CN113445020B - Intelligent winding film coating method - Google Patents
Intelligent winding film coating method Download PDFInfo
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- CN113445020B CN113445020B CN202110729846.9A CN202110729846A CN113445020B CN 113445020 B CN113445020 B CN 113445020B CN 202110729846 A CN202110729846 A CN 202110729846A CN 113445020 B CN113445020 B CN 113445020B
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- 238000004804 winding Methods 0.000 title claims abstract description 224
- 238000000034 method Methods 0.000 title claims abstract description 55
- 239000007888 film coating Substances 0.000 title claims abstract description 26
- 238000009501 film coating Methods 0.000 title claims abstract description 26
- 239000000463 material Substances 0.000 claims abstract description 139
- 238000000576 coating method Methods 0.000 claims abstract description 122
- 239000011248 coating agent Substances 0.000 claims abstract description 99
- 230000008569 process Effects 0.000 claims abstract description 51
- 238000003860 storage Methods 0.000 claims abstract description 35
- 238000004519 manufacturing process Methods 0.000 claims abstract description 27
- 238000005192 partition Methods 0.000 claims abstract description 6
- 239000010408 film Substances 0.000 claims description 57
- 230000007246 mechanism Effects 0.000 claims description 50
- 238000007747 plating Methods 0.000 claims description 37
- 230000009471 action Effects 0.000 claims description 23
- 230000009467 reduction Effects 0.000 claims description 14
- 239000010409 thin film Substances 0.000 claims description 9
- 238000001704 evaporation Methods 0.000 claims description 3
- 230000008020 evaporation Effects 0.000 claims description 3
- 238000005096 rolling process Methods 0.000 claims 1
- 238000010586 diagram Methods 0.000 description 4
- 238000001771 vacuum deposition Methods 0.000 description 4
- 230000009286 beneficial effect Effects 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 1
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/22—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
- C23C14/56—Apparatus specially adapted for continuous coating; Arrangements for maintaining the vacuum, e.g. vacuum locks
- C23C14/562—Apparatus specially adapted for continuous coating; Arrangements for maintaining the vacuum, e.g. vacuum locks for coating elongated substrates
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/22—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
- C23C14/54—Controlling or regulating the coating process
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- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Replacement Of Web Rolls (AREA)
Abstract
The invention discloses an intelligent winding coating method, which is implemented on an intelligent winding coating production line, wherein the intelligent winding coating production line comprises a coating working area, a coiled material storage area, an intelligent control center and an intelligent coiled material loading and unloading system; more than 2 winding coating machines are arranged in the coating working area; the intelligent coiled material loading and unloading system mainly comprises a loading and unloading execution unit and a track, wherein the track is used for a coating working area and a coiled material storage area; winding rollers carrying different types of coiled materials are stored in the coiled material storage area in a partitioned mode, and partitioned bar codes serve as marks in different partitions; the winding coating method mainly comprises a coating working process, a coiled material loading and unloading working process and a coiled material storing and taking working process, wherein the 3 working processes are automatically controlled and completed by an intelligent control center. The intelligent control center collects the film coating process information of each winding film coating machine in real time and forms a process file, and the process file is mapped with the product bar codes of each roll of the flexible film coiled material which is coated with the film one by one.
Description
Technical Field
The invention belongs to the technical field of winding type vacuum coating, and particularly relates to an intelligent winding coating method.
Background
With the increasingly wide application of the winding type vacuum coating technology in new energy power batteries and other emerging fields, the size and the weight of the coiled material adopted by the winding coating machine are gradually expanded. At present, the weight of a flexible film product coiled material produced by some mainstream manufacturers even reaches the magnitude of several tons per coil, the weight makes the operation of loading and unloading the coiled material become time-consuming and labor-consuming when the coiled material is replaced, a large amount of labor is needed to be consumed for completing the operation, and particularly when the number of the winding film coating devices working simultaneously is increased, the heavy operation of loading and unloading the coiled material brings great troubles to production arrangement and scheduling, and the operation is not beneficial to implementation of a high-efficiency production arrangement plan. On the other hand, the automation degree of the current large-scale winding coating equipment workshop is low, and more workers are needed to complete the complex work of vacuum coating, coil loading and unloading, coil ex-warehouse and warehousing and the like. This situation is obviously not in line with the development concept of highly automated intelligent manufacturing and intelligent factories in the current industrial trend.
Disclosure of Invention
In order to solve the problems, the invention provides an intelligent winding coating method which is implemented on an intelligent winding coating production line, wherein the intelligent winding coating production line comprises a coating working area, a coiled material storage area, an intelligent control center and an intelligent coiled material loading and unloading system; more than 2 winding film plating machines are arranged in the film plating working area.
The winding coating machine mainly comprises a vacuum chamber, a vacuum system, a chamber door, a wall plate, a winding roller position and an unwinding roller position, wherein winding rollers are arranged on the winding roller position and the unwinding roller position; one end of the unwinding roller position and one end of the winding roller position are arranged on the inner wall of the chamber door; the chamber door is opened or closed through push-pull, and the unwinding roller position and the winding roller position are driven to move out of the vacuum chamber when the chamber door is opened.
The intelligent coiled material loading and unloading system mainly comprises a loading and unloading execution unit and a track, wherein the track is used for a coating working area and a coiled material storage area; the coil storage area is partitioned to store coil rollers loaded with different types of coils, and different partitions take partitioned bar codes as identifiers; the winding coating method mainly comprises a coating working process, a coiled material loading and unloading working process and a coiled material storing and taking working process, wherein the 3 working processes are controlled by an intelligent control center;
the working process of coating comprises the following steps: the intelligent control center respectively starts the vacuum systems of the winding film plating machines to vacuumize the vacuum chambers according to the film plating working procedures of the winding film plating machines in the working plan; when the vacuum degree reaches a set value, the intelligent control center starts the magnetic control target or the evaporation source, and simultaneously starts the winding system to prepare a film layer on the flexible film; in the coating working process, the intelligent control center collects the coating working state information of each winding coating machine in real time.
The working process of coil loading and unloading comprises the following steps: the coating working state information comprises the weight of the unwinding roller position and the winding roller on the winding roller position; when the weight of a winding roller of a certain winding film plating machine reaches a set value, the intelligent control center sends a coil loading and unloading instruction for loading and unloading the coil to the winding film plating machine; and the loading and unloading execution unit which receives the coil loading and unloading command moves to the loading and unloading position of the winding coating machine, and automatically carries out coil loading and unloading actions on the winding coating machine.
The loading and unloading execution unit comprises a mobile trolley, a base, a material rack, a mobile control module and a mechanical arm; the base and the material rack are fixed on the mobile trolley, and the mechanical arm is arranged on the base; more than 2 clamping positions are arranged on the material rack, and 1 winding roller capable of loading coiled materials can be placed on each clamping position; the loading and unloading execution unit can move between loading and unloading positions of a plurality of winding coating machines along a track under the autonomous control of the intelligent control center, and the operation of loading and unloading coiled materials is automatically completed by a mechanical arm.
The working process of storing and taking out the coiled materials comprises the following steps: before moving to a loading and unloading position of a winding coating machine to load and unload coiled materials, a loading and unloading execution unit moves to a coiled material storage area according to a material taking instruction from an intelligent control center, and a mechanical arm of the loading and unloading execution unit autonomously searches and grabs a coil roll loaded with the coiled materials through a recognition partition bar code and places the coil roll on a clamping position of a material rack on the loading and unloading execution unit; after the loading and unloading execution unit finishes the action of loading and unloading the coiled materials, the coiled materials are moved to a coiled material storage area, and the winding roller which is loaded with the flexible thin film coiled materials and is subjected to film coating and positioned on the material rack clamping position is grabbed and placed in the coiled material storage area by a mechanical arm.
When the loading and unloading execution unit moves to the loading and unloading position of the winding coating machine, at least 1 clamping position in the clamping positions arranged on the material rack is a vacant position without a winding roller before the coiled material loading and unloading action starts; the coiled material loading and unloading action comprises the steps that a mechanical arm clamps and unloads a winding roller which is positioned on a winding roller position in a winding coating machine and is loaded with a flexible thin film coiled material which is subjected to coating and is placed in a vacant position on a material rack, then an empty winding roller on an unwinding roller position in the winding coating machine is clamped and unloaded and is clamped and installed on the winding roller position, and then the winding roller which is loaded with a new flexible thin film coiled material and is clamped and installed on the unwinding roller position is grabbed.
The movement control module comprises a driving mechanism, a movement controller and a position sensor; the driving mechanism can drive the mobile trolley to move along the track, and the mobile controller can receive a trolley moving instruction from the intelligent control center; the position sensor is fixed on the base and sends a position signal of the mobile trolley to the intelligent control center in real time; a speed reduction stop block switch and a stop block switch are arranged on the track; the speed reduction stop block switch is arranged at a position close to the loading and unloading position of the winding film plating machine, and the stop block switch is arranged at the loading and unloading position; each speed reduction stop block switch and each stop block switch are provided with numbers at the intelligent control center; the deceleration stop block switch and the stop block switch are popped up and started, and retracted and failed; the start and the failure of the speed reduction stop block switch and the stop block switch are controlled by the intelligent control center; when the loading and unloading execution unit receives an instruction of an intelligent control center and moves to a loading and unloading position of a certain winding film coating machine, a speed reduction stop block switch and a stop block switch corresponding to the loading and unloading position are firstly popped up and started under the control of the intelligent control center; when the moving trolley touches the deceleration stop switch, the moving controller controls the driving mechanism to make the moving trolley start to decelerate, and when the moving trolley decelerates and moves to touch the stop switch, the moving trolley stops braking, so that the loading and unloading execution unit is positioned at the loading and unloading position to start the action of loading and unloading the coiled material.
The door is opened and then moved to a position corresponding to the loading and unloading position of the winding film plating machine; the push-and-pull of the chamber door is driven by a push rod mechanism, and the driving mode is hydraulic driving or electric driving; the other ends of the unwinding roller position and the winding roller position are fixedly arranged on a wallboard, and the top of the wallboard is hung on a guide rail positioned at the top of the vacuum chamber; when the chamber door moves, the wall plate also moves synchronously with the chamber door.
The winding film plating machines are arranged in a film plating working area according to 1 line or 2 lines; the track can be arranged on one side of the coating working area and can also be arranged around the coating working area; the moving direction of the chamber door is parallel to the direction of the rail by placing the winding film plating machine.
The mechanical arm mainly comprises a fixed vertical arm, a telescopic vertical arm, a fixed cross arm, a telescopic cross arm, a small vertical arm, a cross rod and a gripper; the fixed vertical arm is fixedly arranged on the base; the telescopic vertical arm is connected with the fixed vertical arm and can be driven by the vertical arm driving mechanism to stretch up and down; the top end of the telescopic vertical arm is provided with a rotating platform, the fixed cross arm is fixedly arranged on the rotating platform, and the rotating platform can drive the fixed cross arm to rotate under the driving of the rotating driving mechanism; the telescopic cross arm is connected to the fixed cross arm and can be driven by the cross arm telescopic mechanism to stretch; the small vertical arm is arranged at the tail end of the telescopic cross arm, a telescopic rod is arranged on the small vertical arm, the tail end of the telescopic rod is connected with the cross rod through a worm rotating mechanism, and the cross rod can rotate under the driving of the worm rotating mechanism; the number of the grippers is 2, the grippers are respectively arranged at two ends of the cross rod, and when the mechanical arm carries out coiled material loading and unloading actions, the grippers 2 respectively grab and clamp two ends of the winding roller. The vertical arm driving mechanism, the rotary driving mechanism, the cross arm telescopic mechanism and the worm rotary mechanism are driven in one mode selected from electric, hydraulic and pneumatic modes. The structure enables the mechanical arm to perform telescopic action, lifting action and rotary action, can flexibly and freely adjust the position and the direction of the hand grip, and has the function of gripping and clamping a winding roller carrying coiled materials.
The gripper comprises a supporting plate, a servo lead screw mechanism and 2 gripper hooks in the shape of a bent finger; the waist parts of the 2 grapples are connected by a rotating shaft; the servo screw rod mechanism is fixed on the supporting plate; one end of each of the 2 grapples is connected with two ends of a screw rod of the servo screw rod mechanism respectively, so that the grapples are in a reverse crossing shape; the other end of each of the 2 grappling hooks is a free end to form an opening of the gripper; the part of the grapple between the rotating shaft and the connecting end of the lead screw is connected to the supporting plate through a bolt, and the connecting hole is oblong so that the connecting part can freely slide in the connecting hole; the opening size of the gripper can be adjusted through feeding of the servo screw mechanism.
A load sensor is arranged on the mechanical arm; when the mechanical arm clamps and unloads a winding roll on the winding coating machine, the mechanical arm clamps the winding roll in place, when the load sensor senses that the mechanical arm clamps and reliably clamps the winding roll in place, the load sensor sends a clamping reliable signal to the intelligent control center, the intelligent control center sends a roll unloading signal to the winding coating machine, so that a winding roll connecting mechanism on the winding roll is disconnected, the intelligent control center sends a winding roll transferring instruction to a loading and unloading execution unit when finding that the winding roll connecting mechanism is disconnected, and the mechanical arm starts to transfer the clamped and unloaded winding roll.
When the mechanical arm clamps and installs the winding roller, the mechanical arm firstly clamps the winding roller to a roller position and carries out autonomous fine adjustment and positioning, after the winding roller is accurately positioned on the roller position, the mechanical arm sends a positioning reliable signal to an intelligent control center, the intelligent control center sends a roller loading signal to a winding film coating machine, so that a winding roller connecting mechanism on the roller position is reconnected, the intelligent control center sends a mechanical arm moving-out instruction to a loading and unloading execution unit when finding that the state of the winding roller connecting mechanism is connection, and the mechanical arm finishes clamping and moves out the winding film coating machine.
A bar code recognition device is arranged on the mechanical arm; the winding roller loaded with the coiled materials is stored in different coiled material storage subareas according to different types of the coiled materials, and the different subareas take subarea bar codes as marks; when the mechanical arm grabs the winding roll carrying the coiled material in the coiled material storage area, the mechanical arm can independently search and grab the winding roll carrying the coiled material through identifying the subarea bar code according to a material taking instruction from the intelligent control center.
A process file containing a plurality of flexible film product coating processes is preset in the intelligent control center; the producer only needs to issue a daily scheduling schedule to the intelligent control center, and the rest coating working process, the coil loading and unloading working process and the coil storing and taking working process can be automatically controlled and completed by the intelligent control center.
In the working process of coating, the intelligent control center collects the coating process information of each coating working period of each winding coating machine in real time and forms a process file, and the process file is mapped with the product bar codes of each roll of the flexible film coiled material after coating one by one; the production and manufacturing information of the coated flexible film coiled material can be traced back by scanning the bar code of the product. The intelligent control center collects various information to form a log file, and periodically transmits the log file to the remote database for storage.
The invention has the beneficial effects that:
(1) the intelligent winding coating method of the invention utilizes the intelligent coiled material loading and unloading system, can automatically complete the loading and unloading work of the heavy coiled material winding roller on the winding coating machine without manual work, replaces the heavy work of a large amount of manual work and heavy machinery, has high efficiency and accurate and in-place replacement, saves a large amount of non-coating work process periods except the vacuum coating process time, improves the production link continuity of the whole coating workshop, and improves the production efficiency by more than 40 percent.
(2) In the invention, the film coating work of the winding film coating machine, the coil material loading and unloading work of the intelligent coil material loading and unloading system and the coil material storage and taking-out work of the coil material storage area are automatically controlled and completed by the intelligent control center. The production and manufacturing information of the flexible film product can be traced back by scanning the bar code of the product, and the intelligent control center collects various information to form a log file and periodically transmits the log file to a remote database for storage. The intelligent winding coating method combines the production state of the coating equipment, the quality of the film product and the intelligent carrying device, realizes intelligent seamless connection by different processes, ensures the control stability of the system and the continuity of the production link, and greatly improves the production efficiency, the production stability and the stability of the product quality. The implementation of large-scale winding coating unmanned production line and intelligent factory is realized.
Drawings
Fig. 1 is a schematic view of an embodiment of an intelligent winding coating line according to the present invention.
Fig. 2 is a schematic configuration diagram of an embodiment of a load handling execution unit according to the present invention.
Fig. 3 is a schematic structural view of an embodiment of a gripper according to the present invention.
Detailed Description
The following further describes the embodiments of the present invention with reference to the drawings. It should be understood that the detailed description and specific examples, while indicating the present invention, are intended for purposes of illustration and explanation only and are not intended to limit the scope of the invention.
The intelligent winding coating method mainly comprises a coating working process, a coiled material loading and unloading working process and a coiled material storing and taking working process, wherein the 3 working processes are controlled by an intelligent control center independently.
Wherein, the coating film working process includes: the intelligent control center respectively starts the vacuum systems of the winding film plating machines to vacuumize the vacuum chambers according to the film plating working programs of the winding film plating machines in the working plan; when the vacuum degree reaches a set value, the intelligent control center starts the magnetic control target or the evaporation source, and simultaneously starts the winding system to prepare a film layer on the flexible film; in the coating working process, the intelligent control center collects the coating working state information of each winding coating machine in real time.
The working process of coil loading and unloading comprises the following steps: the coating working state information comprises the weight of the unwinding roller position and the winding roller on the winding roller position; when the weight of a winding roller of a certain winding film plating machine reaches a set value, the intelligent control center sends a coil loading and unloading instruction for loading and unloading the coil to the winding film plating machine to a loading and unloading execution unit; and the loading and unloading execution unit which receives the coil loading and unloading command moves to the loading and unloading position of the winding coating machine, and automatically loads and unloads the coil to the winding coating machine.
The working process of storing and taking out the coiled materials comprises the following steps: before moving to a loading and unloading position of a winding film plating machine to load and unload coiled materials, a loading and unloading execution unit moves to a coiled material storage area according to a material taking instruction from an intelligent control center, and a mechanical arm of the loading and unloading execution unit autonomously searches and grabs a winding roller loaded with the coiled materials through a recognition partition bar code and places the winding roller on a clamping position of a material rack on the loading and unloading execution unit; after the loading and unloading execution unit finishes the action of loading and unloading the coiled materials, the coiled materials are moved to a coiled material storage area, and the winding roller which is loaded with the flexible thin film coiled materials and is subjected to film coating and positioned on the material rack clamping position is grabbed and placed in the coiled material storage area by a mechanical arm.
A process file containing a plurality of flexible film product coating processes is preset in the intelligent control center; the producer only needs to issue a daily scheduling schedule to the intelligent control center, and the rest coating working process, the coil loading and unloading working process and the coil storing and taking out working process can be automatically controlled and completed by the intelligent control center.
In the coating working process, the intelligent control center collects the coating process information of each coating working period of each winding coating machine in real time and forms a process file, and the process file is mapped with the product bar codes of each roll of the flexible film coiled material subjected to coating one by one. The production and manufacturing information of the coated flexible film coiled material can be traced back by scanning the bar code of the product. The intelligent control center collects various information to form a log file, and periodically transmits the log file to the remote database for storage.
The intelligent winding coating method is implemented on an intelligent winding coating production line, and figure 1 is a schematic diagram of one implementation mode of the intelligent winding coating production line, and as shown in the figure, the intelligent winding coating production line mainly comprises a coating working area 4, a coiled material storage area 13, an intelligent control center 3 and an intelligent coiled material loading and unloading system; the coating working area 4 is provided with more than 2 winding coating machines 5; the winding coating machine mainly comprises a vacuum chamber 36, a chamber door 37, a wall plate 38, a winding roller position 39 and an unwinding roller position 40, wherein winding rollers are arranged on the winding roller position 39 and the unwinding roller position 40; one ends of the winding roller position 39 and the unwinding roller position 40 are arranged on the inner wall of the chamber door 37; the door 37 is opened or closed by pushing or pulling, and when the door 37 is opened, the take-up roller 39 and the unwind roller 40 are driven to move out of the vacuum chamber 36.
The door 37 is opened and then moved to a position corresponding to the loading and unloading position 12 of the winding coating machine; the push-and-pull of the chamber door is driven by a push rod mechanism 41, and the driving mode is hydraulic driving or electric driving; the other ends of the unwinding roller position and the winding roller position are fixedly arranged on a wallboard 38, and the top of the wallboard 38 is hung on a guide rail positioned at the top of the vacuum chamber; when the chamber door moves, the wall plate also moves synchronously; the winding film plating machines are arranged in a film plating working area according to 1 line or 2 lines; the track can be arranged on one side of the coating working area and can also be arranged around the coating working area; the winding film plating machine is arranged so that the moving direction of the chamber door is parallel to the direction of the track. In the embodiment of fig. 1, 4 coil coaters were arranged in 2 rows with the track arranged around the coating work area. In addition to the embodiment shown in fig. 1, the coil coaters can also be arranged in 1 row in the coating work area, and the track can be arranged on one side of the coating work area.
The intelligent coiled material loading and unloading system mainly comprises a loading and unloading execution unit 1 and a track 2, wherein the track 2 is connected with a coating working area 4 and a coiled material storage area 13; the coil storage area 13 is provided with coil rollers loaded with different types of coils in different areas, and the different areas take the partitioned bar codes as marks; the film coating work of the winding film coating machine in the film coating work area 4, the coil loading and unloading work of the intelligent coil loading and unloading system and the coil storage and taking out work of the coil storage area are all independently controlled and completed by the intelligent control center 3.
Fig. 2 is a schematic structural diagram of an embodiment of the load handling execution unit, and as shown in the figure, the load handling execution unit 1 includes a mobile trolley 6, a base 7, a rack 8, a movement control module 9, and a robot arm 10; the base 7 and the material rack 8 are fixed on the mobile trolley 6, and the mechanical arm 10 is arranged on the base 7; more than 2 clamping positions 11 are arranged on the material rack 8, and 1 winding roller capable of loading coiled materials can be placed on each clamping position; the loading and unloading execution unit 1 can move between loading and unloading positions of a plurality of winding coating machines along the track 2 under the autonomous control of the intelligent control center 3, and the mechanical arm 10 automatically finishes the operation of loading and unloading the coiled materials.
The movement control module 9 comprises a driving mechanism, a movement controller and a position sensor; the driving mechanism can drive the movable trolley 6 to move along the track, and the movable controller can receive a trolley moving instruction from the intelligent control center 3; the position sensor is fixed on the base 7 and sends a position signal of the mobile trolley 6 to the intelligent control center 3 in real time.
The track is provided with speed reduction stop block switches 32 and 33 and a stop block switch 34; taking the loading and unloading position 35 in fig. 1 as an example, the deceleration stop switches 32 and 33 are disposed adjacent to the loading and unloading position 35, and the stop switch 34 is disposed at the loading and unloading position 35. Each speed reduction stop block switch and each stop block switch are provided with numbers at the intelligent control center 3; the deceleration stop block switch and the stop block switch are popped up and started, and the retraction is invalid; the start and the failure of the speed reduction stop block switch and the stop block switch are controlled by the intelligent control center; when the loading and unloading execution unit receives an instruction of an intelligent control center and moves to a loading and unloading position of a certain winding film plating machine, a speed reduction stop block switch and a stop block switch corresponding to the loading and unloading position are firstly controlled by the intelligent control center to pop up and start; when the moving trolley touches the deceleration stop switch, the moving controller controls the driving mechanism to make the moving trolley start to decelerate, and when the moving trolley decelerates and moves to touch the stop switch, the moving trolley stops braking, so that the loading and unloading execution unit is positioned at the loading and unloading position to start the action of loading and unloading the coiled material.
In the coating work area in fig. 1, 4 coil coaters were arranged, with coil coater 5 being in a coil loading/unloading state. When the loading and unloading execution unit 1 moves to the loading and unloading position 12 of the winding film plating machine 5, at least 1 clamping position in the clamping positions arranged on the material rack 8 is a vacant position without a winding roller before the coiled material loading and unloading action starts; the coiled material loading and unloading action comprises the steps that a mechanical arm clamps and unloads a winding roller which is positioned on a winding roller position in a winding coating machine and is loaded with a flexible thin film coiled material which is subjected to coating and is placed in a vacant position on a material rack, then an empty winding roller on an unwinding roller position in the winding coating machine is clamped and unloaded and is clamped and installed on the winding roller position, and then the winding roller which is loaded with a new flexible thin film coiled material and is clamped and installed on the unwinding roller position is grabbed.
Before moving to the loading and unloading position of the winding coating machine to load and unload the coiled material, the loading and unloading execution unit 1 also moves to a coiled material storage area 13, and a mechanical arm 10 grabs a winding roll loaded with a new flexible film coiled material in the coiled material storage area 13 and places the winding roll on a clamping position of the material rack; after completing the coil loading and unloading operation, the loading and unloading execution unit 1 further moves to the coil storage area 13, and the robot arm 10 picks and places the winding roller loaded with the flexible film coil subjected to film coating on the rack position in the coil storage area 13.
As shown in fig. 2, the robot arm mainly includes a fixed vertical arm 14, a telescopic vertical arm 15, a fixed cross arm 16, a telescopic cross arm 17, a small vertical arm 18, a crossbar 19, and a gripper 20; the fixed vertical arm 14 is fixedly arranged on the base 7; the telescopic vertical arm 15 is connected with the fixed vertical arm 14 and can be driven by the vertical arm driving mechanism 21 to be telescopic up and down; a rotating platform 22 is arranged at the top end of the telescopic vertical arm 15, the fixed cross arm 16 is fixedly arranged on the rotating platform 22, and the rotating platform 22 can drive the fixed cross arm 16 to rotate under the driving of a rotating driving mechanism 23; the telescopic cross arm 17 is connected to the fixed cross arm 16 and can be driven by the cross arm telescopic mechanism 24 to extend and retract; the small vertical arm 18 is arranged at the tail end of the telescopic cross arm 17, a telescopic rod 25 is arranged on the small vertical arm 18, the tail end of the telescopic rod 25 is connected with the cross rod 19 through a worm rotating mechanism 26, and the cross rod 19 can rotate under the driving of the worm rotating mechanism 26; the number of the grippers 20 is 2, the grippers are respectively arranged at two ends of the cross bar 19, and when the mechanical arm carries out the coiled material loading and unloading actions, the 2 grippers respectively grasp and clamp two ends of the winding roller. The vertical arm driving mechanism 21, the rotational driving mechanism 23, the arm extending and retracting mechanism 24, and the worm rotation mechanism 26 are driven by one of electric, hydraulic, and pneumatic methods. The structure enables the mechanical arm to perform telescopic action, lifting action and rotary action, can flexibly and freely adjust the position and the direction of the gripper, and has the functions of gripping and clamping a winding roller carrying coiled materials.
FIG. 3 is a schematic diagram of one embodiment of a gripper, shown as including a support plate 27, a servo- screw mechanism 28, and 2 gripper hooks 29 in the shape of refractive fingers; the waist parts of the 2 grapples are connected by a rotating shaft 30; the servo lead screw mechanism 28 is fixed on the supporting plate 27; one end of each of the 2 grapples is connected with two ends of a screw rod of the servo screw rod mechanism respectively, so that the grapples are in a reverse crossing shape; the other end of each of the 2 grapples is a free end to form an opening of the gripper; the part of the grapple between the rotating shaft and the connecting end of the lead screw is connected on the supporting plate 27 through a bolt 31, and the connecting hole is in an oblong shape, so that the connecting part can freely slide in the connecting hole; the opening size of the gripper can be adjusted through the feeding of the servo screw rod mechanism.
A load sensor is arranged on the mechanical arm; when the mechanical arm clamps and unloads a winding roll on a winding film coating machine, the mechanical arm clamps the winding roll in place, when the load sensor senses that the mechanical arm clamps the winding roll in place reliably, the load sensor sends a clamping reliable signal to the intelligent control center, the intelligent control center sends a roll unloading signal to the winding film coating machine, a winding roll connecting mechanism on the roll position is disconnected, when the intelligent control center finds that the state of the winding roll connecting mechanism is disconnected, a winding roll transferring instruction is sent to a loading and unloading execution unit, and the mechanical arm starts transferring the clamped and unloaded winding roll.
When the mechanical arm clamps and installs the winding roller, the mechanical arm firstly clamps the winding roller to a roller position and carries out autonomous fine adjustment and positioning, after the winding roller is accurately positioned on the roller position, the mechanical arm sends a positioning reliable signal to an intelligent control center, the intelligent control center sends a roller loading signal to a winding film coating machine, so that a winding roller connecting mechanism on the roller position is reconnected, the intelligent control center sends a mechanical arm moving-out instruction to a loading and unloading execution unit when finding that the state of the winding roller connecting mechanism is connection, and the mechanical arm finishes clamping and moves out the winding film coating machine.
A bar code recognition device is arranged on the mechanical arm; the winding roller loaded with the coiled materials is stored in different coiled material storage subareas according to different types of the coiled materials, and the subarea bar codes are used as marks in different subareas; when robotic arm deposited the district and snatched the winding up roller that carries the coiled material at the coiled material, can independently search and snatch the winding up roller that carries the coiled material through discernment subregion bar code according to the instruction of getting from intelligent control center.
Claims (8)
1. An intelligent winding coating method is implemented on an intelligent winding coating production line, and the intelligent winding coating production line comprises a coating working area, a coiled material storage area, an intelligent control center and an intelligent coiled material loading and unloading system; more than 2 winding coating machines are arranged in the coating working area; the winding film plating machine mainly comprises a vacuum chamber, a vacuum system, a chamber door, a wall plate, a winding roller position and an unwinding roller position, wherein winding rollers are arranged on the winding roller position and the unwinding roller position; the intelligent coiled material loading and unloading system mainly comprises a loading and unloading execution unit and a track, wherein the track is used for a coating working area and a coiled material storage area; winding rollers carrying different types of coiled materials are stored in the coiled material storage area in a partitioned mode, and partitioned bar codes serve as marks in different partitions; the winding coating method mainly comprises a coating working process, a coiled material loading and unloading working process and a coiled material storing and taking working process, wherein the 3 working processes are controlled by an intelligent control center;
wherein the coating working process comprises the following steps: the intelligent control center respectively starts the vacuum systems of the winding film plating machines to vacuumize the vacuum chambers according to the film plating working programs of the winding film plating machines in the working plan; when the vacuum degree reaches a set value, the intelligent control center starts the magnetic control target or the evaporation source, and simultaneously starts the winding system to prepare a film layer on the flexible film; in the coating working process, the intelligent control center collects the coating working state information of each winding coating machine in real time;
the working process of coil loading and unloading comprises the following steps: the coating working state information comprises the weights of the unwinding roller position and the winding roller on the winding roller position; when the weight of a winding roller of a certain winding film plating machine reaches a set value, the intelligent control center sends a coil loading and unloading instruction for loading and unloading the coil to the winding film plating machine; the loading and unloading execution unit which receives the coil loading and unloading command moves to the loading and unloading position of the winding film plating machine, and automatically carries out coil loading and unloading actions on the winding film plating machine;
the working process of storing and taking out the coiled materials comprises the following steps: before moving to a loading and unloading position of a winding coating machine to load and unload coiled materials, a loading and unloading execution unit moves to a coiled material storage area according to a material taking instruction from an intelligent control center, and a mechanical arm of the loading and unloading execution unit autonomously searches and grabs a coil roll loaded with the coiled materials through a recognition partition bar code and places the coil roll on a clamping position of a material rack on the loading and unloading execution unit; after the loading and unloading execution unit finishes the action of loading and unloading the coiled materials, the coiled materials are moved to a coiled material storage area, and a rolling roller which is positioned on a material rack clamping position and is loaded with the flexible thin film coiled materials which are finished with film coating is grabbed and placed in the coiled material storage area by a mechanical arm;
the loading and unloading execution unit also comprises a mobile trolley, a base and a mobile control module; the base and the material rack are fixed on the movable trolley, and the mechanical arm is arranged on the base; more than 2 clamping positions are arranged on the material rack, and 1 winding roller capable of loading coiled materials can be placed on each clamping position; the loading and unloading execution unit can move between loading and unloading positions of a plurality of winding film plating machines along a track under the autonomous control of an intelligent control center, and a mechanical arm automatically finishes the operation of loading and unloading coiled materials;
the movement control module comprises a driving mechanism, a movement controller and a position sensor; the driving mechanism can drive the movable trolley to move along the track, and the movable controller can receive a trolley moving instruction from the intelligent control center; the position sensor is fixed on the base and sends a position signal of the mobile trolley to the intelligent control center in real time; a speed reduction stop block switch and a stop block switch are arranged on the track; the speed reduction stop block switch is arranged at a position close to the loading and unloading position of the winding film plating machine, and the stop block switch is arranged at the loading and unloading position; each speed reduction stop block switch and each stop block switch are provided with numbers at the intelligent control center; the deceleration stop block switch and the stop block switch are popped up and started, and the retraction is invalid; the start and the failure of the speed reduction stop block switch and the stop block switch are controlled by the intelligent control center; when the loading and unloading execution unit receives an instruction of an intelligent control center and moves to a loading and unloading position of a certain winding film coating machine, a speed reduction stop block switch and a stop block switch corresponding to the loading and unloading position are firstly popped up and started under the control of the intelligent control center; when the moving trolley touches the deceleration stop switch, the moving controller controls the driving mechanism to make the moving trolley start to decelerate, and when the moving trolley decelerates and moves to touch the stop switch, the moving trolley stops braking, so that the loading and unloading execution unit is positioned at the loading and unloading position to start the action of loading and unloading the coiled material.
2. The intelligent winding coating method according to claim 1, wherein: when the loading and unloading execution unit moves to the loading and unloading position of the winding coating machine, at least 1 clamping position in the clamping positions arranged on the material rack is a vacant position without a winding roller before the coiled material loading and unloading action starts; the coiled material loading and unloading action comprises the steps that a mechanical arm clamps and unloads a winding roller which is positioned on a winding roller position in a winding coating machine and is loaded with a flexible thin film coiled material which finishes coating, and transfers the winding roller to a vacant position on a material rack, then clamps and unloads an empty winding roller on the unwinding roller position in the winding coating machine, clamps and installs the empty winding roller on the winding roller position, then grabs the winding roller loaded with a new flexible thin film coiled material on a clamping position, and clamps and installs the winding roller on the unwinding roller position.
3. The intelligent winding coating method according to claim 1, characterized in that: one end of the unwinding roller position and one end of the winding roller position are arranged on the inner wall of the chamber door; the door is opened or closed by pushing and pulling, and the unwinding roller position and the winding roller position are driven to move out of the vacuum chamber when the door is opened; the chamber door is opened and then moved to a position corresponding to the loading and unloading position of the winding film plating machine; the push-and-pull of the chamber door is driven by a push rod mechanism, and the driving mode is hydraulic driving or electric driving; the other ends of the unwinding roller position and the winding roller position are fixedly arranged on a wallboard, and the top of the wallboard is hung on a guide rail positioned at the top of the vacuum chamber; when the chamber door moves, the wall plate also moves synchronously.
4. The intelligent winding coating method according to claim 3, wherein: the winding film plating machines are arranged in a film plating working area according to 1 line or 2 lines; the track is arranged on one side of the coating working area or arranged around the coating working area; the moving direction of the chamber door is parallel to the direction of the rail by placing the winding film plating machine.
5. The intelligent winding coating method according to claim 1, wherein: when the mechanical arm carries out the coiled material loading and unloading action, 2 grippers on the mechanical arm respectively grab and clamp two ends of the winding roller.
6. The intelligent winding coating method according to claim 2, wherein: a load sensor is arranged on the mechanical arm; when the mechanical arm clamps and unloads a winding roll on a winding film coating machine, the mechanical arm clamps the winding roll in place, when the load sensor senses that the mechanical arm clamps the winding roll in place reliably, the load sensor sends a clamping reliable signal to the intelligent control center, the intelligent control center sends a roll unloading signal to the winding film coating machine, a winding roll connecting mechanism on the roll position is disconnected, when the intelligent control center finds that the state of the winding roll connecting mechanism is disconnected, a winding roll transferring instruction is sent to a loading and unloading execution unit, and the mechanical arm starts transferring the clamped and unloaded winding roll.
7. The intelligent winding coating method according to claim 2, wherein: when the mechanical arm clamps and installs the winding roller, the mechanical arm firstly clamps the winding roller to a roller position and carries out autonomous fine adjustment and positioning, after the winding roller is accurately positioned on the roller position, the mechanical arm sends a positioning reliable signal to an intelligent control center, the intelligent control center sends a roller loading signal to a winding film coating machine, so that a winding roller connecting mechanism on the roller position is reconnected, the intelligent control center sends a mechanical arm moving-out instruction to a loading and unloading execution unit when finding that the state of the winding roller connecting mechanism is connection, and the mechanical arm finishes clamping and moves out the winding film coating machine.
8. The intelligent winding coating method according to claim 1, characterized in that: in the working process of coating, the intelligent control center collects the coating process information of each coating working period of each winding coating machine in real time and forms a process file, and the process file is mapped with the product bar codes of each roll of the flexible film coiled material after coating one by one; the production and manufacturing information of the coated flexible film coiled material can be traced back by scanning the bar code of the product.
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| JP2612038B2 (en) * | 1988-06-22 | 1997-05-21 | 大日本印刷株式会社 | Film bonding equipment for small winding bobbins |
| CN107611486B (en) * | 2017-08-31 | 2019-05-14 | 东莞市莱克软件科技有限公司 | The equipment of manufacture retroactive method and realization this method from naked battery core to finished product battery core |
| CN108103470A (en) * | 2017-11-14 | 2018-06-01 | 安徽伽宝真空科技有限公司 | A kind of automatic control reel system |
| CN110950133B (en) * | 2020-01-02 | 2021-03-16 | 北京中鼎高科自动化技术有限公司 | Full-automatic intelligent material changing system for die-cutting machine |
| CN212951482U (en) * | 2020-06-08 | 2021-04-13 | 江苏卓高新材料科技有限公司 | Packaging production line |
| CN112093538A (en) * | 2020-10-10 | 2020-12-18 | 南京安顺自动化装备有限公司 | Intelligent driving feeding and discharging system for film industry |
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Address after: No. C5-1, 158 Puhe Road, Shenbei New District, Shenyang City, Liaoning Province, 110000 Patentee after: Bosuye Technology (Shenyang) Co.,Ltd. Address before: 110000, No. 37-1, Kaifa 23rd Road, Shenyang Economic and Technological Development Zone, Shenyang City, Liaoning Province, China Patentee before: Bosuye Technology (Shenyang) Co.,Ltd. |