CN115591725A - 一种无溶剂复合恒定涂布量控制方法 - Google Patents

一种无溶剂复合恒定涂布量控制方法 Download PDF

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CN115591725A
CN115591725A CN202211202797.4A CN202211202797A CN115591725A CN 115591725 A CN115591725 A CN 115591725A CN 202211202797 A CN202211202797 A CN 202211202797A CN 115591725 A CN115591725 A CN 115591725A
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李军红
鲁洋华
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Abstract

一种无溶剂复合恒定涂布量控制方法，机速稳定情况下：根据不同的涂布量，选择合适的计量间隙，稳定合适的胶黏剂粘度，选择使用对应计量辊转速比率进行涂布量的控制；机速升降速情况下：根据设备机速实时升降状态中的机速变化值对计量辊电机转速和匀胶辊电机转速进行调节控制，增加主机升降速后对计量辊和匀胶辊涂胶量的补偿。

Description

一种无溶剂复合恒定涂布量控制方法
技术领域
本发明涉及无溶剂复合领域，尤其是一种无溶剂复合恒定涂布量控制方法。
背景技术
现有涂布量可通过几种方式进行控制，第一种通过调节计量间隙的方式控制涂胶量，如中国专利公告号为CN202412898U的一种UV转印机，该种控制方式存在以下缺陷：1)计量间隙与涂布量之间虽在一定范围内具有一定的正向相关性和一定的可使用性，但不同区间比例差别较大，可控性较差甚至不可控；2)计量间隙动态调节和控制的稳定性差，控制结果偏差大；3)从计量间隙调节到达由计量间隙调整变化后而形成的涂布量之间路径太远，滞后量太大，控制反馈太慢，难以形成闭环控制过程。第二种通过闭环控制方式控制涂胶量，如中国专利公告号为CN209174249U一种采用红外线测厚仪进行涂布量闭环控制的涂胶装置，检测装置能够对涂布钢辊上的胶层厚度进行测量并传送到PLC控制装置上，PLC控制装置根据结果对转移钢辊的转速进行调整，实现了对涂布量的实时检测和调节，从而实现对涂布量的闭环控制。该种控制方式的缺陷在于：稳定性较差，只能检测到双组分的其中一种成分，混配比例误差代入了涂胶量误差，成本高。
发明内容
本发明所要解决的技术问题是提供一种无溶剂复合恒定涂布量控制方法，涂布量均匀且稳定性好。
为解决上述技术问题，本发明的技术方案是：一种无溶剂复合恒定涂布量控制方法，包括以下步骤：
机速稳定情况下：根据不同的涂布量，选择合适的计量间隙，稳定合适的胶黏剂粘度，选择使用对应计量辊转速比率进行涂布量的控制；
机速升降速情况下：根据设备机速实时升降状态中的机速变化值对计量辊电机转速和匀胶辊电机转速进行调节控制，增加主机升降速后对计量辊和匀胶辊涂胶量的补偿。
本发明原理：稳定计量间隙控制，但不采用定计量间隙以定涂胶量的控制方式；对不同上胶量范围推荐使用不同的计量间隙和胶黏剂粘度，以到达的更好的控制效果；在不同计量间隙和胶黏剂粘度的基础上，通过测试形成若干不同的计量辊转速比率与涂胶量的相关曲线；在以上曲线的基础上，增加主机升降速计量辊和匀胶辊涂胶量补偿功能，以克服设备在不同速度时涂胶量会有变化的缺陷，达到稳定的恒定涂布量控制效果。
作为改进，基于五辊涂布单元的控制，所述五辊涂布单元包括存胶辊、计量辊、匀胶辊、涂布钢棍和涂布胶辊，存胶辊与计量辊之间形成胶槽和计量间隙，计量辊为独立伺服驱动，匀胶辊为独立伺服驱动，匀胶辊在转移压力作用下与计量辊和涂布钢棍接触。
作为改进，涂布量越大，计量间隙越大，胶黏剂粘度越大，计量辊转速比率与涂布量关系：
C＝a*(I计量辊)2+b*I计量辊+c，
其中，C为涂布量，I计量辊为计量辊转速比率，a、b和c均为系数。
作为改进，a的取值范围-0.268～-0.248，b取值范围2.640～2.840，c的取值范围-3.850～-3.650。
作为改进，根据计量辊转速比率与涂布量关系建立数据库，根据工艺涂布量，在数据库中选择对应的计量间隙、胶黏剂粘度和计量辊转速比率。
作为改进，机速升降速情况下，机速越大，计量辊电机转速的增量越小，匀胶辊电机转速的增量越小。
作为改进，计量辊电机转速与机速关系：
f＝e/c＝(d/i计量)/((a-s)/s)＝d*s/((a-s)*i计量)；
匀胶辊电机转速与机速关系：
j＝h/c＝(g/i匀胶)/((a-s)/s)＝g*s/((a-s)*i匀胶)；
其中，n为机速(m/m)，a为涂布量测定量(g/㎡)，b为涂布量测定值相对于涂布设定量的变化量(g/㎡)，c为涂布量测定值相对于涂布设定量的变化率(％)，c＝b/s＝(a-s)/s，d为计量辊转速(rpm)，e为计量辊电机转速(rpm)，e＝d/i计量，f为调整后计量辊电机转速(rpm)；k为在保证机速n时的涂布钢辊，K＝n/(π*Φ涂钢)，l为涂布钢辊电机转速，l＝K/i涂钢＝n/(π*Φ涂钢*i涂钢)。
本发明与现有技术相比所带来的有益效果是：
稳定计量间隙控制，但不采用定计量间隙以定涂胶量的控制方式；对不同上胶量范围推荐使用不同的计量间隙和胶黏剂粘度，以到达的更好的控制效果；在不同计量间隙和胶黏剂粘度的基础上，通过测试形成若干不同的计量辊转速比率与涂胶量的相关曲线；在以上曲线的基础上，增加主机升降速计量辊和匀胶辊涂胶量补偿功能，以克服设备在不同速度时涂胶量会有变化的缺陷，达到稳定的恒定涂布量控制效果。
附图说明
图1为五辊涂布单元示意图。
图2为计量间隙与涂布量之间正向关联曲线图。
图3为不同机速下的涂布量曲线图。
图4为不同机速下涂布量补偿曲线图。
具体实施方式
下面结合说明书附图对本发明作进一步说明。
一种无溶剂复合恒定涂布量控制方法，基于无溶剂复合机五辊涂布单元进行控制。如图1所示，所述五辊涂布单元包括存胶辊1、计量辊2、匀胶辊3、涂布钢棍4和涂布胶辊5。存胶辊与计量辊之间形成胶槽和计量间隙6，存胶辊1可水平移动以方便清洗和调节计量间隙6，调节计量间隙6后存胶辊1中心位置固定，圆周无驱动动力，固定不旋转。计量辊2中心固定，与存胶辊1形成胶槽和计量间隙6，计量辊2采用独立伺服驱动，辊面胶层厚度主要取决于计量间隙。匀胶辊3采用独立伺服控制，匀胶辊3在转移压力作用下与计量辊2和涂布钢辊4接触，对计量辊辊面胶层厚度进一步拉薄，其速度变化虽然可能在较小长度范围内影响涂布量的变化，但却不能通过改变涂布总量对涂布量进行整线的控制。
如图2所示，经大量测试，计量间隙与涂布量之间在一定范围内具有一定的正向相关性；但是计量间隙动态调节和控制的稳定性不及计量间隙固定调节和控制的稳定性好，同时从计量间隙调节到调整后的计量间隙所形成涂布量之间路径太远，滞后量太大，不能形成有效的闭环控制。
鉴于计量间隙与涂布量之间在一定范围内具有一定的正向相关性，并在一定范围可稳定形成一定的胶黏剂厚度，故本发明根据涂布量大小及胶黏剂性质等工艺参数；对大量实验数据进行整理分析，针对不同机型，机速稳定情况下，根据不同的涂布量，选择合适的计量间隙，稳定合适的胶黏剂粘度，选择使用对应计量辊转速比率进行涂布量的控制。量越大，计量间隙越大，胶黏剂粘度越大，计量辊转速比率与涂布量关系：
C＝a*(I计量辊)2+b*I计量辊+c，
其中，C为涂布量，I计量辊为计量辊转速比率，计量辊与主机线速的速度比率为计量辊转速比率，a、b和c均为系数，a的取值范围-0.268～-0.248，b取值范围2.640～2.840，c的取值范围-3.850～-3.650。
Figure BDA0003873090040000051
Figure BDA0003873090040000061
将计量间隙固定在0.08-0.09mm范围内，将胶黏剂粘度控制在800cps左右，经过测试所得到的计量辊转速比率与涂布量关系可描述如下：
C＝a*(I计量辊)2+b*I计量辊+c，
其中a＝-0.258，b＝2.740，c＝-3.750
即：C＝-0.258(I计量辊)2+2.74I计量辊-3.75。
可根据计量辊转速比率与涂布量关系建立数据库，根据不同的涂布量，选择调整和固定不同的计量间隙，通过不同的温度控制进而控制稳定合适的胶黏剂粘度，同时选择使用对应计量辊转速比率进行涂布量的控制，经过匀胶辊对计量辊辊面胶层厚度进一步拉薄，最终通过涂布钢辊转移至薄膜上，即可得到精准的基础实际涂布量大小。
如图3所示，实际工艺实现过程中，在一定的工艺参数条件下，使用同一计量辊转速比率进行涂布量时，机速稳定情况下可获得较为精准的实际涂布量。但在升降速过程中不同设备运行速度时还会有一定的误差。机速升降速情况下，根据设备机速实时升降状态中的机速变化值对计量辊电机转速和匀胶辊电机转速进行调节控制，增加主机升降速后对计量辊和匀胶辊涂胶量的补偿。机速升降速情况下，机速越大，计量辊电机转速的增量越小，匀胶辊电机转速的增量越小。不同机速时，由于速度对胶黏剂转移率的影响，会在相同转速比率情况下产生不同的涂布量效果，经过大量的试验验证，所得到以对应关系：
计量辊电机转速与机速关系：
f＝e/c＝(d/i计量)/((a-s)/s)＝d*s/((a-s)*i计量)；
匀胶辊电机转速与机速关系：
j＝h/c＝(g/i匀胶)/((a-s)/s)＝g*s/((a-s)*i匀胶)；
其中，n为机速(m/m)，a为涂布量测定量(g/㎡)，b为涂布量测定值相对于涂布设定量的变化量(g/㎡)，c为涂布量测定值相对于涂布设定量的变化率(％)，c＝b/s＝(a-s)/s，d为计量辊转速(rpm)，e为计量辊电机转速(rpm)，e＝d/i计量，f为调整后计量辊电机转速(rpm)；k为在保证机速n时的涂布钢辊，K＝n/(π*Φ涂钢)，l为涂布钢辊电机转速，l＝K/i涂钢＝n/(π*Φ涂钢*i涂钢)。
不同线速涂布量恒定控制数据表
Figure BDA0003873090040000071
Figure BDA0003873090040000081
Figure BDA0003873090040000091
Figure BDA0003873090040000101
如图4所示，在线同步改变计量辊速度，抵消和消减升降速过程的涂布量变化，达到实际涂布量趋于恒定值的精确控制理论：在设备正常运行过程中，根据设备机速实时升降状态中的机速变化值对计量辊转速比率根据测试数据同步进行实施调节控制，相对恒速过程增加主机升降速过程的计量辊和匀胶辊涂胶量补偿功能，以克服设备在不同速度时涂胶量变化的缺陷，达到稳定的恒定涂布量控制效果，改善涂布控制的稳定性。
本发明控制理论均基于设备及供胶系统正常工作运行，为了避免设备及供胶系统非正常状态故障时出现涂布量控制错误，本可引入耗胶总量控制以验证涂布量恒定控制结果，控制涂布量与实际耗胶量两者间误差超过设定值时，系统则会报警，避免出现批量废品。

Claims (7)

1.一种无溶剂复合恒定涂布量控制方法，其特征在于，包括以下步骤：
机速稳定情况下：根据不同的涂布量，选择合适的计量间隙，稳定合适的胶黏剂粘度，选择使用对应计量辊转速比率进行涂布量的控制；
机速升降速情况下：根据设备机速实时升降状态中的机速变化值对计量辊电机转速和匀胶辊电机转速进行调节控制，增加主机升降速后对计量辊和匀胶辊涂胶量的补偿。
2.根据权利要求1所述的一种无溶剂复合恒定涂布量控制方法，其特征在于：基于五辊涂布单元的控制，所述五辊涂布单元包括存胶辊、计量辊、匀胶辊、涂布钢棍和涂布胶辊，存胶辊与计量辊之间形成胶槽和计量间隙，计量辊为独立伺服驱动，匀胶辊为独立伺服驱动，匀胶辊在转移压力作用下与计量辊和涂布钢棍接触。
3.根据权利要求1所述的一种无溶剂复合恒定涂布量控制方法，其特征在于：涂布量越大，计量间隙越大，胶黏剂粘度越大，计量辊转速比率与涂布量关系：
C＝a*(I计量辊)2+b*I计量辊+c，
其中，C为涂布量，I计量辊为计量辊转速比率，a、b和c均为系数。
4.根据权利要求3所述的一种无溶剂复合恒定涂布量控制方法，其特征在于：a的取值范围-0.268～-0.248，b取值范围2.640～2.840，c的取值范围-3.850～-3.650。
5.根据权利要求1所述的一种无溶剂复合恒定涂布量控制方法，其特征在于：根据计量辊转速比率与涂布量关系建立数据库，根据工艺涂布量，在数据库中选择对应的计量间隙、胶黏剂粘度和计量辊转速比率。
6.根据权利要求1所述的一种无溶剂复合恒定涂布量控制方法，其特征在于：机速升降速情况下，机速越大，计量辊电机转速的增量越小，匀胶辊电机转速的增量越小。
7.根据权利要求7所述的一种无溶剂复合恒定涂布量控制方法，其特征在于：
计量辊电机转速与机速关系：
f＝e/c＝(d/i计量)/((a-s)/s)＝d*s/((a-s)*i计量)；
匀胶辊电机转速与机速关系：
j＝h/c＝(g/i匀胶)/((a-s)/s)＝g*s/((a-s)*i匀胶)；
其中，n为机速(m/m)，a为涂布量测定量(g/㎡)，b为涂布量测定值相对于涂布设定量的变化量(g/㎡)，c为涂布量测定值相对于涂布设定量的变化率(％)，c＝b/s＝(a-s)/s，d为计量辊转速(rpm)，e为计量辊电机转速(rpm)，e＝d/i计量，f为调整后计量辊电机转速(rpm)；k为在保证机速n时的涂布钢辊，K＝n/(π*Φ涂钢)，l为涂布钢辊电机转速，l＝K/i涂钢＝n/(π*Φ涂钢*i涂钢)。
CN202211202797.4A 2022-09-29 2022-09-29 一种无溶剂复合恒定涂布量控制方法 Pending CN115591725A (zh)

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