 72. In that case, the rotation of the pressure roll 2 is stopped and it is checked whether there is any malfunction in the rolling bearing 22 of the pressure roll shaft 20. If the tilt of the pressure roll shaft 20 is slight, it is possible to correct the tilt of the pressure roll shaft 20 by moving, for example, the right press cylinder 24 upward and the left press cylinder 24 downward among the press cylinders 24 in Figure 4. Alternatively, the tilt of the pressure roll shaft 20 can also be corrected by moving either the right or left press cylinder 24 up or down.

[0042] The above explains the concept of the correction method. In actual correction, the thickness in the width and length directions of the sheet 11 that has been pressed by the pressure roll 2 is measured with the thickness gauge 3, and based on that, it is decided how much more the roll gap should be widened (or narrowed) and how much the deflection of the pressure roll 2 should be increased (or decreased), and the correction is then performed. In other words, the amount of adjustment of the roll gap in the press mechanism and the amount of deflection correction in the bending mechanism are calculated based on the thickness measurement from the thickness gauge 3 and the measurement from the laser distance sensor 72.

[0043] <Method for analyzing data from temperature sensors and alignment control> The temperature sensor 75 measures the surface temperature of the pressure roll 2 and monitors the thermal expansion of the pressure roll 2. For example, assuming that the pressure roll 2 is a solid roll made of SUS304 stainless steel, the linear thermal expansion coefficient of SUS304 stainless steel is 17.3 × 10⁻⁶. -6 Since it is / K, a pressure roll 2 with a roll diameter of 500 mmφ will be 17.3 × 10 if the temperature rises by 10℃. -6 ×10 × 0.5 = 86.5 × 10 -6 This results in a thermal expansion of m = 86.5 μm. As mentioned above, the thickness accuracy of the sheet 11 after compression processing is required to be ±1 to 2 μm in both the width direction and the flow direction, so the effect of thermal expansion of the pressure roll 2 cannot be ignored.

[0044] Therefore, if the temperature of the pressure roll 2 rises, the roll gap narrows due to thermal expansion of the pressure roll 2. To widen the roll gap, the pressure roll shaft 20 is moved downward using the press cylinder 24 shown in Figure 4. Conversely, if the temperature of the pressure roll 2 decreases, the pressure roll 2 contracts due to thermal expansion, widening the roll gap. To narrow the roll gap, the alignment is adjusted by raising the position of the press cylinder 24. In addition, the temperature distribution in the width direction of the pressure roll 2 is measured using multiple thermometers or a device capable of measuring two-dimensional temperature distribution, such as a thermograph. For example, if the center of the pressure roll 2 is cold and the outside is hot, the bending cylinder 47 shown in Figure 4 is raised to reduce the amount of deflection of the pressure roll 2, thereby adjusting the alignment so that the roll gap in the width direction of the pressure roll 2 becomes uniform.

[0045] The above explains the concept of the correction method. In actual correction, the thickness in the width and length directions of the sheet 11 that has been pressed by the pressure roll 2 is measured with the thickness gauge 3, and based on that, it is decided how much more the roll gap should be widened (or narrowed) and how much the deflection of the pressure roll should be increased (or decreased), and the correction is then performed. In other words, the amount of adjustment for the roll gap in the press mechanism and the amount of correction for the deflection in the bending mechanism are calculated based on the thickness measurement from the thickness gauge 3 and the measurement from the temperature sensor 75.

[0046] <Method for analyzing data from pressure sensors and alignment control> The pressure sensor 73 measures the pressure applied from the pressure roll 2 to the sheet 11 and confirms the uniformity of the pressure. As an adjustment for excessive pressure, if the pressure value measured by the pressure sensor 73 exceeds the set pressure range (e.g., 500 N / cm²), adjustment is made. 2If the above occurs, the rotation of the pressure roll 2 is stopped, and the actuator is used to widen the gap between the pressure rolls 2 to prevent excessive pressure from damaging the sheet 11 or the pressure rolls 2. Specifically, the pressure is reduced by decreasing the pressure of the press cylinder 24 and widening the distance between the pressure rolls 2. In case of insufficient pressure, the pressure sensor 73 measures the pressure applied to the pressure rolls 2, and if it falls below the set pressure range (e.g., 300 N / cm²), the pressure sensor 73 measures the pressure applied to the pressure rolls 2 and adjusts the gap between the pressure rolls 2. 2 If the pressure is insufficient, the actuator is used to adjust the gap between the pressure rolls 2. Specifically, the pressure is increased by increasing the pressure in the press cylinder 24 and reducing the distance between the pressure rolls 2.

[0047] Furthermore, the pressure applied from the pressure roll 2 to the sheet 11 may affect the battery's performance, such as its charge-discharge characteristics, when the manufactured electrode material sheet is incorporated into the battery. Therefore, by storing the measurement values ​​from the pressure sensor 73 during electrode sheet manufacturing in the control panel 71's memory device and using them as one of the parameters for creating the optimal condition map described later, it becomes possible to manufacture batteries with better performance.

[0048] <Method for analyzing data from vibration sensors and alignment control> The vibration sensor 74 detects the vibration pattern of the pressure roll 2 and monitors its balance in real time. The frequency and amplitude of the vibration are analyzed to identify the cause of the vibration. For example, if the vibration is strong at a particular frequency, it may indicate that an uneven load is being applied to a specific part of the pressure roll 2. If an abnormal vibration is detected, the pressure roll 2 is stopped and rebalanced. As a specific adjustment method, after the cause of the vibration is identified, the position and load of the pressure roll 2 are adjusted using an actuator. If necessary, the position of the pressure roll 2 is finely adjusted to equalize the weight distribution of the pressure roll 2.

[0049] Furthermore, during the pressurizing process by the pressurizing roll 2, some vibration occurs, even if it does not lead to an abnormal stop. Since this vibration is transmitted from the pressurizing roll 2 to the sheet 11, it may affect the performance of the battery, such as the charge and discharge characteristics, of the battery into which the manufactured electrode material sheet is incorporated. Therefore, by storing the measurement values ​​from the vibration sensor 74 during electrode sheet manufacturing in the memory device of the control panel 71 and using them as one of the parameters for creating the optimal condition map described later, it becomes possible to manufacture batteries with better performance.

[0050] Figure 7 shows an example of the output values ​​from the various sensors mentioned above and the alignment settings. For example, Figure 7 shows that when the measurement value from the laser distance sensor 72 is 6 μm and the environmental conditions (external conditions) on which the pressure roll 2 is placed are high temperature, the alignment setting (predicted alignment setting) should be set to 5 μm. The rest is self-explanatory, so no further explanation is given.

[0051] The above describes a method for controlling alignment by individually analyzing data from each of the sensors: thickness gauge 3, laser distance sensor 72, pressure sensor 73, vibration sensor 74, and temperature sensor 75. However, for example, the laser distance sensor 72 can determine the surface irregularities (profile) of the pressure roll at the time of measurement, and based on the obtained profile, the roll gap amount and the deflection correction amount of the pressure roll 2 can be calculated. However, it is not possible to predict how the calculated roll gap amount and the deflection correction amount of the pressure roll 2 will change in the future (a trend can be determined by tracking the change over time, but the possibility of that trend reversing cannot be ruled out).

[0052] On the other hand, based on the time-dependent changes in the temperature measurement value in the width direction of the pressure roll 2 measured by the temperature sensor 75, it is possible to predict how the pressure roll 2 will deform in the future and whether the roll gap amount and the deflection correction amount of the pressure roll should be increased or decreased in the future (regarding temperature changes, even if a malfunction occurs in the rolling bearing 22 of the pressure roll 2, causing increased friction and a sudden rise in temperature, under normal circumstances, there is almost no possibility of the temperature change trend reversing).

[0053] Thus, rather than adjusting the alignment individually based on the data obtained from each sensor, a more accurate alignment adjustment is possible by comprehensively evaluating the measurement data obtained from those sensors and performing the alignment adjustment. Consequently, it becomes possible to prevent variations in the quality of the manufactured electrode material sheet due to fluctuations in the thickness in the width and length directions of the manufactured electrode material sheet, or fluctuations in the temperature of the pressure roll 2 during pressurization, vibration of the pressure roll 2, or the pressure applied from the pressure roll 2 to the sheet 11.

[0054] Therefore, it is desirable to create a database of measurement data obtained from various sensors, manufacturing conditions during roll pressing (pressure, roll gap, deflection of the pressure roll 2), information on the thickness of the manufactured electrode material sheet, and battery performance (charge / discharge characteristics, etc.) of secondary batteries manufactured using the manufactured electrode material sheet, and to apply well-known multivariate analysis methods to reflect this in the alignment adjustment. Such multivariate analysis methods will be described below.

[0055] <Learning and generating conditional maps> The learning method will be explained below, using the learning and condition map generation flowchart shown in Figure 8.

[0056] • Construction of a model for predicting alignment adjustment amounts (S800): (1) Data collection (step S801): The system collects measurement data from the past to the most recent, measured by sensors such as the aforementioned laser distance sensor 72, temperature sensor 75, pressure sensor 73, and vibration sensor 74 (other sensors may be added), as well as manufacturing-related data (roll gap amount, deflection correction amount of the pressure roll 2, type of electrode sheet manufactured, etc.) and quality-related data (battery performance data such as charge / discharge characteristics). These sensors can capture in detail the operating state of the pressure roll 2 and fluctuations in environmental conditions, and are used for comprehensive control. The data will include usage time, operating conditions, and maintenance history of the pressure roll 2. This will allow us to understand the lifespan and performance changes of the pressure roll 2, enabling optimal timing for maintenance and parts replacement.

[0057] (2) Data preprocessing (step S802): The collected data is cleaned to remove noise and outliers. This improves data quality and increases the reliability of the analysis results. Data normalization is also performed to ensure consistency across different sensors and units of measurement. For example, temperature and pressure data can be converted to the same scale, making them easier to compare. Furthermore, by converting the data to a format suitable for machine learning algorithms, missing values ​​can be imputed, ensuring the overall integrity of the dataset.

[0058] (3) Feature engineering (step S803): From the data preprocessed in (2) above, we select features that may affect the thickness of the electrode material sheet and the performance of the battery manufactured using the manufactured electrode material sheet. These include temperature fluctuations, pressure fluctuations, vibration patterns, and operating time. New features are generated to improve the accuracy of the model. For example, based on data obtained from each sensor, the effect of temperature fluctuations from the temperature sensor on the thickness of the electrode material sheet and battery performance is analyzed, and the effect of temperature fluctuations is extracted as a feature. In addition, by combining data from pressure sensors and vibration sensors, the effect of pressure fluctuations and vibration patterns of the pressure roll 2 on the quality of the electrode material sheet is evaluated, and these effects are incorporated as features.

[0059] Furthermore, new features are generated from the collected data. For example, sensor data is used to create composite features that take into account the operating time and maintenance history of pressure roll 2. This improves the accuracy of the model and enables more precise predictions.

[0060] (4) Model selection and training (Step S804): Select an appropriate machine learning algorithm. For example, choose from well-known regression models (linear regression, random forest regression) or deep learning models (neural networks). Split the dataset into a training set and a test set, and train the model.

[0061] Furthermore, during the training phase, the optimal model is selected using cross-validation and grid search. This prevents overfitting and makes it possible to build a more general-purpose model. For example, in linear regression models, multicollinearity is checked and unnecessary features are removed to improve the model's accuracy. In deep learning models, hyperparameters such as the number of layers, the number of neurons, and the activation function are adjusted to find the optimal architecture.

[0062] (5) Model evaluation and tuning (Step S805): The model's performance is evaluated using a test set. Evaluation metrics include the mean absolute error (MAE) and the mean squared error (MSE). Hyperparameter tuning is performed as needed to improve the model's accuracy. For example, in the case of a deep learning model, hyperparameters such as the number of layers, the number of neurons, and the learning rate are adjusted to achieve optimal performance. Using accumulated historical operating data, a machine learning algorithm is constructed and stored in a database along with historical manufacturing and quality data. The predictive model predicts the optimal alignment settings in response to changes in external conditions and product changes. For example, it can consider the impact of temperature and humidity changes in different seasons on the quality of electrode material sheets. By analyzing historical and current data, a predictive model is constructed to identify patterns in alignment adjustment amounts.

[0063] Next, we will explain how to create an optimal conditions map.

[0064] • Creation of an optimal condition map (S810): Based on the constructed predictive model, an optimal alignment condition prediction map is generated for the position, pressure, vibration, and temperature of the pressure roll 2. This alignment condition prediction map is updated in real time, adapting to the latest operating conditions. This ensures that optimal alignment adjustments are always achieved, even when operating conditions fluctuate. Furthermore, this map analyzes historical and current operating data to identify patterns in the amount of alignment adjustment. Based on this, it becomes possible to simulate optimal operating conditions under various circumstances.

[0065] (1) Simulation and prediction (step S811): Using the constructed predictive model, alignment conditions are simulated under various operating conditions. The optimal alignment conditions for each condition are predicted, and the optimal operating conditions are identified. For example, the alignment behavior under different temperature and pressure conditions is simulated in detail to find the optimal settings for each condition. This process uses data obtained during operation in real time, and the predictive model is continuously updated to achieve more accurate predictions.

[0066] (2) Generation of the condition map (step S812): Based on the prediction results, an optimal condition map is generated for each parameter such as temperature, pressure, vibration, and distance. The condition map shows the optimal range for each parameter and is used to set the operating conditions. An example of a condition map is shown in Figure 9. In reality, there are several types of parameters, such as the roll gap amount, the deflection amount of the pressure roll 2, the pressure applied from the pressure roll 2 to the electrode material sheet, and temperature, and a multidimensional condition map is created in the computer, but here a condition map is shown with two parameters, A and B, on the vertical and horizontal axes. In the figure, × indicates a condition where the quality of the manufactured electrode material sheet (here, the thickness of the manufactured electrode material sheet) was below the set lower limit (failure), △ indicates a condition where the quality exceeded the set upper limit (failure), and ○ indicates a condition where the quality was within the appropriate range (pass). From this, the centroid position (●) of the distribution of circles is selected as the optimal operating condition (the optimal alignment adjustment value (left diagram in Figure 7)). Even if the optimal alignment adjustment amount is initially selected, if pressurized processing with the pressurized rolls continues, the optimal alignment adjustment amount will change due to the temperature rise of the pressurized rolls, wear of the pressurized rolls, etc. This is shown in the right diagram in Figure 7. In the data set acquired after XX months of operation, the distribution of circles has changed, and the centroid position has shifted from the dotted circle (the position of ● in the left diagram in Figure 7) to a different ● position, indicating that the optimal alignment adjustment amount has changed in the direction of the white arrow. As mentioned above, data related to quality can also be used to create a multidimensional condition map, including data such as the charge-discharge characteristics of batteries manufactured using the manufactured electrode sheets, and lifespan (the number of charge-discharge cycles until the charge-discharge characteristics no longer meet the specified characteristics).

[0067] (3) Real-time update (step S813): The condition map is continuously updated using real-time data from sensors. This process employs algorithms to respond quickly and appropriately to fluctuations in various parameters (temperature, pressure, vibration, etc.) during operation. Each time new data is obtained, the predictive model is retrained to keep the condition map up-to-date. For example, if the temperature changes rapidly during operation, the system immediately reflects this change and automatically adjusts the optimal alignment conditions.

[0068] (4) Integration into the control system (step S814): The optimal conditions map is integrated into the control system to automatically adjust operating conditions. Operating conditions are monitored through a feedback loop, and adjustments are made as needed. This feedback loop plays a role in improving the overall efficiency and quality of the system by fine-tuning operating conditions based on real-time data from sensors. For example, if wear on the pressure rolls progresses, the pressure can be optimized to take this into account.

[0069] • Updating the optimal conditions map Based on the output of the alignment condition prediction model, the optimal condition map is modified. Specifically, the optimal ranges for each parameter—temperature, pressure, vibration, and distance—are re-evaluated and adjusted as needed. A simulation is performed using the modified condition map to verify the validity of the modifications. Based on the simulation results, the condition map is further fine-tuned. For example, if the temperature is higher than predicted, the effect is simulated to find the optimal operating conditions to minimize the impact of temperature.

[0070] <Automatic alignment control> (S1001) The steps for performing automatic alignment control based on the alignment control amount calculated based on the measured values ​​from each sensor, as explained using Figure 8 (<Learning and Condition Map Generation>), will be explained in conjunction with the flowchart in Figure 10. • Control (Step S1002): Based on the alignment condition map, actuators such as motors and solenoids automatically adjust the position of the pressure roll 2. The actuators are positioned at both ends and the center of the pressure rolls 2A and 2B to achieve precise position control.

[0071] • Feedback loop (step S1003): A feedback loop may be implemented to receive feedback from each sensor and further improve the accuracy of alignment control. The feedback data can also be used for the continuous improvement of the learned model.

[0072] As described above, through the <learning and condition map generation> process, the alignment control amount is calculated based on the measured values ​​from each sensor, and <automatic alignment control> is executed based on the calculated alignment control amount. [Explanation of Symbols]

[0073] 1: Roll press machine 2A: Upper pressure roll 2B: Lower pressure roll 3: Thickness gauge 4: Unwinding machine 5: Winder 6: Upstream conveying mechanism 7: Downstream conveying mechanism 8: Guide Roll 9: Dancer Roll 10: Preheating roll 11: Sheet 11a: Coating section 11b: Base material 20: Pressure Roll Shaft 21: Housing 22: Rolling bearings 23: Bearing box 24: Press Cylinder 25: Outer surface 46: Bend bearing housing 47: Bend Cylinder 71: Control Panel 72: Laser distance sensor 73: Pressure sensor 74: Vibration sensor 75: Temperature sensor 78: Pre-press coil 79: Coil after pressing

Claims

1. A pair of pressure rolls for continuously pressurizing a sheet, having a pressure roll shaft supported and rotated by rolling bearings, A press mechanism for adjusting the roll gap of the aforementioned pressure roll, A bending mechanism for correcting the deflection of the aforementioned pressure roll, A thickness gauge for measuring the thickness of the sheet compressed by the aforementioned pressure roll, A laser distance sensor for measuring the shape of the outer surface of the pressure roll, A calculation unit calculates the amount of adjustment for the roll gap in the press mechanism and the amount of deflection correction in the bending mechanism based on the thickness measurement value from the thickness gauge and the measurement value from the laser distance sensor. A roll press machine characterized by comprising: a control unit that controls the press mechanism and the bend mechanism based on the adjustment amount of the roll gap and the deflection correction amount calculated by the calculation unit.

2. A pair of pressure rolls for continuously pressurizing a sheet, having a pressure roll shaft supported and rotated by rolling bearings, A press mechanism for adjusting the roll gap of the aforementioned pressure roll, A bending mechanism for correcting the deflection of the aforementioned pressure roll, A thickness gauge for measuring the thickness of the sheet compressed by the aforementioned pressure roll, A temperature sensor for detecting the surface temperature of the pressure roll, A calculation unit calculates the amount of adjustment for the roll gap in the press mechanism and the amount of deflection correction in the bending mechanism based on the thickness measurement value from the thickness gauge and the temperature measurement value from the temperature sensor. A roll press machine characterized by comprising: a control unit that controls the press mechanism and the bend mechanism based on the adjustment amount of the roll gap and the deflection correction amount calculated by the calculation unit.

3. In the roll press machine according to claim 1, The system includes a temperature sensor for detecting the surface temperature of the pressure roll, The roll press machine is characterized in that the calculation unit calculates the adjustment amount of the roll gap and the deflection correction amount based on the measurement value from the temperature sensor, the measurement value from the laser distance sensor, and the thickness measurement value from the thickness gauge.

4. In the roll press machine according to claim 1, The system includes a pressure sensor for measuring the pressure applied to the sheet by the aforementioned pressure roll, The roll press machine is characterized in that the calculation unit calculates the adjustment amount of the roll gap and the deflection correction amount based on the measurement value from the pressure sensor, the measurement value from the laser distance sensor, and the thickness measurement value from the thickness gauge.

5. In the roll press machine according to claim 1, The system includes a vibration sensor that detects vibrations of the pressure roll, The roll press machine is characterized in that the calculation unit calculates the adjustment amount of the roll gap and the deflection correction amount based on the measurement value from the vibration sensor, the measurement value from the laser distance sensor, and the thickness measurement value from the thickness gauge.

6. In the roll press machine according to claim 1, A database that stores measurement data measured by the laser distance sensor and the thickness gauge, the roll gap amount and deflection correction amount during the pressure processing of the sheet, and performance data as a battery including the charge and discharge characteristics of the battery manufactured using the sheet, A roll press machine characterized by comprising: a predictive model construction unit that constructs a predictive model that identifies patterns in alignment adjustment amounts by constructing a machine learning algorithm using data stored in the aforementioned database.

7. In the roll press machine according to claim 6, A roll press machine characterized by comprising an alignment condition prediction map generation unit that generates an alignment condition prediction map that predicts the optimal alignment conditions corresponding to the measurement data measured by the laser distance sensor and the thickness gauge, based on the prediction model.

8. In the roll press machine according to claim 7, The roll press machine is characterized in that the control unit controls the press mechanism and the bending mechanism based on the alignment condition prediction map generated by the alignment condition prediction map generation unit.

9. A method for adjusting the roll gap and correcting the deflection of a pressure roll in a roll press machine, comprising: a pair of pressure rolls for continuously pressurizing a sheet, having a pressure roll shaft supported and rotating by a rolling bearing; a press mechanism for adjusting the roll gap of the pressure rolls; a bending mechanism for correcting the deflection of the pressure rolls; a thickness gauge for measuring the thickness of the sheet compressed by the pressure rolls; and a laser distance sensor for measuring the shape of the outer surface of the pressure rolls. A calculation step to calculate the amount of adjustment for the roll gap in the press mechanism and the amount of deflection correction in the bending mechanism based on the thickness measurement value from the thickness gauge and the measurement value from the laser distance sensor, A method for adjusting the roll gap and correcting the deflection of a pressure roll in a roll press machine, comprising: a control step of controlling the press mechanism and the bend mechanism based on the roll gap adjustment amount and deflection correction amount calculated in the calculation step.

10. A method for adjusting the roll gap and correcting the deflection of a pressure roll in a roll press machine, comprising: a pair of pressure rolls for continuously pressurizing a sheet, having a pressure roll shaft supported and rotating by a rolling bearing; a press mechanism for adjusting the roll gap of the pressure rolls; a bending mechanism for correcting the deflection of the pressure rolls; a thickness gauge for measuring the thickness of the sheet compressed by the pressure rolls; and a temperature sensor for detecting the surface temperature of the pressure rolls, wherein A calculation step to calculate the amount of adjustment for the roll gap in the press mechanism and the amount of deflection correction in the bending mechanism based on the thickness measurement value from the thickness gauge and the temperature measurement value from the temperature sensor, A method for adjusting the roll gap of a roll press machine and correcting the deflection of a pressure roll, characterized by including a control step of controlling the press mechanism and the bending mechanism based on the adjustment amount of the roll gap and the deflection correction amount calculated in the calculation step.

11. In the method for adjusting the roll gap of a roll press machine and correcting the deflection of a pressure roll according to claim 9, A storage step involves storing in a database the measurement data measured by the laser distance sensor and the thickness gauge, the roll gap amount and deflection correction amount during the pressure processing of the sheet, and battery performance data including the charge and discharge characteristics of the battery manufactured using the sheet. A method for adjusting the roll gap of a roll press machine and correcting the deflection of a pressure roll, characterized by comprising: a predictive model construction step of constructing a machine learning algorithm using the data stored in the database in the storage step, and constructing a predictive model that identifies patterns in the amount of alignment adjustment.

12. In the method for adjusting the roll gap of a roll press machine and correcting the deflection of a pressure roll according to claim 11, A method for adjusting the roll gap of a roll press machine and correcting the deflection of a pressure roll, characterized by including an alignment condition prediction step of predicting optimal alignment conditions corresponding to measurement data measured by the laser distance sensor and the thickness gauge, based on the prediction model constructed in the prediction model construction step.

13. In the method for adjusting the roll gap of a roll press machine and correcting the deflection of a pressure roll according to claim 12, A method for adjusting the roll gap of a roll press machine and correcting the deflection of a pressure roll, characterized by including a control step of controlling the press mechanism and the bending mechanism based on the alignment conditions predicted in the alignment condition prediction step.

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