CN103935811A - Online roll-to-roll tension control system for flexible thin-film solar cell - Google Patents
Online roll-to-roll tension control system for flexible thin-film solar cell Download PDFInfo
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- CN103935811A CN103935811A CN201410131291.8A CN201410131291A CN103935811A CN 103935811 A CN103935811 A CN 103935811A CN 201410131291 A CN201410131291 A CN 201410131291A CN 103935811 A CN103935811 A CN 103935811A
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Abstract
The invention discloses an online roll-to-roll tension control system for a flexible thin-film solar cell. According to the online roll-to-roll tension control system, rollers are symmetrically arranged, and contact between the rollers and a single face of the flexible thin-film solar cell can be achieved. The online roll-to-roll tension control system is simple and easy to realize, fast in response, high in control accuracy, stable and reliable in operation and applicable to winding and unwinding tension control of materials with different thicknesses and different types, especially the materials with the process requirement for single-faced contact.
Description
Technical field
The present invention relates to area of solar cell, be specifically related to the online volume to volume tension control system of a kind of flexible thin-film solar cell.
Background technology
In recent years, along with Portable article increase in demand, the demand of flexible light weight thin-film solar cells is grown with each passing day.Flexible thin-film solar cell adopts unwinding and rewinding explained hereafter conventionally, need in process of production the flexible thin-film solar cell of rolling to clean, plated film, longitudinally the process such as cut, it is one of its crucial control technology that tension force is controlled, particularly the functional film layer fragility of flexible thin-film solar cell is very thin again, only several microns of thickness, tension force is controlled and is seemed particularly important.Excessive tension force can cause flexible thin-film solar cell to stretch, and makes functional film layer fracture, and too small tension force can cause flexible thin-film solar cell rolling lax, causes the extruding of rolling layer, makes that functional film layer is cracked to come off.Therefore, the control of the flexible thin-film solar cell on-line tension of volume to volume is extremely important to defencive function film quality.
Unwinding and rewinding tension control method is conventionally divided into indirect tension force and controls and direct tension control.For indirect tension force, controlling, is mainly to adopt the variation of calculating coil diameter, by controlling the output torque of motor, indirectly controls the tension force of coiled strip.Direct tension control view sensor structure is different, can be divided into the control of position model tension force and reaction type tension force and control.Position model tension force control to adopt floating roller as tension pick-up, utilizes mechanical type potential device to detect dancer rools position, and with given position comparison, its deviation is sent into position control, thereby forms the closed loop control of position-speed-electric current three-loop system.Reaction type tension force is controlled and adopted microprocessor is control core, realizes complicated control algorithm, and hardware using tension pick-up detects tension force in real time, forms the feedback of tension force to realize closed loop control.Existing tension control, no matter be that indirect tension force is controlled or direct tension control, all need to use transition roller to contact to change coiled strip direction of travel with coiled strip, form measuring roll bearing and tension force is detected tension force, like this, transition roller and measuring roll all, by direct contact solar cell functional film layer material, can cause the damage of flexible thin-film solar cell functional film layer, reduce yields.There is no at present failure-free flexible thin-film solar cell volume one side contact tension control system.
CN 102024563 provides a kind of memberane stress method of adjustment, this method adopts air injection unit, through pore, band-like film is sprayed to air, band-like film is pushed through and on another parts, forms suitable tension force, but this can cause that functional film layer and this parts surface rub, damage functional film layer.CN 102583086 provides a kind of method that memberane stress in thin film cladding processing is controlled, adopt negative-pressure adsorption film without overlay one side, film is produced to adsorption affinity, thereby make the film between nip rolls and negative-pressure adsorption plate form tension force, coating drawing tension is controlled and is matched with thin-film unreeling tension force, by application roll, with bottom roller, coating material is coated to the side that film contacts with application roll, from using, this tension control method is not suitable for flexible thin-film solar cell volume to volume equipment.
Summary of the invention
For tension control system in prior art, directly contact with solar cell functional film layer; the problem that causes battery functi on rete to damage; the invention provides a kind of one side contact tension control system of flexible thin-film solar cell volume to volume; can avoid flexible thin-film solar cell coiled strip functional film layer directly to contact with measuring roll with transition roller; defencive function rete is injury-free, and has the advantages that control accuracy is high, be easy to realization.
The online volume to volume tension control system of a kind of flexible thin-film solar cell, the rolling shaft structure that comprises programmable logic controller (PLC) (PLC), frequency converter, rotary encoder (PG), tension pick-up, tension link, motor and one group of symmetrical layout, as shown in Figure 1.Wherein, rolling shaft structure comprises for hull cell and unreels with the roller apparatus of rolling, for the protection of film rolling and the roller apparatus unreeling, is installed on two driven vollers on hull cell width, is installed on two driven vollers on protection film web and is installed on two rollers on hull cell width.
Described hull cell unwinding device is identical with hull cell wrap-up roll shaft specification, axle center in same plane, symmetrical layout; Described protective film wrap-up is identical with protective film unwinding device roll shaft specification, axle center in same plane, symmetrical layout; Described be installed on driven voller on hull cell width one of them has installed rotary encoder, another has installed tension pick-up, and roll shaft specification is identical, and axle center is in same plane, symmetrical layout.Above-described hull cell unwinding device and wrap-up axle center plane, protective film wrap-up and unwinding device axle center plane, the driven voller axle center plane being installed on hull cell width are parallel to each other, between at regular intervals.
Described two rollers that are installed on hull cell width rise and flatten and guiding function hull cell width.
During work, the drive motor of described protective film unwinding device roll shaft is operated under speed control mode, and the drive motor of described protective film wrap-up roll shaft is operated under torque master mode.
Described hull cell width is identical with the cornerite of having installed on the driven roll shaft of tension pick-up at the cornerite of having installed on the driven roll shaft of rotary encoder, and cornerite scope is between 5 °-180 °.
Theoretical foundation and the working process of the online volume to volume tension control system of the present invention are as follows:
When let off roll is normally worked, the electrical motor that control unreels is conventionally in dynamic brake state, and its equation of motion is:
( 1 )
Wherein,
m t the torque that flexible thin-film battery width tension force produces,
m ethe electromagnetic torque of electrical motor,
m 0the no-load torque sum of electrical motor and driving device,
it is the dynamic torque of motor.
In conjunction with producing reality, ignore the no-load torque of electrical motor and driving device
m 0, electrical motor is operated in speed stabilizing state lower time,
, formula (1) can be written as:
( 2 )
By vector converter volume, vector controlled is set up with Equivalent DC motor model, the torque current of alternating-current motor/AC motor and exciting current have been carried out to decoupling zero control, realization can as operation DC motor controlling torque electric current, therefore, alternating-current motor/AC motor adopts after vector controlled, can analyze with following formula:
M e =K m Φ I m ( 3 )
Wherein,
k m motor torque constant,
Φmagnetic flux,
i m it is motor torque electric current.
Again because:
( 4 )
Wherein,
dto unreel coil diameter,
thull cell width tension force.
Convolution (2), formula (3) and formula (4) are known
( 5 )
After motor given, in formula (5)
k m for constant.From formula (5), when electrical motor steady-state operation, as long as hull cell coil diameter detected
dand tension force
tvalue, just can be by controlling the torque current of alternating-current motor/AC motor
i m control tension force.
In like manner, when rolling winding up roller is normally worked, the electrical motor that control unreels is in driving condition, and its equation of motion is:
( 6 )
Derivation with unreel similarly, repeat no more.From analysis above, can see, the electrical motor equation of motion of material retractable part is closely similar, is that suffered electromagnetic torque is different with tension torque direction.
Below only analyzed tension force and be controlled at the situation under speed stabilizing state, in unwinding and rewinding tension control system real-world operation, the dynamic torque in the time of need to be to acceleration and deceleration compensates, and makes dynamic torque be
m moving:
( 7 )
Wherein,
j 1total rotor inertia of hull cell and protective film,
j 2it is the rotor inertia of sky roller.
When unreeling,
j 2definite value,
j 1with hull cell coil diameter
dreduce and diminish, therefore, must calculate it:
( 8 )
Wherein,
ρthe average density of hull cell and protective film,
whull cell fabric width,
rsky roller radius,
rit is total radius of hull cell volume and protective film volume.
Order
d=2R, d=2r:
( 9 )
( 10 )
Formula (7), formula (9) and formula (10) simultaneous, can obtain:
( 11 )
When rolling, computation process is similar, and an is-symbol difference, repeats no more.
Therefore, as long as hull cell coil diameter D and percentage speed variation detected
dynamic variable quantity, the dynamic torque that just can folding and unfolding spool need to be compensated when the acceleration and deceleration according to formula (11) calculates.
Consider the particularity of flexible thin-film solar cell coiled strip, in whole technological process, must meet permanent tension force and control, and control accuracy requires high.Existing theoretical analysis shows, " permanent tension force control problem is exactly constant linear velocity control problem in essence, and tension control system is a linear velocity track channel " (seeing the 47th page of < < high precision Vacuum Roll Coating Equipment tension control technology research > >).Therefore, one side contacts permanent tension force control problem and is just converted into constant linear velocity control problem.
To achieve the object of the present invention, control the frequency converter unreel motor and be operated under velocity mode, the motor of Frequency Converter Control with unreel roll shaft and be directly connected.According to
ω=V/R=
2 π f, know hull cell width linear velocity
vwith hull cell volume radius
rafter, by controlling motor speed frequency
f, just can control unreeling shaft spin velocity, thereby realize permanent linear speed uncoiling.
Of the present inventionly unreel control system functional block diagram as shown in Figure 2, linear velocity and the torque set are calculated and are transferred to frequency converter by PLC, frequency converter converts through internal element speed and the torque limit signal of controlling motor to again, PLC coordinates counting module to calculate actual linear velocity, then completes coil diameter calculating, dynamic torque compensation calculating and motor speed frequency computation part.Linear velocity
v 0calculating meets following formula:
( 12 )
Wherein,
t 0for the sampling period,
c 0for acquisition pulse number, rotary encoder precision is
mindividual pulse/turn, rotary encoder code-disc diameter is
d 0.
While unreeling, winding up roller often turns around and reduces by hull cell volume and the protective film volume thickness of 2 times, establishes initial volume diameter and is
d 1, the two thickness sum of battery and protective film band is
d 0, the current speed-frequency of motor is
f 1, photoelectric switch meter circle detects coil diameter in real time, and transmitting ratio is
i, meter circle is
n, when N encloses, motor speed frequency is:
( 13 )
In this case, can only guarantee the permanent linear speed operation of band under stable state, for meeting in the dynamically permanent tension force operation of lower permanent linear speed, need to unreel the tension feedback compensating signal ± Δ that superposes in command signal
f,tension force detects need choose Linear displacement transducer, and the real-time rotate speed frequency of now frequency converter output is
f 2, motor drives let off roll uncoiling by this frequency operation.
To achieve the object of the present invention; when hull cell volume and protective film volume winding; frequency converter is operated under torque master mode; winding control system functional block diagram of the present invention as shown in Figure 3; the rotating speed of setting and initial moment are calculated and are sent frequency converter to through PLC; frequency converter converts torque and the restricted speed signal of the motor of control again to through internal element, motor is directly connected with wind-up roll.According to
t=M/R, know hull cell volume radius
rafter, by controlling frequency converter output torque
m, just can control unreeling shaft rotating torques, thereby realize the permanent tension force of rolling, control.The real-time coil diameter of Scroll can be calculated as follows:
( 14 )
Wherein,
n d for servomotor rotating speed (rev/min).
Because linear velocity is constant, therefore the cireular frequency that only need use sensor to detect Scroll can calculate the real-time coil diameter of Scroll.
Dynamic torque because of need to be to acceleration and deceleration time compensates, so set a curvilinear function, M can be changed with the variation of radius:
M = M
0[l+ K (D
2–D
min) / (D
max – D
min)] ( 15 )
Wherein, K is decline factor, D
minfor empty shaft diameter, D
maxfor maximum gauge.
By the real-time coil diameter numerical value D obtaining
2substitution (15) formula can be obtained difference and increase progressively the real-time torque that under COEFFICIENT K, motor need be exported.
Compared with prior art, the one side contact tension control system of a kind of flexible thin-film solar cell equipment provided by the invention, system is simply easy to realize, response is fast, control accuracy is high, stable and reliable operation, be applicable to multiple different-thickness, different cultivars especially technological requirement be that the material unwinding and rewinding tension force of one side contact is controlled.
Accompanying drawing explanation
Fig. 1 is tension control system running roller distribution form schematic diagram in the embodiment of the present invention;
Fig. 2 is unwinding tension control system functional block diagram of the present invention;
Fig. 3 is winding tension control system functional block diagram of the present invention;
Fig. 4 is the main terminal block diagram of tension control system control setup in the embodiment of the present invention.
The specific embodiment
For technological means, creation characteristic that the present invention is realized, reach object and effect is easy to understand, below in conjunction with embodiment and accompanying drawing, further set forth the present invention, but the present invention is not limited to this.
In the present embodiment, take the volume to volume tension control system of a kind of flexibility compound of rip cutting thin-film solar cells is example.
In the volume to volume tension control system of a kind of flexibility compound of rip cutting thin-film solar cells, roll shaft layout part as shown in Figure 1.This distribution form comprises the roller 5 on hull cell unwinding device 1, hull cell wrap-up 2, protective film wrap-up 3, protective film unwinding device 4, hull cell width, driven voller 6, the driven voller 7 on hull cell width and the driven voller 8 on protection film web.Wherein, the roll shaft of hull cell unwinding device 1 is identical with the roll shaft specification of wrap-up 2, and axle center, in same plane, adopts coaxial rolling after the laser rip cutting that the cut device 10 of hull cell 11 is launched; The roll shaft of protective film wrap-up 3 is identical with the roll shaft specification of protective film unwinding device 4, and axle center is in same plane; On driven voller 7 on hull cell width, rotary encoder has been installed, on driven voller 8, tension pick-up has been installed, also rotary coding can be arranged on driven voller 8 as required, tension pick-up is arranged on driven voller 7, driven voller 7 is identical with the axle center specification of driven voller 8 roller bearings, is in same plane.The plane in the plane in above-described hull cell winding/unwinding device 1,2 roller bearing axle center, the plane in protective film winding/unwinding device 3,4 roller bearing axle center and driven voller 7, driven voller 8 roller bearing axle center is parallel to each other, between at regular intervals.The cornerite 9a of hull cell 11 on driven voller 7 is identical with the cornerite 9b angle on driven roll shaft 8, and cornerite angle value can change between 5-180 ° according to actual needs, and in the present embodiment, cornerite angle is preferably 60 °.
Running roller structure described in the present embodiment can change according to actual needs.
In the volume to volume tension control system of a kind of flexibility compound of rip cutting thin-film solar cells that the present embodiment provides, unwinding tension control part as shown in Figure 2, mainly comprises man-machine interface (HMI) 13, PLC 14, frequency converter 15a, motor 16a, unreeling shaft 17a, tachogen 18a, tension pick-up 19, tension link 20 and counting module 21, arithmetic and logic unit 22.PLC 14 and HMI 13 join, and form intuitively, easy to operate HMI, can revise easily control parameter, the state of whole system inside, and corresponding data can be shown at HMI by this HMI.Unreeling frequency converter 15a is operated under velocity mode.On the one hand, tension pick-up 19 is for detecting in real time the tension force of unwinding and rewinding process, and by the value detecting
f f form corresponding electric signal, be transferred to arithmetic and logic unit 22, meanwhile, the tension force of setting
f 0 value is also transferred to arithmetic and logic unit 22 through PLC, by arithmetic and logic unit 22, the signal calculating is transferred to tension link 20 and calculates, and calculates produced motor speed frequency offset ± Δ
f; On the other hand, the linear velocity of being set by man-machine interface
v 0 the linear velocity that signal, torque settings signal, counting module 21 obtain
vthe unreeling shaft tach signal of signal, tachogen 18a feedback is transferred to PLC, by PLC, calculates the current speed-frequency of motor
f 1.Side-play amount ± Δ
fcalculate the motor speed frequency of output with PLC
f 1carry out calculating at frequency converter 15a superposition the speed-frequency that motor is about to operation
f 2, frequency converter 15a controls motor makes it according to speed-frequency
f 2operation, unreels the permanent tension force control of permanent linear speed thereby realize.
Referring to Fig. 3, winding tension control part in the volume to volume tension control system of a kind of flexibility compound of rip cutting provided by the invention thin-film solar cells, mainly comprises HMI 13, PLC 14, frequency converter 15b, motor 16b, unreeling shaft 17b, tachogen 18b.PLC 14 and HMI 13 join, and revise control parameter, the state of whole system inside by HMI, and corresponding data are shown at HMI.Rolling frequency converter 15b is operated under torque mode.The rotating speed of setting on HMI 13 and initial moment value are calculated and are changed electric signal into through PLC 14 and send frequency converter 15b to, and frequency converter converts through internal element torque and the restricted speed signal of controlling motor 16b to again, and motor 16b is directly connected with wind-up roll 17b.Tachogen 18b is directly connected with motor shaft, detect the angular velocity signal of motor shaft (Scroll), and this signal feedback to frequency converter 15b, by frequency converter 15b, calculated the real-time coil diameter of Scroll, according to the real-time coil diameter calculating, frequency converter 15b calculates the torque that motor 16b is about to operation again, thereby realize the permanent tension force of rolling, controls.
In the present embodiment, the rotary encoder of choosing is that incremental encoder, tension pick-up are linear displacement formula tension pick-up, and choosing remittance river MD330 series coiling special converter is example, and the electric diagram of whole electric machine control is described.
Electric machine control system layout circle in the present embodiment as shown in Figure 4, by tension pick-up 19a, 19b; Tension link 20; Frequency converter 401,402,403,404; Motor 41,42,43,44; Tachogen PG 41a, PG 42a, PG 43a, PG 44a; Given tension device 4a, 4b; Linear velocity setter 4c; PLC14; High speed counting module 21; Calculating unit 24 compositions such as grade.
During application, the total power switch that closes, presses electric system start button, and system obtains electric, and each motor starts immediately, and each roll shaft rotates.The frequency converter 401 of unwinding device 1 is operated under velocity mode, the pulse that the rotary encoder of installing on driven voller 7 sends is sent to counting module 21, PLC 14 coordinates counting module 21 to calculate the actual linear velocity of flexible thin-film battery 11, and PLC 14 is according to the linear velocity of setting
v 0 , actual linear velocity, the PG 41a feedback that calculates the rotating speed of motor 41 complete that coil diameter is calculated, dynamic compensation calculates and the given calculating of speed in frequency, calculate the speed-frequency of motor 41
f 1 , the speed preset calculating unit 24 in PLC 14 is the speed-frequency calculating
f 1 signal is exported to the AI2 terminal of frequency converter 401, thus the roll shaft running velocity of automatic control and adjustment unwinding device 1.In order to reach needed system control accuracy and degree of stability, in flexible thin-film battery 11 transport process, by tension pick-up 19a, 19b, directly measured the actual tension value of flexible thin-film battery 11, with predefined tension value contrast, then by tension link 20, become standard signal to feed back to the frequency converter 401 of unwinding device 1 data transfer, frequency converter 401 carries out PID calculating the signal of the signal of tension link 20 outputs and the acceptance of AI2 terminal, calculates the due speed-frequency of reality that motor 41 is controlled in output
f 2 , make motor at this speed-frequency
f 2 lower operation, equates with setting tension value thereby realize actual tension value, to reach tension stability.In the present embodiment, the tension value of setting is preferably 20-30N.The frequency converter 402 of wrap-up 2 is operated under torque mode, do not need the speed of rolling to control, the cireular frequency that a given speed limit can make Scroll is according to the size of torque and automatic floating, and realize constant linear velocity rolling, the torque measuring ability of frequency converter inside can accurately detect electric current, realizes the high precision of torque and controls.In the present embodiment, speed limit is preferably 1-15m/min.The frequency converter 403 of protective film unwinding device 3 is operated under torque mode, and the frequency converter 404 of protective film unwinding device 4 is operated under velocity mode, and control process is identical with foregoing.
To those of ordinary skill in the art, can to beaming roller layout of the present invention or electric system, do multiple variation, replacement and modification as required, in every case according to the equalization of doing within the scope of inventive concept, claim, change, replace and modify, all belonging to the covering scope of the claims in the present invention.
Claims (4)
1. the online volume to volume tension control system of flexible thin-film solar cell; comprise programmable logic controller (PLC) (PLC), frequency converter, rotary encoder (PG), tension pick-up, tension link and motor; it is characterized in that; also comprise for hull cell and unreel with the roller apparatus of rolling, for the protection of film rolling and the roller apparatus unreeling, be installed on two driven vollers on hull cell width, be installed on two driven vollers on protection film web and be installed on two rollers that play spreading on hull cell width, wherein:
Described hull cell unwinding device is identical with hull cell wrap-up roll shaft specification, axle center in same plane, symmetrical layout;
Described protective film wrap-up is identical with protective film unwinding device roll shaft specification, axle center in same plane, symmetrical layout;
Described be installed on driven voller on hull cell width one of them has installed rotary encoder, another has installed tension pick-up, and roll shaft specification is identical, and axle center is in same plane, symmetrical layout.
2. the online volume to volume tension control system of flexible thin-film solar cell as claimed in claim 1; it is characterized in that; described hull cell unwinding device and wrap-up axle center plane, protective film wrap-up and unwinding device axle center plane, the driven voller axle center plane being installed on hull cell width are parallel to each other, between at regular intervals.
3. the online volume to volume tension control system of flexible thin-film solar cell as claimed in claim 2; it is characterized in that; the drive motor of described protective film unwinding device roll shaft is operated under speed control mode, and the drive motor of described protective film wrap-up roll shaft is operated under torque master mode.
4. the online volume to volume tension control system of flexible thin-film solar cell as claimed in claim 2, it is characterized in that, described hull cell width is identical with the cornerite of having installed on the driven roll shaft of tension pick-up at the cornerite of having installed on the driven roll shaft of rotary encoder, and cornerite scope is between 5 °-180 °.
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| CN112561317A (en) * | 2020-12-15 | 2021-03-26 | 广东工业大学 | Flexible material roll-to-roll processing control decision generation method and device |
| WO2022126679A1 (en) * | 2020-12-15 | 2022-06-23 | 广东工业大学 | Decision-generating method and apparatus for flexible material roll-to-roll processing control |
| CN112561317B (en) * | 2020-12-15 | 2023-07-28 | 广东工业大学 | Flexible material roll-to-roll processing control decision generation method and device |
| CN113911802A (en) * | 2021-10-25 | 2022-01-11 | 福建省计量科学研究院（福建省眼镜质量检验站） | Constant tension control system of mask machine based on servo controller |
| CN114686838A (en) * | 2022-03-28 | 2022-07-01 | 尚越光电科技股份有限公司 | High-stability transmission system of CIGS co-evaporation equipment |
| CN114686838B (en) * | 2022-03-28 | 2024-06-11 | 尚越光电科技股份有限公司 | High-stability transmission system of CIGS co-evaporation equipment |
| CN116675066A (en) * | 2023-08-04 | 2023-09-01 | 宁德时代新能源科技股份有限公司 | Winding and unwinding control method, winding and unwinding control device, control equipment and storage medium |
| CN116675066B (en) * | 2023-08-04 | 2024-01-16 | 宁德时代新能源科技股份有限公司 | Winding and unwinding control method, winding and unwinding control device, control equipment and storage medium |
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Application publication date: 20140723 |