WO2024027204A1 - 收卷机构、涂布机、收卷预警方法及系统 - Google Patents

收卷机构、涂布机、收卷预警方法及系统 Download PDF

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Publication number
WO2024027204A1
WO2024027204A1 PCT/CN2023/088959 CN2023088959W WO2024027204A1 WO 2024027204 A1 WO2024027204 A1 WO 2024027204A1 CN 2023088959 W CN2023088959 W CN 2023088959W WO 2024027204 A1 WO2024027204 A1 WO 2024027204A1
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WIPO (PCT)
Prior art keywords
edge
film roll
early warning
information
patrol
Prior art date
Application number
PCT/CN2023/088959
Other languages
English (en)
French (fr)
Inventor
杨海军
杨伟涛
骆昌胜
Original Assignee
江苏时代新能源科技有限公司
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Publication of WO2024027204A1 publication Critical patent/WO2024027204A1/zh

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H23/00—Registering, tensioning, smoothing or guiding webs
    • B65H23/02—Registering, tensioning, smoothing or guiding webs transversely
    • B65H23/0204—Sensing transverse register of web
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H26/00—Warning or safety devices, e.g. automatic fault detectors, stop-motions, for web-advancing mechanisms
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/05—Accumulators with non-aqueous electrolyte
    • H01M10/058—Construction or manufacture
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H2701/00—Handled material; Storage means
    • B65H2701/10—Handled articles or webs
    • B65H2701/11—Dimensional aspect of article or web
    • B65H2701/113—Size
    • B65H2701/1133—Size of webs
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product

Definitions

  • the present application relates to the technical field of battery production equipment, and in particular to a rewinding mechanism, a coating machine, a rewinding early warning method and a system.
  • the production process of lithium batteries is divided into multiple processes, some of which are difficult to complete continuously, so they need to be carried out step by step. Since the length of the pole pieces in the production process of lithium batteries is long, in the step-by-step process, part of the process requires the pole pieces to be rolled up to form a film roll, so as to facilitate the storage of the pole pieces and facilitate the development of subsequent processes. . During the winding process of some pole pieces, the "cannon barrel” phenomenon is prone to occur.
  • the “cannon barrel” phenomenon means that some pole pieces are offset to one end along the axis of the film roll, and the width of the multi-layer pole pieces along the radial direction of the film roll is (The width direction of the pole piece is consistent with the axial direction of the film roll) The center is misaligned and the end face of the film roll is poorly flush. If the "barrel” phenomenon occurs in the film roll, it will have a great impact on the product quality and production efficiency of the subsequent processes. Therefore, it is usually necessary to make the end face of the film roll formed during the winding process as flush as possible to avoid the film roll being offset and causing Form a "cannon barrel".
  • the "barrel” phenomenon is mainly improved by correcting the deflection of the pole piece before winding.
  • the risk of "cannon barrel” of film rolls always exists. Whether the “cannon barrel” phenomenon occurs during the winding process mainly depends on the real-time observation of the operator, and the reliability is low.
  • the purpose of this application is to at least solve the problem that whether the "cannon barrel” phenomenon occurs during the winding process mainly depends on real-time observation by the operator, and the reliability is low. This purpose is achieved through the following technical solutions:
  • the first aspect of this application proposes a winding early warning method, which includes: obtaining the actual axial edge information of the film roll within the early warning time period, where the early warning time period is the local time corresponding to the winding process of the current film roll or All the time; according to the edge position corresponding to the actual edge information exceeding the preset edge range of the film roll, the display device is controlled to make an early warning response.
  • the display device by obtaining the actual axial edge information of the film roll within the warning time period, when the edge position corresponding to the actual edge information exceeds the preset edge range of the film roll, the display device is controlled to make an early warning response .
  • the display device can make an early warning response, and the operator can check the progress of the winding process based on the early warning response of the display device. Whether there is a "barrel” phenomenon on the film roll. Early warning of the "cannon barrel” phenomenon no longer relies on manual real-time observation.
  • the method includes: obtaining the actual edge information of both axial ends of the film roll respectively during the warning time period; according to the actual edge information of the two axial ends of the film roll, the actual edge information of at least one end When the edge position corresponding to the edge information exceeds the preset edge range corresponding to the end, the display device is controlled to make an early warning response.
  • the winding early warning method of the embodiment of the present application obtains the actual edge information of the two axial ends of the film roll, and when the edge position of any one of the two axial ends of the film roll exceeds the preset edge range corresponding to that end, the control The display device responds with an early warning, so that when an abnormality occurs at either end of the film roll, the operator can be promptly reminded, further improving the reliability of the "barrel" early warning.
  • the method includes: obtaining the real-time actual edge information of both axial ends of the film roll respectively within the warning time period; according to the real-time actual edge information of both axial ends of the film roll, When the edge position corresponding to the real-time actual edge information of at least one end exceeds the preset edge range corresponding to the end, the display device is controlled to make an early warning response.
  • the winding early warning method of the embodiment of the present application obtains the real-time actual edge information of both axial ends of the film roll, and When one of the real-time edge positions at both ends exceeds the preset edge range corresponding to that end, the display device is controlled to make an early warning response. Therefore, through real-time monitoring, an early warning prompt can be issued at the early stage of the "barrel" phenomenon of the film roll. , which is helpful to avoid the formation of serious "cannon barrel”.
  • the edge position corresponding to the actual edge information exceeds the preset edge range of the film roll, and the display device is controlled to make an early warning response, including: based on the actual edge information at both axial ends of the film roll The corresponding edge positions and the reference edge positions of the axial ends of the film roll are used to obtain the actual offsets of the two axial ends of the film roll respectively; according to the actual offset of at least one end of the axial ends of the film roll If the offset is greater than the preset offset, the display device will be controlled to respond with an early warning.
  • the winding early warning method of the embodiment of the present application is based on the edge positions corresponding to the actual edge information of the axial ends of the film roll and the reference edge positions of the axial ends of the film roll, respectively obtaining the actual offsets of the axial ends of the film roll,
  • the reference edge position can be the edge position at the initial stage of film roll formation during the current winding process.
  • the actual offset is determined by the actual edge information.
  • the edge position is related to the reference edge position, and the actual offset is used as a reference value for whether "barrel" occurs. Its accuracy is high, film roll anomaly detection is more accurate, and the probability of false alarms is reduced.
  • the method further includes obtaining the reference edge positions of both axial ends of the film roll: within a predetermined time period, respectively obtaining actual edge information of both axial ends of the film roll, wherein , the predetermined time period and the pre-warning time period are in the same winding process, and the predetermined time period is before the pre-warning time period; based on the axial direction of the film roll obtained within the predetermined time period
  • the edge position corresponding to the actual edge information of the first end of the two ends is calculated.
  • the average position of the first end of the film roll within the predetermined time period is calculated.
  • the average position of the first end of the film roll within the predetermined time period is calculated.
  • the position is the reference edge position of the first end of the film roll; based on the edge position corresponding to the actual edge information of the second end of the two axial ends of the film roll obtained within the predetermined time period, the film roll is calculated
  • the average position of the second end of the film roll within the predetermined time period, and the average position of the second end of the film roll within the predetermined time period is the reference edge position of the second end of the film roll.
  • the winding early warning method of the embodiment of the present application uses the average value of the edge positions of the two axial ends of the film roll in the predetermined time period before the early warning time period as the reference edge positions of the two axial ends of the film roll.
  • the edge position of the film roll at the initial stage of formation is used as the reference edge position to calculate the actual offset of both ends of the film roll within the current film roll warning time period.
  • the accuracy is high and the film roll is used as the reference edge position.
  • the roll abnormality detection is more accurate, reducing the probability of false alarms; and there is no need to calibrate the position of the film rolls in different winding processes, making the operation more convenient.
  • the predetermined time period is 60 seconds to 120 seconds after the start of the current winding process; and/or the pre-warning time period is 120 seconds after the start of the winding process to the current winding process. end time.
  • the predetermined time period is 60 seconds to 120 seconds after the start of the current winding process, that is, the time from 60 seconds to 120 seconds after the winding shaft starts to drive the drum to rotate for winding. for the scheduled time.
  • the diameter of the film roll completed within the first 60 seconds of the winding process is small, the position of the film roll on the roll fluctuates greatly, and the end face alignment of the film roll is poor, that is, the axial ends of the film roll are
  • the stability of the edge position is poor; within the period of 60 seconds to 120 seconds, the flatness of the end face of the film roll is relatively stable, so the 60 seconds to 120 seconds from the beginning of the winding process are used as the reference edge position obtained at the scheduled time.
  • the reference significance of the overall film roll is good, so that the "cannon barrel” phenomenon of subsequent film rolls can be accurately warned. Taking 120 seconds after the start of the current winding process as the starting time of the warning period, the "cannon barrel” phenomenon can be discovered as early as possible during the winding process to avoid serious "cannon barrel” occurrences.
  • the method further includes: obtaining the tape cutting information of the previous winding process of the automatic roll changing operation, and using the time when the tape cutting information is received as the start time of the current winding process; Or obtain the tape start information after the winding mechanism is turned on, and use the time when the tape start information is received as the start time of the current winding process.
  • the winding early warning method of the embodiment of the present application determines the start time of the current winding process based on the tape cutting information of the automatic winding operation or the tape start information after the winding mechanism is turned on, achieving intelligent judgment of the start time and improving the winding efficiency. The degree of automation of early warning.
  • the method further includes: controlling the automatic edge patrol equipment to perform automatic edge patrol positioning on the axial edge position of the film roll; obtaining the position information of the automatic edge patrol equipment, and using the automatic edge patrol equipment to perform automatic edge patrol positioning.
  • the position information of the equipment is used as the actual edge information of the film roll in the axial direction.
  • the winding early warning method of the embodiment of the present application automatically locates the axial edge position of the film roll by controlling the automatic edge patrol equipment, and uses the position information of the automatic edge patrol equipment as the actual axial edge information of the film roll, which can Real-time acquisition of the actual edge information of the film roll, making it easy to obtain the actual edge information And the accuracy is higher.
  • the control of the automatic edge patrol equipment to automatically patrol and position the axial edge position of the film roll includes: controlling the automatic edge patrol equipment at both ends of the film roll to respectively adjust the axial edge position of the film roll.
  • the edge positions at both ends are automatically patrolled and positioned.
  • the winding early warning method of the embodiment of the present application can obtain the film at both axial ends of the film roll in real time by controlling the automatic edge patrol equipment at both ends of the film roll to automatically patrol and position the real-time edges of both axial ends of the film roll.
  • the actual edge information of the volume is accurate and convenient to obtain.
  • the automatic edge patrol equipment that controls both ends of the film roll performs automatic edge patrol positioning on the edge positions of both axial ends of the film roll, including: controlling the first automatic edge patrol device to start from the first The initial position moves to the position where the edge position of the first axial end of the film roll is detected, and the first automatic edge patrol device is controlled to automatically patrol the edge position of the first axial end of the film roll; the second automatic edge patrol device is controlled.
  • the edge patrol device moves from the second initial position to a position where the edge position of the axial second end of the film roll is detected, and the second automatic edge patrol device is controlled to automatically patrol the edge position of the axial second end of the film roll;
  • the automatic edge patrol devices at both ends of the film roll are respectively the first automatic edge patrol device and the second automatic edge patrol device, and the first end and the second end are respectively the first end and the second end of the film roll.
  • the first initial position is located on the side of the first end away from the second end
  • the second initial position is located on the side of the second end away from the first end.
  • the first initial position is located on the side of the first end away from the second end, so that the first automatic edge patrol device patrols inward from the first initial position to position the direction of the film reel for the first time.
  • the edge position of the first end; the second initial position is located on the side of the second end away from the first end.
  • the second automatic edge patrol device patrols inward from the second initial position away from the film roll to first position the film roll toward the edge.
  • the two automatic edge patrol devices locate the edge position of the film roll for the first time, which is not easily affected by the film roll, and the positioning is more accurate.
  • the automatic edge patrol equipment that controls both ends of the film roll respectively performs automatic edge patrol positioning on the edge positions of both axial ends of the film roll, and further includes: controlling the first automatic edge patrol device. Move along a straight line from the first initial position to the second initial position within a first preset distance, and control the second automatic edge patrol device to move along a straight line from the second initial position to the first initial position.
  • the first preset distance is greater than or equal to the maximum distance between the first initial position and the edge position of the first end of the film roll, and the second The preset distance is greater than or equal to the maximum distance between the second initial position and the edge position of the second end of the film roll, and the sum of the first preset distance and the second preset distance is less than the first initial position. distance to the second initial position.
  • the first preset distance is greater than or equal to the maximum distance between the first initial position and the edge position of the first end of the film roll, ensuring that the first automatic edge patrol device can locate the first
  • the second preset distance is greater than the maximum distance between the second initial position and the edge position of the second end of the film roll, ensuring that the second automatic edge patrol device can locate the edge position of the second end.
  • the sum of the first preset distance and the second preset distance is less than the distance between the first initial position and the second initial position. In this way, the first automatic edge patrol device is controlled to move within the first preset distance, and the second automatic edge patrol device is controlled.
  • edge device moves within the second preset distance, even if the first automatic edge patrol device and the second automatic edge patrol device move to the maximum stroke, they will not interfere with each other, ensuring that the first automatic edge patrol device and the second automatic edge patrol device The safety of edge equipment during patrolling.
  • the method further includes: controlling the first automatic edge patrol device to move back to the first initial position according to the closing operation instruction, and controlling the second automatic edge patrol device to move back to the first initial position.
  • the edge patrol device moves back to the second initial position.
  • the rewinding early warning method of the embodiment of the present application controls the first automatic edge patrol device to move back to the first initial position and controls the second automatic edge patrol device to move back to the second initial position according to the shutdown operation command, so that the automatic edge patrol device can be avoided Affect subsequent operations, such as preventing automatic edge patrol equipment from affecting the roll changing process.
  • the edge position corresponding to the actual edge information exceeds the preset edge range of the film roll, and controlling the display device to make an early warning response includes: the edge position corresponding to the actual edge information exceeds the preset edge range of the film roll.
  • the preset edge range of the film roll is used to generate early warning information, and the early warning information is sent to the display screen for display; and/or, according to the edge position corresponding to the actual edge information exceeds the preset edge range of the film roll, the alarm is sent to the alarm. Issue early warning instructions and control the alarm to sound the alarm.
  • the winding early warning method of the embodiment of the present application displays the early warning information on the display screen and/or controls the alarm to alarm, so that the operator can obtain the early warning information in a timely and intuitive manner, so that the film roll can be inspected in a timely manner.
  • the display device after controlling the display device to make an early warning response, it also includes: receiving an input closing operation instruction; judging that the early warning period is over according to the input closing operation instruction, and stopping acquiring the axial direction of the film roll. the actual edge information and control the display device Stop the warning response.
  • the winding early warning method of the embodiment of the present application stops obtaining the actual axial edge information of the film roll according to the closing operation command, and controls the display device to stop the early warning response, so that after the operator inputs the closing operating command, the early warning program can be closed in time and display equipment to prevent the early warning response of the display equipment from continuing to turn on, causing trouble to the operator.
  • the method further includes: after receiving the input closing operation instruction for a preset time period, starting to obtain the actual axial edge information of the film roll again, and calculating the edge corresponding to the actual edge information according to the If the position exceeds the preset edge range of the film roll, the display device is controlled to make an early warning response.
  • the winding early warning method of the embodiment of the present application starts to obtain the actual axial edge information of the film roll again after receiving the preset time period of the closing operation command, and controls the display device according to the actual edge information exceeding the preset edge range of the film roll.
  • Make an early warning response that is, after the early warning program stops for a preset period of time, the early warning program is started again.
  • the program can automatically start after a preset time period. For example, in the event of a false alarm, it will automatically start after a preset time period, which improves the automation of the winding warning method.
  • the method further includes: obtaining the pre-stored operation record, the operator identification corresponding to the operation record, the film roll identification information of the film roll corresponding to the operation record, and an early warning of the winding process of the film roll.
  • Information, reference edge position and the maximum value of the actual offset, the operation record, the operator identification, the film roll identification information, the early warning information, the reference edge position, the actual offset The maximum value is associated and stored in the local database.
  • the winding early warning method of the embodiment of the present application associates and stores relevant information in a local database, so that the operation and monitoring information of the winding process of each film roll can be traced.
  • the second aspect of this application proposes a rewinding early warning system, including: a controller, a detection component and a display device; the detection component is used to detect the actual edge information of the axial direction of the film roll, and use the actual edge information to Sent to the controller; the controller is used for the winding early warning method proposed in the first aspect of this application; and the display device is used to make an early warning response according to the control information of the controller.
  • the actual edge information of the film roll is detected through the detection component, and the actual edge information is sent to the controller.
  • the controller obtains the actual axial edge information of the film roll within the warning time period, When the edge position corresponding to the actual edge information exceeds the preset edge range of the film roll, the display device is controlled to make an early warning response, and the operator can respond based on the early warning of the display device. Check whether there is a "cannon barrel” phenomenon in the film roll during the winding process. Early warning of the "barrel" phenomenon no longer relies on manual real-time observation, which reduces the labor intensity of operators and improves reliability.
  • winding early warning system may also have the following additional technical features:
  • the rewinding early warning system further includes a signal receiving component; the signal receiving component is connected to the detection component and the controller, and the signal receiving component is used to receive the detection component
  • the detection information is sent out and the detection information is sent to the controller.
  • the winding early warning system of the embodiment of the present application sends the detection information of the detection component to the controller through the signal receiving component, so that the detection information can be received by the controller in time, and the transmission stability of the detection information is improved.
  • the detection component includes two automatic edge patrol devices.
  • the two automatic edge patrol devices are respectively used to automatically patrol both axial ends of the film roll to detect the axis of the film roll.
  • the winding early warning system of the embodiment of the present application automatically patrols both axial ends of the film roll through two automatic edge patrol devices, and the actual edge information of the film roll is detected with high accuracy.
  • the detection component further includes a guide rail
  • the guide rail is used to be arranged parallel to the axial direction of the rewinding shaft of the rewinding mechanism
  • the two automatic edge patrol devices are both slidably installed on the rewinding shaft. on the guide rail.
  • the guide rail of the winding early warning system in the embodiment of the present application is arranged parallel to the axial direction of the winding shaft, so that the two automatic edge patrol devices move along the guide rail, that is, along the axial direction of the film roll, and the two automatic edge patrol devices can be more accurately informed.
  • the moving distance of the equipment can better obtain the edge position information of the film roll through the automatic edge patrol equipment.
  • a length scale is provided on the guide rail.
  • the length scale mark set on the guide rail of the rewinding early warning system in the embodiment of the present application can facilitate the installation of detection components. For example, when installing the guide rail and automatic edge patrol equipment, the center position of the guide rail and automatic patrol can be positioned through the length scale mark. The installation location of edge equipment.
  • the middle part of the guide rail is a zero scale line, and the scales on both sides of the zero scale line gradually increase;
  • the two automatic edge patrol devices are respectively a first automatic edge patrol device and a second automatic edge patrol device.
  • Automatic edge patrolling equipment, the first automatic edge patrolling equipment and the second automatic edge patrolling equipment are respectively arranged on both sides of the zero scale line.
  • the zero scale line of the winding early warning system in the embodiment of the present application is set in the middle of the guide rail, and the scales on both sides of the zero scale line gradually increase, so that the zero scale line That is, it is the center position of the guide rail, which facilitates the operator to locate the position of the guide rail when installing the guide rail; at the same time, the increasing scales on both sides of the guide rail facilitate the positioning and installation of the two automatic edge patrol devices.
  • both ends of the guide rail are respectively provided with a first initial position and a second initial position, and the distance between the first initial position and the second initial position is greater than the axis of the film roll. direction length; in the initial state, the first automatic edge patrol device is located in the first initial position, and the second automatic edge patrol device is located in the second initial position.
  • the distance between the first initial position and the second initial position on the guide rail is greater than the axial length of the film roll. In this way, the two automatic edge patrol devices are respectively located at the first initial position and the second initial position.
  • the interference of the automatic edge patrol equipment on the film roll can be avoided; and during the actual winding process, the film roll can be placed between the first initial position and the second initial position.
  • the two automatic edge patrol devices are Move inward from the far end to locate the edge position of the film roll for the first time to avoid the impact of the film roll on the edge tracking accuracy of the automatic edge patrol equipment.
  • the guide rail is provided with a first limit position and a second limit position respectively on both sides of the zero scale line, and the first limit position and the second limit position are located at Between the first initial position and the second initial position, the first limit position and the first initial position are located on one side of the zero scale line, the second limit position and the second The initial position is located on the other side of the zero scale line, and the first limit position and the second limit position are both separated from the zero scale line by a preset distance, and the preset distance is greater than zero.
  • the first automatic edge patrol device is configured to move between the first initial position and the first limit position
  • the second automatic edge patrol device is configured to move between the second initial position and the first limit position. Move between two limit positions.
  • the first automatic edge patrol device is configured to move between the first initial position and the first limit position
  • the second automatic edge patrol device is configured to move between the second initial position and the second limit position. Moving between positions avoids the situation where the two automatic edge patrol devices cannot locate the edge of the film roll under certain unexpected circumstances, causing the second automatic edge patrol device and the first automatic edge patrol device to collide with each other.
  • the display device includes a display screen, the display screen is used to display early warning information generated by the controller; and/or the display device includes an alarm, the alarm is used to display the alarm information according to the controller Send an early warning command to alarm.
  • the rewinding early warning system in the embodiment of the present application can display early warning information through the display screen and/or alarm by controlling the alarm, so that the operator can Early warning information can be obtained timely and intuitively, so that film rolls can be inspected in a timely manner.
  • the third aspect of this application proposes a rewinding mechanism, which includes a rewinding shaft and the rewinding early warning system proposed in the second aspect of this application.
  • the detection component is provided corresponding to the rewinding shaft.
  • the actual edge information of the film roll is detected through the detection component, and the detection information is sent to the controller.
  • the controller obtains the actual axial edge information of the film roll within the warning time period.
  • the control display device will make an early warning response.
  • the operator can use the early warning response of the display device to check whether the "barrel" phenomenon occurs in the film roll during the winding process. Early warning of the "barrel" phenomenon no longer relies on manual real-time observation, which reduces the labor intensity of operators and improves reliability.
  • winding mechanism according to the present application may also have the following additional technical features:
  • the rewinding mechanism includes two rewinding shafts, and the two rewinding shafts are respectively provided with one of the detection members.
  • the two winding reels of the winding mechanism of the embodiment of the present application can be used alternately to perform the winding operation, so that the corresponding winding operation process can be continuously produced.
  • detection components corresponding to the two rewinding reels the film rolls on the two rewinding reels can be inspected to improve the quality of all film rolls in the continuous production process and avoid the occurrence of the film roll "barrel" phenomenon.
  • the fourth aspect of this application provides a coating machine, including the winding mechanism proposed in any embodiment of this application.
  • the rewinding early warning method, rewinding early warning system, rewinding mechanism and coating machine provided by this application can all remind the operator to check the film roll during the rewinding process when the edge position of the film roll exceeds the preset edge range of the film roll. Whether there is a "cannon barrel” phenomenon. Early warning of the "barrel” phenomenon no longer relies on manual real-time observation, which reduces the labor intensity of operators and improves reliability.
  • Figure 1 is a flow chart of a winding early warning method provided by some embodiments of the present application.
  • Figure 2 is an edge position superposition corresponding to actual edge information provided by some embodiments of the present application.
  • Figure 3 is a flow chart for obtaining the reference edge positions of both axial ends of the film roll provided by some embodiments of the present application;
  • Figure 4 is a schematic diagram of a winding early warning system according to some embodiments of the present application.
  • Figure 5 is a schematic diagram of the automatic edge patrol equipment of the rewinding early warning system shown in Figure 4 in an automatic edge patrol state;
  • Figure 6 is a diagram of the actual monitoring process of the winding early warning system in some embodiments of the present application.
  • 1-film roll 11-reference edge position; 12-edge position corresponding to actual edge information; 13-barrel starting position; 14-actual offset; 2-roll; 3-controller; 4-signal reception Components; 5-guide rail; 51-zero scale mark; 52-first initial position; 53-second initial position; 6-display screen; 71-laser beam; 72-first automatic edge patrol equipment; 73-second automatic Border patrol equipment; 8-alarm.
  • an embodiment means that a particular feature, structure or characteristic described in connection with the embodiment can be included in at least one embodiment of the present application.
  • the appearances of this phrase in various places in the specification are not necessarily all referring to the same embodiment, nor are they mutually exclusive with other embodiments. or alternative embodiments. Those skilled in the art understand, both explicitly and implicitly, that the embodiments described herein may be combined with other embodiments.
  • multiple refers to more than two (including two).
  • multiple groups refers to two or more groups (including two groups), and “multiple pieces” refers to It is more than two pieces (including two pieces).
  • Power batteries are not only used in energy storage power systems such as hydropower, thermal power, wind power and solar power stations, but are also widely used in electric vehicles such as electric bicycles, electric motorcycles and electric cars, as well as in many fields such as military equipment and aerospace. . As the application fields of power batteries continue to expand, their market demand is also constantly expanding.
  • the winding mechanism is the last part of the coating process. After the coating process, the pole pieces are cold-pressed. process.
  • the most common abnormality of the film roll completed by the winding mechanism is the "cannon barrel” phenomenon.
  • the “cannon barrel” phenomenon means that some pole pieces are offset toward one end along the axial direction of the film roll, and the width of the multi-layer pole pieces along the radial direction of the film roll (the width direction of the pole piece is consistent with the axial direction of the film roll) is misaligned in the center.
  • the flatness of the end face of the film roll is poor.
  • the current coating process mainly improves the "cannon barrel” phenomenon by adjusting the winding tension, adjusting the taper coefficient, adjusting the starting roll diameter, and adjusting the roller level.
  • different pole pieces have an impact on the above factors (the influencing factor is the winding tension).
  • taper coefficient, initial roll diameter and roller levelness) are different, coupled with other abnormalities in the coating process, the base material with a small friction coefficient is inevitably included in the middle of the film roll, resulting in The pole piece is prone to slipping, and the risk of "barrel" appearing on the film roll during the coating process is always present and unavoidable.
  • unpredictable risks greatly increase the possibility of abnormalities.
  • the supervision of the "cannon” phenomenon of film rolls mainly relies on the operator to observe in real time whether “cannon” occurs in the film roll during the rewinding process of the winding mechanism.
  • the reliability is low and the labor intensity of the operator is high.
  • the inventor proposed a rewinding early warning method after in-depth research.
  • the rewinding early warning method obtains the actual axial edge information of the film roll within the warning time period, and based on the actual edge information, the edge position corresponding to the exceeds
  • the preset edge range of the film roll controls the display device to make an early warning response.
  • the display device can make an early warning response, and the operator can respond accordingly.
  • the early warning response of the display device check whether there is a "barrel” phenomenon in the film roll during the winding process.
  • Early warning of the "cannon barrel” phenomenon no longer relies on manual real-time observation.
  • Early warning can be given at the early stage of the film roll forming a "cannon barrel” in the coating process, so as to promptly curb the deterioration of the film roll "cannon barrel", avoid actual losses, and reduce The labor intensity of operators is reduced and the reliability is improved.
  • the winding early warning method disclosed in the embodiment of the present application can be, but is not limited to, used to provide early warning to the film roll formed by winding up by the winding mechanism in the coating process.
  • the rewinding early warning method disclosed in the embodiments of the present application can be used to provide early warning for film rolls formed by the rewinding mechanism in other processes, such as but not limited to the cold pressing process and the die-cutting and slitting process, so that the rewinding process can be discovered in time. "Cannon barrel” in the process to avoid serious "cannon barrel” in the film roll.
  • the coating process is a process of coating active materials on the base material to form pole pieces.
  • the electrode pieces include positive electrode pieces and negative electrode pieces.
  • the base material used in the coating process of processing the positive electrode pieces is the positive electrode base material, and the coated active material is the positive electrode active material;
  • the coating process used in processing the negative electrode pieces is
  • the base material is a negative electrode base material, and the coated active material is a negative electrode active material.
  • the positive electrode base material can be aluminum foil, and the positive electrode active material can be lithium cobalt oxide, lithium iron phosphate, ternary lithium or lithium manganate, etc.;
  • the negative electrode base material can be copper foil, and the negative electrode active material layer includes the negative electrode.
  • the negative active material can be carbon or silicon.
  • the part of the pole piece coated with the active material forms the main part of the pole piece, and the blank area is used to form the tab, and the tab is used to connect the adapter piece or the electrode terminal.
  • the positive active material and negative active material react with the electrolyte, and the tabs are connected to the electrode terminals to form a current loop.
  • the cold pressing process is a pole piece processing step after the coating process. It is mainly used to cold press the coated pole pieces to reduce the volume of the pole pieces and at the same time pre-slit the pole pieces. Die-cutting and slitting process After the cold pressing process, the die-cutting and slitting process mainly involves slitting the pole piece from the middle in the width direction, so that the formed pole piece only has tabs on one side, which can be used for subsequent pole piece winding or Stacked to form battery cells in preparation.
  • the winding early warning method according to an embodiment of the present application is applied to the coating process as an example.
  • This embodiment provides a rewinding early warning system capable of executing the above rewinding early warning method.
  • the rewinding early warning system is applied to a rewinding mechanism.
  • the rewinding mechanism is provided with a rewinding shaft and a driving shaft to rotate. moving motors and transmission components.
  • the winding mechanism can be applied to coating machines.
  • the winding mechanism is a device used to complete the winding of the pole piece, that is, a device used to wind the pole piece to form a film roll 1.
  • a device used to wind the pole piece to form a film roll 1 Before the current winding process starts, first install drum 2 on the winding shaft, then stick the end of the pole piece to drum 2, drive the winding shaft through the motor to drive drum 2 to rotate, and winding on drum 2 The pole piece finally forms the film roll 1.
  • the motor is also called an electric motor, which is a power device for winding.
  • the motor can convert electrical energy into mechanical energy.
  • the working principle of the motor is to rely on the force exerted by the magnetic field on the current to make the motor rotate.
  • the rewinding reel is a shaft that drives the reel 2 to rotate. It is connected to the motor through a transmission assembly. Under the rotation of the motor, the rewinding reel can rotate on its own.
  • the drum 2 is a cylinder used for winding the pole piece. It is usually a hollow cylindrical shape. The two ends of the drum 2 are used to connect to the winding shaft and are coaxially arranged with the winding shaft. The circumferential direction of the drum 2 is used to connect the winding shaft. On the coiled pole piece.
  • Film roll 1 refers to the cylindrical structure formed by the pole piece on roll 2 during the continuous winding process.
  • the width direction of the pole piece on film roll 1 is consistent with the axial direction of film roll 1.
  • the radial direction of film roll 1 It consists of multiple layers of continuously wound pole pieces.
  • the coating machine is a device used to complete the coating process of the pole piece.
  • FIG. 1 is a flow chart of a winding early warning method provided by some embodiments of the present application.
  • This application provides a rewinding early warning method, including:
  • Step S1 Obtain the actual axial edge information of the film roll within the warning time period.
  • the warning time period is the partial time or the entire time corresponding to the current film roll winding process.
  • Step S2 According to the fact that the edge position corresponding to the actual edge information exceeds the preset edge range of the film roll, control the display device to make an early warning response.
  • the rewinding early warning method is applied to the controller 3.
  • the controller 3 is a control unit with functions such as signal processing and calculation. Specifically, it can be a PLC (PLC refers to a programmable logic controller) control system.
  • PLC PLC refers to a programmable logic controller
  • the current film roll refers to the film roll 1 in the winding process, and the film roll 1 is in a monitored state.
  • the winding process of the current film roll is also the process from the start of the current film roll to the completion of the winding.
  • the partial time or the entire time corresponding to the winding process of the current film roll that is, part of the time period or the entire time period from the start of the current film roll to the completion of the winding.
  • the warning period starts a certain time after the winding starts. This is because, in the initial stage of winding, the film roll 1 has just begun to form, the diameter of the film roll 1 is small, and the film roll 1 is on the roll. 2 to form the initial position, basically no "barrel" will be produced.
  • the edge position of the film roll 1 in the initial stage is actually the basic position for the formation of the film roll 1, which can be used as the reference edge position of the film roll 1 in the subsequent warning period.
  • the actual edge information of the film roll 1 in the axial direction refers to the actual edge information of all the pole pieces on the film roll 1 in the axial direction of the film roll 1. In the coating process, the actual edge information of the film roll 1 is also left. The actual edge information of the white area.
  • the film roll 1 has two ends in the axial direction, so the actual edge information of the film roll 1 in the axial direction may include the actual edge information of the two ends of the film roll 1 in the axial direction.
  • step S1 the actual edge information in the axial direction of the film roll 1 within the warning time period is obtained.
  • the actual edge information can correspond to the quantified data information after being processed by the controller.
  • the preset edge range is a reference edge range preset in the controller 3.
  • the preset edge range can be input to the controller through an input device connected to the controller 3 (the input device can be a display panel with a touch screen input function, etc.). Controller 3 and can be changed via input device.
  • the preset edge range can also be corresponding position information, which is also quantifiable data information.
  • position information which is also quantifiable data information.
  • the display device is a device that can respond to an alarm. Specifically, it can be a display screen 6 that displays early warning information, an alarm device 8 that can issue an audible alarm, an alarm device 8 that can issue a photoelectric alarm, etc.
  • the early warning response made by the display device is a response that can remind the operator.
  • the early warning information is displayed on the display screen 6, and the alarm 8 emits sound or light to remind the operator.
  • the display device By obtaining the actual axial edge information of the film roll 1 within the warning time period, when the edge position corresponding to the actual edge information exceeds the preset edge range of the film roll 1, the display device is controlled to make an early warning response. In this way, when the edge position of the film roll 1 exceeds the preset edge range of the film roll 1, that is, when there is a serious risk of "cannon barrel", the display device can make an early warning response, and the operator can check the receipt according to the early warning response of the display device. Check whether there is a "barrel” phenomenon on film roll 1 during the rolling process. Early warning of the "cannon barrel” phenomenon no longer relies on manual real-time observation.
  • the film roll early warning method of this embodiment includes obtaining the actual edge information of both axial ends of the film roll respectively within the warning time period; according to the actual edge information of the two axial ends of the film roll, at least one end When the edge position corresponding to the actual edge information exceeds the preset edge range corresponding to that end, the display device is controlled to make an early warning response.
  • the two axial ends of the film roll 1 are the first end and the second end respectively, and the input device can be connected to the controller 3 (the input device can be a display panel with a touch screen input function, etc.) for the first end.
  • the first end and the second end respectively input corresponding preset edge ranges to the controller 3.
  • Obtaining the actual edge information of the two axial ends of the film roll 1 respectively means respectively obtaining the actual edge information of the axial first end of the film roll 1 and the actual edge information of the axial second end of the film roll 1 .
  • the controller 3 is used to compare the edge position corresponding to the obtained actual edge information of the first end with the preset edge range of the first end, and compare the edge position corresponding to the obtained actual edge information of the second end with the preset edge range of the second end. Edge ranges are compared. When the edge position corresponding to the actual edge information of the first end exceeds the preset edge range of the first end, and/or when the edge position corresponding to the actual edge information of the second end exceeds the preset edge range of the second end, the controller 3 Control the display device to make an early warning response.
  • the winding early warning method of the embodiment of the present application obtains the actual edge information of both axial ends of the film roll 1.
  • the edge position corresponding to the actual edge information of any one of the two axial ends of the film roll 1 exceeds the edge position corresponding to that end.
  • the display device is controlled to make an early warning response when the edge range is preset, so that when an abnormality occurs at either end of the film roll 1, the operator can be promptly reminded, further improving the reliability of the "cannon barrel” early warning.
  • the film roll early warning method in this embodiment includes: obtaining the real-time actual edge information of the two axial ends of the film roll respectively during the warning time period; according to the real-time actual edge information of the two axial ends of the film roll.
  • the display device is controlled to make an early warning response.
  • the real-time actual edge information at both ends of the axis is the actual edge information at the first end and the actual edge information at the second end at any point in time during the warning period.
  • the display device By obtaining the real-time actual edge information of both axial ends of the film roll 1, and when the edge position corresponding to one of the real-time actual edge information of the two ends exceeds the corresponding preset edge range of the end, the display device is controlled to make an early warning response , so that through real-time monitoring, early warning prompts can be given at the early stage of the "cannon" phenomenon in the film roll 1, which is helpful to avoid the formation of serious "cannon".
  • Step S2 includes:
  • Step S21 Based on the edge positions corresponding to the actual edge information of the two axial ends of the film roll and the reference edge positions of the two axial ends of the film roll, the actual offsets of the two axial ends of the film roll 1 are obtained respectively.
  • Step S22 According to the fact that at least one of the actual offsets of the two axial ends of the film roll is greater than the preset offset, the display device is controlled to make an early warning response.
  • the reference edge position can be understood as the reference position of the film roll 1 during the winding process. This position can be manually set into the controller 3 through an input device (the input device can be a display panel with a touch screen input function, etc.)
  • the position parameter can also be determined by obtaining the edge position of the film roll 1 in the early stage of formation during the current winding process. When the edge position of the film roll 1 is consistent with the reference edge position, the film roll 1 is considered to be in the most ideal winding state, and the end surface of the film roll 1 formed by it is a plane perpendicular to the axial direction of the film roll 1 .
  • the first end and the second end of the film roll 1 respectively correspond to corresponding reference edge positions. Compare the edge position corresponding to the actual edge information of the first end with the reference edge position of the first end, that is, the difference between the position parameter corresponding to the actual edge information of the first end and the parameter corresponding to the reference edge position of the first end. And get the actual offset of the first end.
  • the edge position corresponding to the actual edge information of the second end is compared with the reference edge position of the second end, that is, the position parameter corresponding to the actual edge information of the second end is compared with the parameter corresponding to the reference edge position of the second end to obtain the second end.
  • the actual offset of the end is compared with the reference edge position of the second end.
  • the preset offset is a displacement parameter input into the controller 3 in advance through an input device (the input device can be a display panel with a touch screen input function, etc.), which is the allowable edge position of the film roll 1 relative to the reference edge position.
  • Maximum offset The preset offset of the first end is the maximum offset by which the edge position of the first end of the film roll 1 can deviate from the reference edge position of the first end.
  • the preset offset of the second end is the second end of the film roll 1.
  • the maximum offset by which the edge position of one end can be offset from the reference edge position of the second end.
  • the preset offsets of the first end and the second end may be the same or different.
  • the The preset offsets for one end and the second end are the same.
  • the preset offset can be set in the range of 0-15 mm, specifically 1 mm, 2 mm, 5 mm, 10 mm, 15 mm, etc.
  • the actual offsets of the two axial ends of the film roll 1 are obtained respectively.
  • the actual offset at at least one end When the offset is greater than the preset offset, the display device is controlled to make an early warning response.
  • the reference edge position can be the edge position at the initial stage of the film roll 1 in the current winding process.
  • the actual offset is obtained by correlating the edge position corresponding to the actual edge information with the reference edge position, and the actual offset is used as whether it occurs.
  • the reference value of the "barrel" has high accuracy, and the abnormality detection of film roll 1 is more accurate, which reduces the probability of false warning.
  • Figure 3 is a flow chart for obtaining the reference edge positions of the axial ends of the film roll 1 in some embodiments of the present application.
  • the film roll early warning method in this embodiment also includes: film Obtain the reference edge positions of both axial ends of Volume 1.
  • the specific steps include:
  • Step S31 Within a predetermined time period, obtain the actual edge information of both ends of the film roll in the axial direction.
  • the predetermined time period and the pre-warning time period are in the same winding process, and the predetermined time period is before the pre-warning time period.
  • Step S32 Based on the edge position corresponding to the actual edge information of the first end of the two axial ends of the film roll obtained within the predetermined time period, calculate the average position of the first end of the film roll within the predetermined time period, and the film roll is within the predetermined time period.
  • the average position of the first end within the time period is the reference edge position of the first end of the film roll; based on the edge position corresponding to the actual edge information of the second end of the two axial ends of the film roll obtained within the predetermined time period, the film is calculated
  • the average position of the second end of the film roll within a predetermined time period, and the average position of the second end of the film roll within a predetermined time period is the reference edge position of the second end of the film roll 1 .
  • the predetermined time period is a time period in the winding process of the current film roll, which is usually a time period in the initial stage of the winding process.
  • the position information corresponding to the actual edge information at both ends of the film roll 1 in the axial direction within a predetermined time period is usually displayed as position data.
  • the actual edge information of the first end and the second end of the film roll 1 are obtained in real time within a predetermined time period.
  • the edge position corresponding to the actual edge information of each end may be unchanged within the predetermined time period, or it may be Slightly changed.
  • the average position of the first end of the film roll 1 within a predetermined time period that is, the average position data corresponding to the actual edge information of the first end of the film roll 1 obtained within the predetermined time period.
  • Film roll The average position of the second end of 1 within a predetermined time period, that is, the average position data corresponding to the actual edge information of the second end of the film roll 1 obtained within the predetermined time period.
  • the predetermined time period and the warning time period may be continuous, that is, the warning time period begins after the predetermined time period ends.
  • the edge position of the predetermined time period can be considered as the edge position of the current film roll in the initial stage of formation, and the average edge position of the current film roll in the early stage of formation is used as a reference.
  • the edge position is used to calculate the actual offset of both ends of the film roll 1 within the current film roll warning time period.
  • the accuracy is high.
  • the abnormality detection of the film roll 1 is more accurate, which reduces the probability of false alarms; and there is no need to check different
  • the position of film roll 1 during the winding process is calibrated to make the operation more convenient.
  • the predetermined time period is 60 seconds to 120 seconds after the start of the current winding process; and/or the warning time period is the time from 120 seconds after the start of the winding process to the end of the winding process.
  • the predetermined time period is 60 seconds to 120 seconds after the current winding process starts, that is, the winding shaft starts to drive the drum 2 to rotate, and the time from 60 seconds to 120 seconds after the winding is carried out is the predetermined time.
  • the diameter of the film roll 1 completed within the first 60 seconds of the winding process is smaller, the position stability of the film roll 1 on the roll 2 is poor, and the end surface alignment of the film roll 1 is poor. , that is, the edge position stability of the axial ends of the film roll is poor; within the time period from 60 seconds to 120 seconds, the end surface flatness of film roll 1 is relatively stable, so from 60 seconds to the beginning of the winding process 120 seconds is used as the reference edge position obtained at the predetermined time, which has a good reference significance for the entire film roll 1, so that it can accurately warn the "cannon barrel” phenomenon of the subsequent film roll 1.
  • the winding early warning method of this embodiment also includes: obtaining the tape cutting information of the previous winding process of the automatic roll changing operation, and using the time when the tape cutting information is received as the start time of the current winding process. . Or obtain the tape start information after the winding mechanism is turned on, and use the time when the tape start information is received as the start time of the current winding process.
  • the roll change operation can be completed automatically or manually.
  • the process of automatically completing the roll change operation can be called automatic roll change operation, and the process of manually completing the roll change operation can be called manual roll change operation.
  • the winding mechanism for automatic roll changing operations usually includes two winding reels that are used alternately. While one rewinding reel is performing the rewinding operation, the other rewinding reel performs preparation operations (preparation operations include installing reel 2 on the rewinding reel, applying double-sided tape to reel 2, etc.), and performs rewinding operations.
  • preparation operations include installing reel 2 on the rewinding reel, applying double-sided tape to reel 2, etc.
  • rewinding operations include installing reel 2 on the rewinding reel, applying double-sided tape to reel 2, etc.
  • the roll 2) on the winding reel that performs the preparation operation starts to idle until the linear speed is consistent with the production speed of the coating process; then the cutter performs a cutting action, cutting off the pole piece, and at the same time, the winding of the previous film roll is completed , the winding shaft newly connected to the pole piece starts the winding operation.
  • an automatic winding process is completed. The operator uses the corresponding mechanical equipment to disassemble the completed film roll 1 from the winding reel, replace it with a new reel 2, and start the preparatory work for the winding reel again.
  • the automatic roll changing operation enables continuous production of the coating process without frequent shutdowns.
  • the cutting tape information is the information of the cutter cutting the pole piece. That is, after the winding of a film roll 1 is completed, the cutter performs a cutting action to cut off the pole piece, so that the pole piece in the production process is consistent with the pole piece on the film roll 1. Fragment disconnection information. Specifically, the information about the cutting action performed by the cutter can be used as the tape cutting information. That is, when the controller obtains the cutting action performed by the cutter, it is considered that the tape cutting information has been obtained.
  • the time when the tape cutting information of the previous winding process is obtained is used as the start time of the current winding process, which can automatically monitor the continuously produced film rolls and realize each winding process. Intelligent judgment of process start time improves the automation of winding warning.
  • the rewinding mechanism for manual roll changing operations usually has a rewinding shaft.
  • the rewinding shaft completes the rewinding operation of a film roll 1, it is necessary to pause production, cut off the pole piece, and then rewind the reel 2 on the rewinding shaft.
  • the film roll 1 is disassembled and replaced with a new roll 2, and then the pole piece is connected to the new roll 2 to restart production.
  • the winding process and other operations in the coating process are carried out continuously.
  • production suspended by manual roll change, all operations in the coating process will basically stop, that is, the coating machine is shut down.
  • production is restarted after the roll change is completed all operations will be stopped. The operation is restarted, that is, the coater is turned on.
  • the tape start information after the winding mechanism is opened that is, after the coating machine changes from the closed state to the open state, the pole piece starts to move along the production process.
  • the time when the tape start information is received after the winding mechanism is turned on is used as the start time of the current winding process, which can realize the intelligent judgment of the start time of each winding process and improve The degree of automation of winding early warning is improved.
  • the coating machine may also shut down under other working conditions, such as: shutdown conditions when the pole piece is broken and needs to be spliced, shutdown conditions caused by temporary lack of slurry used in the coating process, when the operator is off work or Shutdown conditions during rest, abnormal equipment shutdown conditions, etc. Under these working conditions, all operations of the coating machine are also opened or closed synchronously with the winding mechanism. Therefore, when the coating machine is stopped and restarted in any condition, the time when the tape start information is received after the winding mechanism is turned on can be used as the start time of the current winding process, so as to start the coating machine. Intelligent judgment is made on the start time of the next first film roll, which improves the automation of winding warning.
  • other working conditions such as: shutdown conditions when the pole piece is broken and needs to be spliced, shutdown conditions caused by temporary lack of slurry used in the coating process, when the operator is off work or Shutdown conditions during rest, abnormal equipment shutdown conditions, etc.
  • all operations of the coating machine are also opened or closed synchronously
  • the winding early warning method also includes controlling the automatic edge patrol equipment to perform automatic edge patrol positioning on the axial edge position of the film roll; obtaining the position information of the automatic edge patrol equipment to determine the position of the automatic edge patrol equipment.
  • the information is used as the actual edge information of the film roll 1 in the axial direction.
  • the automatic edge patrol equipment is a device that automatically positions and patrols the edge of the film roll. It can automatically locate the edge of the film roll 1 and output position information in real time.
  • a common automatic edge patrol device is a laser automatic edge patrol device.
  • the laser automatic edge patrol device identifies the edge of the film roll 1 through a laser sensing component. Specifically, in the coating process, the motor drives the laser sensing component to move, and the laser sensing component identifies and locates the edge of the blank area of the pole piece.
  • the laser sensing component carries a displacement sensing component such as a position sensor. The position of the laser sensing component can be obtained in real time through the displacement sensing component. The position of the laser sensing component corresponds to the edge position of the film roll 1, so the automatic edge patrol device can be obtained by The position information is used as the actual edge information of the film roll 1 in the axial direction.
  • the laser automatic edge patrol equipment can control the forward and reverse movement of the laser sensing component through forward and reverse rotation of the motor.
  • the two motors are configured to rotate forward (or reversely)
  • the two laser sensing components move away from each other, so that the distance the laser sensing component moves outward is a positive value.
  • the automatic edge patrol equipment gradually patrols outwards, and the displacement of its movement is positive, which conforms to the positive thinking habits of the operator and facilitates the conversion of the displacement of the automatic edge patrol equipment. .
  • the laser automatic edge patrol equipment can locate the edge position of the film roll 1 in real time during the entire rewinding process of the film roll 1. That is to say, the acquisition of the actual axial edge information of the film roll 1 within the predetermined time period and the warning time period can be achieved through the automatic edge patrol equipment.
  • the actual edge of the film roll 1 can be realized Real-time acquisition of information, the actual edge information of film roll 1 is easy to obtain and has high accuracy.
  • controlling the automatic edge patrol equipment to perform automatic edge patrol positioning on the axial edge position of the film roll includes: controlling the automatic edge patrol equipment at both ends of the film roll to respectively position the edges on both axial ends of the film roll. The location is automatically patrolled and positioned.
  • the automatic edge patrol devices at both ends of the film roll are respectively a first automatic edge patrol device 72 and a second automatic edge patrol device 73 .
  • the first automatic edge patrol device 72 is used to measure the edge position of the first axial end of the film roll 1 .
  • the second automatic edge patrolling device 73 is used to perform automatic edge patrolling and positioning on the edge position of the second axial end of the film roll 1 .
  • the winding early warning method of the embodiment of the present application controls the automatic edge patrol equipment at both ends of the film roll to automatically patrol and position the edge positions of the two axial ends of the film roll 1, so that the two axial edges of the film roll 1 can be obtained in real time.
  • the actual edge information of the film roll 1 at the end is accurate and convenient to obtain.
  • the step of controlling the automatic edge patrol equipment at both ends of the film roll to automatically patrol and position the edge positions of the two axial ends of the film roll 1 includes: controlling the first automatic edge patrol device 72 from the first An initial position 52 moves to a position where the edge position of the first axial end of the film roll 1 is detected, and the first automatic edge patrol device 72 is controlled to automatically patrol the edge position of the first axial end of the film roll 1 ; Control the second automatic edge patrol device 73 to move from the second initial position 53 to a position where the edge position of the second end of the axial direction of the film roll 1 is detected, and control the second automatic edge patrol device 73 to perform axial movement of the film roll 1 The edge position of the second end is automatically patrolled.
  • the automatic edge patrol devices at both ends of the film roll are respectively the first automatic edge patrol device and the second automatic edge patrol device.
  • the first end and the second end are respectively the two axial ends of the film roll 1.
  • the second initial position 53 is located on a side of the first end away from the second end, and the second initial position 53 is located on a side of the second end away from the first end.
  • the first initial position 52 is the position of the first automatic edge patrol device 72 in the initial state, also It can be understood as the position of the first automatic edge patrol device 72 when it is not in use.
  • the second initial position 53 is the position of the second automatic edge patrol device 73 in the initial state, which can also be understood as the position of the second automatic edge patrol device 73 in the non-use state.
  • the first initial position 52 is located on the side of the first end away from the second end, so that the first automatic edge patrol device 72 moves from a position without the film roll 1 to a position where the film roll 1 is located.
  • the first automatic edge patrol device 72 detects When it reaches the edge position of the first end of the film roll 1, automatic edge patrol begins.
  • the second initial position 53 is located on the side of the second end away from the first end, so that the second automatic edge patrol device 73 moves from a position without the film roll 1 to a position where the film roll 1 is located.
  • the second automatic edge patrol device 73 is at When the edge position of the second end of the film roll 1 is detected, automatic edge patrolling starts.
  • the axial edge of the film roll 1 can only deflect axially away from the center during the pole piece winding process, so the first automatic edge patrolling device 72 may The movement is from the edge position of the first end detected for the first time to the first initial position 52.
  • the possible movement of the second automatic edge patrol device 73 during the automatic edge patrol is from the edge position of the second end detected for the first time to the second initial position 52.
  • the initial position 53 is moved.
  • the first initial position 52 is located on the side of the first end away from the second end, so the first automatic edge patrol device 72 patrols inward from the first initial position 52 to position the film for the first time.
  • the edge position of the first end of the roll 1 in the axial direction; the second initial position 53 is located on the side of the second end away from the first end, and the second automatic edge patrol device 73 is inward from the second initial position 53 away from the film roll 1 Patrol the edge to locate the edge position of the second axial end of the film roll 1 for the first time. Since the automatic edge patrol equipment performs positioning through induction pole pieces, the edge position of the film roll 1 positioned by the two automatic edge patrol equipment for the first time is not easily affected by the film roll 1, and the positioning is more accurate.
  • controlling the display device to make an early warning response it also includes: controlling the first automatic edge patrol device 72 to move back to the first initial position 52 according to the closing operation instruction, and controlling the second automatic edge patrol device 73 Move back to second initial position 53.
  • the shutdown operation instruction may be an instruction manually input by the operator, or may be a shutdown operation instruction issued by the controller 3 based on other circumstances.
  • the shutdown operation instruction is manually input by the operator. Specifically, after the display device makes an early warning response, the operator inputs a closing operation instruction to the controller 3 by operating on the input device (the input device may be a display panel with a touch screen input function, etc.).
  • step S2 includes: according to the edge position corresponding to the actual edge information exceeds the preset edge range of the film roll 1
  • the preset edge range of the film roll 1 is generated, and the early warning information is sent to the display screen 6 for display; and/or, according to the actual edge information, the edge position corresponding to the film roll 1 exceeds the preset edge range of the film roll 1, and the alarm information is sent to the alarm 8 Issue an early warning command and control the alarm 8 to alarm.
  • the early warning information may be prompt information to confirm whether the gun barrel is used, and may be displayed on the display screen 6 in the form of a pop-up window.
  • the display screen 6 is a screen capable of displaying information, and may specifically be a display screen of a computer, a display interface of a PLC, etc.
  • the early warning instruction is a control instruction for controlling the alarm device 8 to alarm.
  • the alarm 8 can be a buzzer alarm, a light alarm, a sound and light alarm, etc.
  • the operator can obtain the early warning information timely and intuitively, so that the film roll 1 can be inspected in a timely manner.
  • the display device after controlling the display device to make an early warning response, it also includes: receiving an input closing operation instruction; judging based on the input closing operation instruction that the early warning time period is over, and stopping acquiring the actual axial direction of the film roll 1 Edge information, and control the display device to stop early warning response.
  • the closing operation command is generally input by the operator. Specifically, after the display device makes an early warning response, the operator manually inputs the closing operation command through the input device (the input device can be a display panel with a touch screen input function, etc.), and the controller 3 receives the closing operation command. When the shutdown operation command is reached, the early warning program for film roll 1 is stopped. At this time, the operator can follow the reminder to check whether the "cannon barrel” phenomenon appears on the film roll 1. If it is confirmed that the film roll 1 has a cannon barrel, replace the film roll 1; if the "cannon barrel” phenomenon does not appear, it may be a false alarm. , at this time the winding process proceeds normally.
  • the input device can be a display panel with a touch screen input function, etc.
  • the early warning program and the display device can be closed in time to avoid failure of the display device.
  • the early warning response continues to be activated, causing trouble to the operator.
  • the winding early warning method of this embodiment also includes: after receiving the input closing operation instruction for a preset time period, starting to obtain the actual axial edge information of the film roll 1 again, and based on the actual edge information If the edge position exceeds the preset edge range of film roll 1, the control display device will make an early warning response.
  • the preset time length can be input through an input device (the input device can be a display panel with a touch screen input function, etc.), and the time is preset in the controller 3.
  • the preset time length can be 2 minutes, 3 minutes, or 4 minutes. , 5 minutes or 6 minutes, etc.
  • the specific preset time can be determined according to the actual operating conditions. It should be noted that the preset time length must first ensure that the operator has enough time to check whether the film roll 1 is barreled.
  • the specific process of judging whether the input closing operation command reaches the preset duration is: the controller 3 starts timing when it receives the closing operation command. When the timing duration reaches the preset duration, it is considered that the input closing operation command reaches the preset duration. . In response to the timing reaching the preset time, the controller 3 starts to obtain the actual axial edge information of the film roll again, that is, it controls the early warning program of restarting the winding early warning system again, and starts monitoring the film roll 1.
  • the controller 3 when the controller 3 receives the shutdown operation command and starts timing, if the film roll 1 is replaced or the machine is shut down, the timing will stop.
  • the early warning program of the winding early warning system can be started according to the start of tape transport information after the coating machine is turned on; during the automatic roll changing operation, the early warning program of the winding early warning system can be started based on the upper information during the automatic rolling changing operation. The cutting information of the winding process is started. In other words, only when the current film roll is not replaced and production continues, the rewinding warning system will be automatically controlled to restart after receiving the input shutdown operation command for a preset time.
  • the winding early warning method in the embodiment of the present application starts to obtain the actual axial edge information of the film roll 1 again after receiving the preset time period of the closing operation command, and the edge position corresponding to the actual edge information exceeds the preset limit of the film roll 1.
  • Set the edge range to control the display device to make an early warning response that is, after the early warning program of the rewinding early warning system stops for a preset period of time, the early warning program is started again.
  • the alarm program can be automatically turned on after a preset period of time, and the film roll 1 can be monitored again to remind the operator, thus improving the winding warning method. degree of automation and reliability.
  • the roll-up early warning method in this embodiment also includes obtaining the pre-stored The operation record, the operator identification corresponding to the operation record, the film roll 1 identification information of the film roll 1 corresponding to the operation record, the early warning information of the winding process of the film roll 1, the reference edge position and the maximum value of the actual offset, will Operation records, operator identification, film roll 1 identification information, warning information, reference edge position, and the maximum value of the actual offset are associated and stored in the local database.
  • the operation record is a record of the operations performed by the operator in the winding warning program.
  • the operation record includes but is not limited to inputting the shutdown operation command, the procedure for replacing the film roll 1 when the "barrel" phenomenon occurs, etc.
  • the operator identification is also the identification corresponding to the person who performs the corresponding operation.
  • the operator identification can be the operator's work badge number, name, etc.
  • the identification information of the film roll is identification information that distinguishes the film roll 1.
  • the identification information may be a film roll number, etc.
  • the early warning information is the information that the controller 3 makes an early warning response during the winding process of the film roll 1, which includes but is not limited to whether an early warning occurs, the number of early warnings, etc.
  • the maximum value of the actual offset is the maximum value of the offset of the edge position corresponding to the actual edge information of the film roll 1 relative to the reference edge position during the winding process of the film roll 1.
  • the information about the rewinding reels corresponding to film roll 1 can also be associated and stored in the local database.
  • FIG. 4 is a schematic diagram of a rewinding early warning system according to some embodiments of the present application.
  • This embodiment provides a rewinding early warning system, including a controller 3, a detection component and a display device.
  • the detection component is used to detect the actual edge information of the film roll 1 in the axial direction, and sends the actual edge information to the controller 3;
  • the controller 3 is used to execute the winding early warning method of the embodiment of the present application;
  • the display device is used to control the film roll according to the controller. 3. Make an early warning response to the control information.
  • the detection component is a component that can detect the actual edge information of the film roll 1. It can be an automatic edge patrol device, or other inductive sensors, three-dimensional imaging modules, etc.
  • the actual edge information of the film roll 1 is detected through the detection component, and the detection information is sent to the controller 3.
  • the controller 3 obtains the actual axial edge information of the film roll 1 within the warning time period, and then detects the actual edge information corresponding to the actual edge information.
  • the control display device will make an early warning response.
  • the operator can check whether the "barrel" phenomenon occurs in the film roll 1 during the rewinding process based on the early warning response of the display device. Early warning of the "barrel” phenomenon no longer relies on manual real-time observation, which reduces the labor intensity of operators and improves reliability.
  • the rewinding early warning system also includes a signal receiving component 4 .
  • the signal receiving component 4 is connected to the detection component and the controller 3 .
  • the signal receiving component 4 is used to receive detection information sent by the detection component and send the detection information to the controller 3 .
  • the signal receiving component 4 mainly receives the signal in the detection component, transforms it into information in the same physical form as when sent, and then transmits it to the controller 3, which completes the so-called decoding process.
  • the rewinding early warning system in the embodiment of the present application sends the detection information of the detection component to the controller 3 through the signal receiving component 4, so that the detection information can be received by the controller 3 in time, which improves the transmission stability of the detection information.
  • Figure 5 is a schematic diagram of the automatic edge patrol equipment of the rewinding early warning system shown in Figure 4 in an automatic edge patrol state.
  • the detection component in this embodiment includes two automatic edge patrol devices.
  • the two automatic edge patrol devices are respectively used to automatically patrol the two axial ends of the film roll 1 to detect the actual edge information of the two axial ends of the film roll 1.
  • the winding early warning system of the embodiment of the present application uses two automatic edge patrol devices to automatically patrol the two axial ends of the film roll 1, and the actual edge information of the film roll 1 is detected with high accuracy.
  • the detection component also includes a guide rail 5.
  • the guide rail 5 is used to be arranged parallel to the axial direction of the winding shaft. Both automatic edge patrol devices can be slidably installed on the guide rail. 5 on.
  • the guide rail 5 is a track extending in a straight line. When installed, the guide rail 5 is parallel to the axial direction of the rewinding shaft and is located on one side of the rewinding shaft. The guide rail 5 can provide guidance for the movement of the two automatic edge patrol devices.
  • the two automatic edge patrol devices By setting the guide rail 5 parallel to the axial direction of the winding shaft, the two automatic edge patrol devices move along the guide rail 5, that is, along the axial direction of the film roll 1, so that the moving distance of the two automatic edge patrol devices can be known more accurately.
  • the edge position information of the film roll 1 can be better obtained through the automatic edge patrol equipment.
  • the guide rail 5 is provided with a length scale.
  • the length scale is also a scale that can display the length.
  • the length scale is arranged along the length direction of the guide rail.
  • the length scale can be set with corresponding numbers to facilitate the operator to read the length value.
  • the installation of the detection component can be facilitated.
  • the center position of the guide rail 5 and the installation position of the automatic edge patrol equipment can be positioned through the length scale. .
  • the middle part of the guide rail 5 in this embodiment is a zero scale line, and the scales on both sides of the zero scale line gradually increase; the two automatic edge patrol devices are respectively The first automatic edge patrol device 72 and the second automatic edge patrol device 73 are respectively arranged on both sides of the zero scale line.
  • the zero scale mark is also the starting point of the length scale.
  • the measuring ranges of the length scales on both sides of the zero scale line are 500 mm respectively.
  • the zero scale position of the guide rail 5 can be set roughly corresponding to the axial center of the drum 2. At this time, the scales on both sides of the axial center of the drum 2 are approximately the same.
  • the axial length of the film roll 1 in the coating process is usually not greater than 800 mm.
  • 500 mm long scales on both sides of the zero scale line, that is, the entire guide rail 5 has a range of 1000 mm. It can cover the length of the film roll 1 in the axial direction, and can reserve enough space at both ends of the film roll 1 for disassembling the film roll 1 .
  • the zero scale line By setting the zero scale line in the middle of the guide rail 5, the scales on both sides of the zero scale line gradually increase. In this way, the zero scale line is also the center position of the guide rail 5.
  • the guide rail 5 When the guide rail 5 is installed, it is convenient for the operator to locate the position of the guide rail 5. ; At the same time, the increasing scales on both sides of the guide rail 5 facilitate the positioning and installation of the two automatic edge patrol devices.
  • the first initial position 52 and the second initial position 53 are respectively provided at both ends of the guide rail 5 of the present application.
  • the distance between the first initial position 52 and the second initial position 53 is greater than the film roll 1 axial length.
  • the first automatic edge patrol device 72 is located at the first initial position 52
  • the second automatic edge patrol device 73 is located at the second initial position 53 .
  • the initial state is also the state in which the automatic edge patrol equipment is not performing edge patrol work.
  • the first initial position 52 and the second initial position 53 of this embodiment are respectively located at both ends of the guide rail 5 , specifically, they may be positions corresponding to the 500 mm scale at both ends.
  • the two automatic edge patrol devices are respectively located at the first initial position 52 and the second initial position 53.
  • the film roll 1 can be placed between the first initial position 52 and the second initial position 53. In this way, the two automatic edge patrol devices move inward from the far end to position the edge of the film roll 1 for the first time, preventing the film from slipping.
  • Volume 1 affects the edge patrol accuracy of automatic edge patrol equipment.
  • the guide rail 5 of the present application is provided with a first limit position and a second limit position respectively on both sides of the zero scale line 51.
  • the first limit position and the second limit position are respectively The position is between the first initial position 52 and the second initial position 53.
  • the first limit position and the first initial position 52 are located on one side of the zero scale line 51.
  • the second limit position and the second initial position 53 are located on the zero scale.
  • the first limit position and the second limit position are both separated from the zero scale line 51 by a preset distance, and the preset distance is greater than zero.
  • the first automatic edge patrol device 72 is configured to move between the first initial position 52 and the first limit position
  • the second automatic edge patrol device 73 is configured to move between the second initial position 53 and the second limit position.
  • the first limit position is used to limit the furthest distance that the first automatic edge patrol device 72 can move inward (that is, toward the side where the film roll 1 is located), and the second limit position is used to limit the second automatic edge patrol device 73 The furthest distance moved inwards.
  • the first automatic edge patrol device 72 or the second automatic edge patrol device 73 may not locate the edge position of the film roll 1 at the corresponding end when performing the edge patrol operation. At this time, the first automatic edge patrol device 72 Or the second automatic edge patrol device 73 will continue to move forward along the axial direction of the film roll 1, and the first automatic edge patrol device 72 and the second automatic edge patrol device 73 may collide.
  • the first automatic edge patrol device 72 is configured to move between the first initial position 52 and the first limit position
  • the second automatic edge patrol device 73 is configured to move between the second initial position 53 and the second limit position. Moving between positions avoids the situation where the two automatic edge patrol devices cannot locate the edge of the film roll 1 under certain unexpected circumstances, causing the second automatic edge patrol device 73 and the first automatic edge patrol device 72 to collide with each other. .
  • the display device of the rewinding warning system in this embodiment includes a display screen 6 , and the display screen 6 is used to display the warning information generated by the controller 3 . And/or the display device includes an alarm 8, which is used to issue an alarm according to the early warning instruction issued by the controller 3.
  • the winding early warning system of the embodiment of the present application displays early warning information through the display screen 6 and/or alarms by controlling the alarm 8, so that the operator can obtain the early warning information in a timely and intuitive manner.
  • the film roll 1 can be inspected in time.
  • this embodiment also provides a rewinding mechanism, including a rewinding shaft and the rewinding early warning system provided in any of the above embodiments, and the detection component is provided for the rewinding shaft.
  • the actual edge information of the film roll 1 is detected through the detection component, and the actual edge information is sent to the controller 3.
  • the controller 3 obtains the actual axial edge information of the film roll 1 within the warning time period, corresponding to the actual edge information.
  • the control display device will make an early warning response.
  • the operator can check whether the "cannon barrel” phenomenon occurs in the film roll 1 during the rewinding process based on the early warning response of the display device. Early warning of the "barrel” phenomenon no longer relies on manual real-time observation, which reduces the labor intensity of operators and improves reliability.
  • the rewinding mechanism of this embodiment includes two rewinding shafts, and the two rewinding shafts are respectively provided with a detection component.
  • any one of the two rewinding reels is equipped with two automatic edge patrol devices.
  • the two automatic edge patrol devices corresponding to each rewinding reel are used to respectively detect the edge positions of the two axial ends of the film roll 1 on the current rewinding reel.
  • the two winding reels are usually used alternately to form an automatic roll changing operation. While one rewinding reel is performing the rewinding operation, the other rewinding reel performs the preparation operation; after the rewinding of one rewinding reel is completed, the pole piece is automatically switched from the current rewinding reel to another rewinding reel, ensuring the continuity of the production process.
  • the automatic edge patrol equipment corresponding to the two rewinding reels is turned on alternately according to the usage status of the rewinding reels. That is to say, when the rewinding operation is performed on the rewinding reel, the two automatic edge patrol devices corresponding to the rewinding reel are turned on and perform edge patrol on the film roll 1 on the rewinding reel.
  • the switching of automatic edge patrol equipment is signaled by pole piece cutting. That is, after receiving the information that the pole piece is cut off, the controller 3 controls the automatic edge patrol equipment corresponding to the current rewinding reel to stop patrolling, resets the automatic edge patrolling device corresponding to the current rewinding reel to the initial position, and controls the other rewinding reel to corresponding The automatic patrol equipment starts patrolling.
  • the two winding reels of the winding mechanism of the embodiment of the present application can be used alternately to perform the winding operation, so that the corresponding winding operation process can be continuously produced.
  • detection components corresponding to the two rewinding reels both film rolls 1 on the two rewinding reels can be inspected to improve the quality of all film rolls 1 in the continuous production process and avoid the occurrence of the film roll "barrel" phenomenon.
  • this embodiment provides a coating machine, the coating machine includes The winding mechanism provided by any of the above embodiments.
  • the rewinding early warning system of the rewinding mechanism can detect the "cannon barrel” phenomenon of the film roll 1, avoiding the formation of serious "cannon barrels” and facilitating subsequent processes. Processing the pole pieces of film roll 1 improves the efficiency and yield rate of battery production.
  • this embodiment provides a film roll early warning system, including a controller 3, a signal receiving component 4, two laser automatic edge patrol devices, a guide rail 5, a display screen 6 and Alarm 8.
  • the farthest distance between the two ends of the guide rail 5 (the range of the guide rail 5 is 1000 mm, the zero scale line 51 is centered, and the left/right are 500 mm each) is the default initial position of the laser automatic edge patrol equipment.
  • the controller 3 has authority for opening or closing the rewinding warning system, and the setting of the authority can be input or confirmed through the input device to avoid monitoring failure. That is to say, only authorized operators can turn on or off the rewinding warning system.
  • the laser automatic edge patrol equipment When the warning program is turned off, the laser automatic edge patrol equipment returns to its initial position.
  • the intermediate roll change process if it is an automatic roll change operation, the cutting of the pole piece of the winding process performed by the previous winding reel will be used as a signal to control the opening of the laser automatic edge patrol equipment corresponding to the next winding reel; if it is a manual roll change operation , still taking the start of the coating process as a signal to control the laser automatic edge patrol equipment to perform edge patrol operations.
  • the "cannon barrel” phenomenon is not formed on the right side of the film roll 1 in Figure 5, but the “cannon barrel” phenomenon is formed on the left side of the film roll 1.
  • the “cannon barrel” phenomenon starts from the starting position 13 of the barrel along the film.
  • the radial direction of roll 1 extends outward (to the left in Figure 5).
  • the edge position of the pole piece corresponding to the starting position 13 of the barrel is the edge position of the outermost pole piece at the left end of film roll 1 with reference to edge position 11.
  • the position difference between the edge position 12 corresponding to the actual edge information and the reference edge position 11 is the actual offset 14.
  • the actual offset is also the position of the film roll 1. The maximum offset of this end.
  • FIG 6 is a diagram of the actual monitoring process of the winding early warning system in some embodiments of the present application.
  • This actual monitoring process is the embodiment of the winding early warning method.
  • the preset offset is set to a specific value within the range of 0-15mm allowed by the system.
  • the preset offset is also the sensing spacing.
  • the sensing spacing is the maximum offset allowed by the system for the blank area on the edge of the pole piece. When the offset of the edge of the blank area of the pole piece reaches the sensing spacing, an alarm will occur.
  • the early warning program of the winding early warning system is automatically started.
  • the winding mechanism of the coating machine clearly defines the position of the winding drum 2 according to the substrate width of the film roll 1 being detected.
  • the laser automatic edge patrol equipment emits a laser beam 71 to automatically patrol inward at a set moving speed (moving speed range is 20 ⁇ 10 mm/second) to detect the film roll 1.
  • the outermost position of the blank area on the edge of the pole piece in order to avoid collision of the left/right laser automatic edge patrol equipment, set the maximum displacement of 450 mm to prevent foolproofing).
  • the reference edge position is also the initial position of the outermost edge of the pole piece blank area defaulted by the warning program
  • the default rewinding warning system is turned on.
  • the average value of the outermost position of the pole piece edge detected in the period of 60 seconds to 120 seconds is the reference edge position, which is the reference zero position of the early warning program.
  • the left blank area edge and the right blank area edge of the film roll 1 have two independent zero-point positions.
  • any actual offset that is, the maximum displacement
  • the preset offset that is, the sensing distance
  • the early warning mechanism is triggered, and the display device makes an early warning response, that is, The corresponding warning message pops up on the computer's display screen, accompanied by audible and visual alarms.
  • the maximum displacement is less than the sensing distance
  • the early warning mechanism will not be triggered, normal production will continue until normal shipment, and the current film roll monitoring will end.
  • the operator inputs a shutdown operation command to the controller 3 by clicking the shutdown program button (the rewinding warning system only provides a "barrel” warning and does not force the equipment to shut down), and the manual temporary shutdown
  • the early warning program of the winding early warning system and confirm whether a "barrel” occurs. If a "barrel” occurs, the film roll in the coating process is shipped, and the monitoring of the current film roll barrel ends. If “barrel” does not occur, normal production will continue until normal shipment, and the current film roll monitoring will end.
  • the controller 3 can receive the roll change signal. After the film roll of the new coating process starts to be rolled up, the average value of the outermost position of the white space on the edge of the pole piece detected in the 60-120 second period is the zero point position of the new film roll 1, that is, the reference edge position.
  • the maximum displacement is 450 mm to prevent foolproofing, that is, the first preset distance corresponding to the first laser automatic edge patrol device and the second preset distance corresponding to the second laser automatic edge patrol device are set to 450 mm respectively to avoid two The laser automatic border patrol equipment collided.
  • the farthest distance between the two ends of the guide rail 5 that is, the positions of 500 mm on the left and right respectively correspond to the first initial position 52 and the second initial position 53 .
  • Move 450 mm inward from the first initial position 52, and the corresponding position of 50 mm is the first limiting position.
  • the second initial position 53 is moved inward by 450 mm
  • the corresponding position of 50 mm is also the second limiting position.
  • the left and right sides correspond to the first end and the second end of the film roll 1.
  • the maximum displacement is also the maximum value of the actual offset.
  • the rewinding early warning method and system of this embodiment can promptly identify an abnormality after the horizontal offset of the blank area on the edge of the pole piece reaches the sensing distance during the production process, and pop up an early warning message to remind the startup operator to confirm and handle the abnormality in a timely manner.
  • the deterioration of the cannon barrel should be contained in a timely manner to avoid actual losses.

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Abstract

一种收卷预警方法包括：获取预警时间段内的膜卷（1）的轴向的实际边缘信息，其中预警时间段是当前膜卷的收卷过程对应的局部时间或全部时间；根据实际边缘信息对应的边缘位置（12）超出膜卷的预设边缘范围，控制显示设备作出预警反应。该收卷预警方法使得操作人员可根据显示设备的预警反应，查看收卷过程的膜卷是否出现"炮筒"现象，在膜卷形成"炮筒"的初期阶段即可作出预警。还包括一种收卷预警系统、收卷机构及涂布机。

Description

收卷机构、涂布机、收卷预警方法及系统
相关申请的交叉引用
本申请要求享有于2022年8月02日提交的名称为“收卷机构、涂布机、收卷预警方法及系统”的中国专利申请202210918923.X的优先权，该申请的全部内容通过引用并入本文中。
技术领域
本申请涉及电池生产设备技术领域，尤其涉及一种收卷机构、涂布机、收卷预警方法及系统。
背景技术
本部分提供的仅仅是与本申请相关的背景信息，其并不必然是现有技术。
锂电池的生产过程分为多个工序，其中部分工序难以连续完成，所以需要分步进行。由于锂电池生产过程中的极片长度较长，所以在分步完成的工序中，部分工序需要对极片进行收卷形成膜卷，以便于对极片进行收纳，并方便于后续工序的开展。在一些极片收卷过程中，容易出现“炮筒”现象，“炮筒”现象也即部分极片沿膜卷的轴向往一端偏移，沿膜卷径向上的多层极片的宽度(极片的宽度方向与膜卷的轴向一致)中心错位，膜卷的端面平齐度较差的现象。膜卷如果出现“炮筒”现象，对后续工序的产品优率和生产效率影响极大，所以通常需要收卷过程形成的膜卷的端面尽可能平齐，以避免膜卷发生偏移而导致形成“炮筒”。
当前主要通过对收卷之前的极片进行纠偏，以改善“炮筒”现象，但生产因素存在变量，膜卷“炮筒”风险始终存在。收卷过程中是否出现“炮筒”现象主要靠操作人员实时观察，可靠性较低。
发明内容
本申请的目的是至少解决收卷过程中是否出现“炮筒”现象主要靠操作人员实时观察，可靠性低的问题。该目的是通过以下技术方案实现的：
本申请的第一方面提出了一种收卷预警方法，包括：获取预警时间段内的膜卷的轴向的实际边缘信息，其中预警时间段是当前膜卷的收卷过程对应的局部时间或全部时间；根据所述实际边缘信息对应的边缘位置超出膜卷的预设边缘范围，控制显示设备作出预警反应。
本申请实施例的技术方案中，通过获取预警时间段内的膜卷的轴向的实际边缘信息，在实际边缘信息对应的边缘位置超出膜卷的预设边缘范围时，控制显示设备作出预警反应。这样，在膜卷的边缘位置超出膜卷预设边缘范围时，也即存在出现“炮筒”风险时，显示设备可作出预警反应，操作人员可根据显示设备的预警反应，查看收卷过程的膜卷是否出现“炮筒”现象。“炮筒”现象预警不再依靠人工实时观察，可在涂布工序的膜卷形成“炮筒”的初期阶段即可作出预警，及时遏制膜卷“炮筒”恶化，避免造成实际损失，降低了操作人员的劳动强度，且可靠性提高。
另外，根据本申请的收卷预警方法，还可具有如下附加的技术特征：
在本申请的一些实施例中，所述方法包括：在预警时间段内，分别获取膜卷的轴向两端的实际边缘信息；根据膜卷的轴向两端的实际边缘信息中，至少一端的实际边缘信息对应的边缘位置超出该端对应的所述预设边缘范围时，控制显示设备作出预警反应。本申请实施例的收卷预警方法通过获取膜卷的轴向两端的实际边缘信息，在膜卷的轴向的两端中的任意一端的边缘位置超出该端对应的预设边缘范围时，控制显示设备作出预警反应，从而能够在膜卷的任意一端出现异常时，及时提醒操作人员，进一步提高了对“炮筒”预警的可靠性。
在本申请的一些实施例中，所述方法包括：在预警时间段内，分别获取膜卷的轴向两端的实时的实际边缘信息；根据膜卷的轴向两端的实时的实际边缘信息中，至少一端的实时的实际边缘信息对应的边缘位置超出该端对应的所述预设边缘范围时，控制显示设备作出预警反应。本申请实施例的收卷预警方法通过获取膜卷的轴向两端的实时的实际边缘信息，并在 两端的实时的边缘位置中的一者超出该端对应的预设边缘范围时，控制显示设备作出预警反应，从而通过实时监控，可在膜卷发生“炮筒”现象的初期即可作出预警提示，有利于避免严重“炮筒”的形成。
在本申请的一些实施例中，所述根据所述实际边缘信息对应的边缘位置超出膜卷的预设边缘范围，控制显示设备作出预警反应，包括：基于膜卷的轴向两端的实际边缘信息对应的边缘位置和膜卷的轴向两端的参照边缘位置，分别得到膜卷的轴向两端的实际偏移量；根据膜卷的轴向两端的实际偏移量中的至少一端的实际偏移量大于预设偏移量，控制显示设备作出预警反应。本申请实施例的收卷预警方法基于膜卷的轴向两端的实际边缘信息对应的边缘位置和膜卷的轴向两端的参照边缘位置，分别得到膜卷的轴向两端的实际偏移量，至少一端的实际偏移量大于预设偏移量时，控制显示设备作出预警反应，参照边缘位置可以是当前收卷过程中膜卷形成初期的边缘位置，实际偏移量通过实际边缘信息对应的边缘位置和参照边缘位置关联得出，并将实际偏移量作为是否发生“炮筒”的参考值，其准确性较高，膜卷异常检测更加准确，降低了误预警的几率。
在本申请的一些实施例中，所述方法还包括所述膜卷的轴向两端的参照边缘位置的获取：在预定时间段内，分别获取膜卷的轴向的两端的实际边缘信息，其中，所述预定时间段和所述预警时间段处于同一个收卷过程中，且所述预定时间段处于所述预警时间段之前；基于所述预定时间段内获取的所述膜卷的轴向两端中第一端的实际边缘信息对应的边缘位置，计算所述膜卷的第一端在所述预定时间段内的平均位置，所述膜卷在预定时间段内的第一端的平均位置为所述膜卷的第一端的参照边缘位置；基于所述预定时间段内获取的所述膜卷的轴向两端中第二端的实际边缘信息对应的边缘位置，计算所述膜卷的第二端在所述预定时间段内的平均位置，所述膜卷在预定时间段内的第二端的平均位置为所述膜卷的第二端的参照边缘位置。本申请实施例的收卷预警方法，将预警时间段之前的预定时间段内的膜卷的轴向两端的边缘位置的平均值，分别作为膜卷的轴向两端的参照边缘位置，由于预定时间段和预警时间段处于同一个收卷过程中，且预定时间段处于预警时间段之前，所以预定时间段的边缘位置可认为是当前 膜卷形成初期的边缘位置，以当前膜卷形成初期的边缘位置的平均值作为参照边缘位置，来计算当前膜卷预警时间段内的膜卷两端的实际偏移量，准确度较高，膜卷异常检测更加准确，降低了误预警的几率；且不需要对不同收卷过程的膜卷的位置进行校准，操作更加方便。
在本申请的一些实施例中，所述预定时间段为当前收卷过程开始后的60秒-120秒；和/或所述预警时间段为收卷过程开始后的120秒至该收卷过程结束的时间。本申请实施例的收卷预警方法，预定时间段为当前收卷过程开始后的60秒-120秒，也即收卷轴开始带动卷筒转动，以进行收卷后的60秒到120秒的时间为预定时间。在收卷过程刚开始的60秒之内完成的膜卷的直径较小，膜卷在卷筒上的位置波动较大，膜卷端面对齐度较差，也即，膜卷的轴向两端的边缘位置稳定性较差；在60秒到120秒的时间段内，膜卷的端面平齐度较为稳定，所以以收卷过程开始的60秒到120秒作为预定时间获取的参照边缘位置，对整体膜卷的参照意义较好，从而可准确预警后续膜卷的“炮筒”现象。以当前收卷过程开始后的120秒作为预警时间段的起始时间，能够在收卷过程中尽可能早的发现“炮筒”现象，避免发生严重“炮筒”。
在本申请的一些实施例中，所述方法还包括：获取自动换卷作业的上一收卷过程的切带信息，根据接收到所述切带信息的时间作为当前收卷过程的开始时间；或获取收卷机构开启后的开始走带信息，根据接收到所述开始走带信息的时间作为当前收卷过程的开始时间。本申请实施例的收卷预警方法，根据自动换卷作业的切带信息或收卷机构开启后的开始走带信息判断当前收卷过程的开始时间，实现开始时间的智能判断，提高了收卷预警的自动化程度。
在本申请的一些实施例中，所述方法还包括：控制自动巡边设备对膜卷的轴向的边缘位置进行自动巡边定位；获取自动巡边设备的位置信息，以所述自动巡边设备的位置信息作为膜卷的轴向的实际边缘信息。本申请实施例的收卷预警方法，通过控制自动巡边设备对膜卷的轴向的边缘位置进行自动定位，并以自动巡边设备的位置信息作为膜卷的轴向的实际边缘信息，能够实现膜卷的实际边缘信息的实时获取，实际边缘信息获取方便 且准确性较高。
在本申请的一些实施例中，所述控制自动巡边设备对膜卷的轴向的边缘位置进行自动巡边定位，包括：控制膜卷两端的自动巡边设备分别对膜卷的轴向的两端的边缘位置进行自动巡边定位。本申请实施例的收卷预警方法，通过控制膜卷两端的自动巡边设备分别对膜卷的轴向的两端的实时边缘进行自动巡边定位，能够实时获取膜卷的轴向的两端的膜卷的实际边缘信息，信息获取准确且方便。
在本申请的一些实施例中，所述控制膜卷两端的自动巡边设备分别对膜卷的轴向的两端的边缘位置进行自动巡边定位，包括：控制第一自动巡边设备从第一初始位置移动至检测到膜卷的轴向的第一端的边缘位置的位置，控制第一自动巡边设备对膜卷的轴向的第一端的边缘位置进行自动巡边；控制第二自动巡边设备从第二初始位置移动至检测到膜卷的轴向的第二端的边缘位置的位置，控制第二自动巡边设备对膜卷的轴向的第二端的边缘位置进行自动巡边；其中，膜卷两端的所述自动巡边设备分别为所述第一自动巡边设备和所述第二自动巡边设备，所述第一端和所述第二端分别为所述膜卷的轴向的两端，所述第一初始位置位于所述第一端远离所述第二端的一侧，所述第二初始位置位于所述第二端远离所述第一端的一侧。本申请实施例的收卷预警方法，第一初始位置位于第一端远离第二端的一侧，从而第一自动巡边设备是从第一初始位置向内巡边，以首次定位膜卷轴向的第一端的边缘位置；第二初始位置位于第二端远离第一端的一侧，第二自动巡边设备是从远离膜卷的第二初始位置向内巡边，以首次定位膜卷轴向的第二端的边缘位置。两自动巡边设备首次定位膜卷的边缘位置不易受膜卷的影响，定位更加准确。
在本申请的一些实施例中，所述控制膜卷两端的自动巡边设备分别对膜卷的轴向的两端的边缘位置进行自动巡边定位，还包括：控制所述第一自动巡边设备从所述第一初始位置向所述第二初始位置沿直线在第一预设距离内移动，控制所述第二自动巡边设备从所述第二初始位置向所述第一初始位置沿直线在第二预设距离内移动；所述第一预设距离大于等于所述第一初始位置至所述膜卷的第一端的边缘位置之间的最大距离，所述第二 预设距离大于等于所述第二初始位置至所述膜卷的第二端的边缘位置之间的最大距离，所述第一预设距离与所述第二预设距离的和小于第一初始位置至所述第二初始位置之间的距离。本申请实施例的收卷预警方法，第一预设距离大于等于第一初始位置至膜卷的第一端的边缘位置之间的最大距离，保证了第一自动巡边设备能够定位到第一端的边缘位置；第二预设距离大于第二初始位置至膜卷的第二端的边缘位置之间的最大距离，保证了第二自动巡边设备能够定位到第二端的边缘位置。第一预设距离与第二预设距离的和小于第一初始位置至第二初始位置之间的距离，这样控制第一自动巡边设备在第一预设距离内移动，控制第二自动巡边设备在第二预设距离内移动时，即使第一自动巡边设备和第二自动巡边设备移动至最大行程也不会发生相互干涉，保证了第一自动巡边设备和第二自动巡边设备在巡边过程中的安全性。
在本申请的一些实施例中，在控制显示设备作出预警反应之后，还包括：根据关闭操作指令，控制所述第一自动巡边设备移动回所述第一初始位置，控制所述第二自动巡边设备移动回所述第二初始位置。本申请实施例的收卷预警方法，根据关闭操作指令，控制第一自动巡边设备移动回第一初始位置，控制第二自动巡边设备移动回第二初始位置，这样可避免自动巡边设备影响后续的作业，例如避免自动巡边设备影响换卷过程。
在本申请的一些实施例中，所述根据所述实际边缘信息对应的边缘位置超出膜卷的预设边缘范围，控制显示设备作出预警反应，包括：根据所述实际边缘信息对应的边缘位置超出膜卷的预设边缘范围，生成预警信息，将所述预警信息发给显示屏进行显示；和/或，根据所述实际边缘信息对应的边缘位置超出膜卷的预设边缘范围，向报警器发出预警指令，控制报警器报警。本申请实施例的收卷预警方法，通过显示屏显示预警信息，和/或通过控制报警器报警，可使操作人员及时且直观的获取到预警信息，从而能够及时对膜卷进行检查。
在本申请的一些实施例中，在控制显示设备作出预警反应之后，还包括：接收输入的关闭操作指令；根据输入的关闭操作指令，判断所述预警时间段结束，停止获取膜卷的轴向的实际边缘信息，并控制所述显示设备 停止预警反应。本申请实施例的收卷预警方法，根据关闭操作指令，停止获取膜卷的轴向的实际边缘信息，并控制显示设备停止预警反应，从而在操作人员输入关闭操作指令后，能够及时关闭预警程序和显示设备，避免显示设备的预警反应持续开启，对操作人员造成困扰。
在本申请的一些实施例中，所述方法还包括：在接收输入的关闭操作指令预设时长后，再次开始获取膜卷的轴向的实际边缘信息，并根据所述实际边缘信息对应的边缘位置超出膜卷的所述预设边缘范围，控制显示设备作出预警反应。本申请实施例的收卷预警方法，在接收到关闭操作指令预设时长后，再次开始获取膜卷的轴向的实际边缘信息，并根据实际边缘信息超出膜卷的预设边缘范围控制显示设备作出预警反应，也即预警程序停止预设时长后，再次开启预警程序。一方面程序能够在预设时长后自动开启，例如在误预警时，在预设时长后自动开启，提高了收卷预警方法的自动化程度。
在本申请的一些实施例中，所述方法还包括：获取预存的操作记录、操作记录对应的操作人标识、操作记录对应的膜卷的膜卷标识信息以及该膜卷的收卷过程的预警信息、参照边缘位置及实际偏移量的最大值，将所述操作记录、所述操作人标识、所述膜卷标识信息、所述预警信息、所述参照边缘位置、所述实际偏移量的最大值关联并存储至本地数据库。本申请实施例的收卷预警方法，将相关信息进行关联存储至本地数据库中，使得每个膜卷的收卷过程的操作及监控信息可追溯。
本申请的第二方面提出了一种收卷预警系统，包括：控制器、检测构件和显示设备；所述检测构件用于检测膜卷的轴向的实际边缘信息，并将所述实际边缘信息发送给所述控制器；所述控制器用于本申请的第一方面提出的收卷预警方法；所述显示设备用于根据控制器的控制信息作出预警反应。
本申请实施例的技术方案中，通过检测构件检测膜卷的实际边缘信息，并将该实际边缘信息发给控制器，控制器通过获取预警时间段内的膜卷的轴向的实际边缘信息，在实际边缘信息对应的边缘位置超出膜卷的预设边缘范围时，控制显示设备作出预警反应，操作人员可根据显示设备的预警 反应，查看收卷过程的膜卷是否出现“炮筒”现象。“炮筒”现象预警不再依靠人工实时观察，降低了操作人员的劳动强度，且可靠性提高。
另外，根据本申请的收卷预警系统，还可具有如下附加的技术特征：
在本申请的一些实施例中，所述收卷预警系统还包括信号接收组件；所述信号接收组件与所述检测构件和所述控制器连接，所述信号接收组件用于接收所述检测构件发出的检测信息并将该所述检测信息发送给所述控制器。本申请实施例的收卷预警系统通过信号接收组件将检测构件的检测信息发送给控制器，使得检测信息能够被控制器及时接收，提高了检测信息的传输稳定性。
在本申请的一些实施例中，所述检测构件包括两自动巡边设备，所述两自动巡边设备分别用于对膜卷的轴向的两端进行自动巡边，以检测膜卷的轴向的两端的实际边缘信息。本申请实施例的收卷预警系统通过两自动巡边设备分别对膜卷的轴向的两端进行自动巡边，膜卷的实际边缘信息检测准确性高。
在本申请的一些实施例中，所述检测构件还包括导轨，所述导轨用于与收卷机构的收卷轴的轴向平行设置，所述两自动巡边设备均可滑动的安装在所述导轨上。本申请实施例的收卷预警系统的导轨与收卷轴的轴向平行设置，从而两自动巡边设备沿导轨移动，也即是沿膜卷的轴向移动，能够更准确的获知两自动巡边设备的移动距离，从而可更好的通过自动巡边设备获知膜卷的边缘位置信息。
在本申请的一些实施例中，所述导轨上设置有长度刻度线。本申请实施例的收卷预警系统在导轨上设置的长度刻度线，可方便于检测构件的安装，例如在安装导轨和自动巡边设备时，可通过长度刻度线定位导轨的中心位置以及自动巡边设备的安装位置。
在本申请的一些实施例中，所述导轨的中部为零刻度线，所述零刻度线两侧的刻度分别逐渐递增；两所述自动巡边设备分别为第一自动巡边设备和第二自动巡边设备，所述第一自动巡边设备和所述第二自动巡边设备分别设置在所述零刻度线的两侧。本申请实施例的收卷预警系统的零刻度线设置在导轨的中部，零刻度线两侧的刻度分别逐渐递增，这样零刻度线 也即是导轨的中心位置，在导轨安装时，便于操作人员定位导轨的位置；同时，导轨两侧递增的刻度，方便于两自动巡边设备的定位安装。
在本申请的一些实施例中，所述导轨的两端分别设置有第一初始位置和第二初始位置，所述第一初始位置与所述第二初始位置之间的距离大于膜卷的轴向长度；在初始状态，所述第一自动巡边设备位于所述第一初始位置，所述第二自动巡边设备位于所述第二初始位置。本申请实施例的收卷预警系统，导轨上的第一初始位置与第二初始位置之间的距离大于膜卷的轴向长度，这样，两自动巡边设备分别位于第一初始位置和第二初始位置时，可避免自动巡边设备对膜卷造成干涉；并且在实际收卷过程中，可将膜卷置于第一初始位置和第二初始位置之间，如此，两自动巡边设备是从远端向内移动以首次定位膜卷的边缘位置，避免膜卷对自动巡边设备的巡边准确性造成影响。
在本申请的一些实施例中，所述导轨在所述零刻度线的两侧分别设置有第一限位位置和第二限位位置，所述第一限位位置和第二限位位置位于所述第一初始位置和所述第二初始位置之间，所述第一限位位置和第一初始位置位于所述零刻度线的一侧，所述第二限位位置和所述第二初始位置位于所述零刻度线的另一侧，所述第一限位位置和所述第二限位位置均与所述零刻度线间隔预设距离，所述预设距离大于零。所述第一自动巡边设备配置为在所述第一初始位置和所述第一限位位置之间移动，所述第二自动巡边设备配置为在所述第二初始位置和所述第二限位位置之间移动。本申请实施例的收卷预警系统，第一自动巡边设备配置为在第一初始位置和第一限位位置之间移动，第二自动巡边设备配置为在第二初始位置和第二限位位置之间移动，避免了在某些意外情况下，两自动巡边设备定位不到膜卷的边缘位置而导致第二自动巡边设备与第一自动巡边设备相互碰撞的情况发生。
在本申请的一些实施例中，所述显示设备包括显示屏，所述显示屏用于显示控制器生成的预警信息；和/或所述显示设备包括报警器，所述报警器用于根据控制器发出的预警指令进行报警。本申请实施例的收卷预警系统，通过显示屏显示预警信息，和/或通过控制报警器报警，可使操作人员 及时且直观的获取到预警信息，从而能够及时对膜卷进行检查。
本申请的第三方面提出了一种收卷机构，包括收卷轴和本申请的第二方面提出的收卷预警系统，所述检测构件对应所述收卷轴设置。
本申请实施例的技术方案中，通过检测构件检测膜卷的实际边缘信息，并将该检测信息发给控制器，控制器通过获取预警时间段内的膜卷的轴向的实际边缘信息，在实际边缘信息对应的边缘位置超出膜卷的预设边缘范围时，控制显示设备作出预警反应，操作人员可根据显示设备的预警反应，查看收卷过程的膜卷是否出现“炮筒”现象。“炮筒”现象预警不再依靠人工实时观察，降低了操作人员的劳动强度，且可靠性提高。
另外，根据本申请的收卷机构，还可具有如下附加的技术特征：
在本申请的一些实施例中，所述收卷机构包括两收卷轴，两所述收卷轴分别对应设置一所述检测构件。本申请实施例的收卷机构的两收卷轴可交替使用进行收卷作业，以使收卷对应的作业工序连续生产。通过对应两个收卷轴分别设置检测构件，可对两根收卷轴上的膜卷均进行检测，以提高连续生产过程的所有膜卷的质量，避免膜卷“炮筒”现象的发生。
本申请的第四方面提出了一种涂布机，包括本申请的任意一实施例提出的收卷机构。
本申请提供的收卷预警方法、收卷预警系统、收卷机构和涂布机，均可以在膜卷的边缘位置超出膜卷的预设边缘范围时，提醒操作人员查看收卷过程的膜卷是否出现“炮筒”现象。“炮筒”现象预警不再依靠人工实时观察，降低了操作人员的劳动强度，且可靠性提高。
附图说明
通过阅读下文优选实施方式的详细描述，各种其他的优点和益处对于本领域普通技术人员将变得清楚明了。附图仅用于示出优选实施方式的目的，而并不认为是对本申请的限制。而且在整个附图中，用相同的附图标记表示相同的部件。在附图中：
图1为本申请一些实施例提供的收卷预警方法的流程图；
图2为本申请一些实施例提供的根据实际边缘信息对应的边缘位置超 出膜卷的预设边缘范围，控制显示设备作出预警反应的流程图；
图3为本申请一些实施例提供的膜卷的轴向两端的参照边缘位置的获取流程图；
图4为本申请一些实施例的收卷预警系统的示意图；
图5为图4所示的收卷预警系统的自动巡边设备处于自动巡边状态的示意图；
图6为本申请一些实施例的收卷预警系统的实际监控过程图。
附图标记如下：
1-膜卷；11-参照边缘位置；12-实际边缘信息对应的边缘位置；13-炮筒起始位置；14-实际偏移量；2-卷筒；3-控制器；4-信号接收组件；5-导轨；51-零刻度线；52-第一初始位置；53-第二初始位置；6-显示屏；71-激光束；72-第一自动巡边设备；73-第二自动巡边设备；8-报警器。
具体实施方式
下面将结合附图对本申请技术方案的实施例进行详细的描述。以下实施例仅用于更加清楚地说明本申请的技术方案，因此只作为示例，而不能以此来限制本申请的保护范围。
除非另有定义，本文所使用的所有的技术和科学术语与属于本申请的技术领域的技术人员通常理解的含义相同；本文中所使用的术语只是为了描述具体的实施例的目的，不是旨在于限制本申请；本申请的说明书和权利要求书及上述附图说明中的术语“包括”和“具有”以及它们的任何变形，意图在于覆盖不排他的包含。
在本申请实施例的描述中，技术术语“第一”“第二”等仅用于区别不同对象，而不能理解为指示或暗示相对重要性或者隐含指明所指示的技术特征的数量、特定顺序或主次关系。在本申请实施例的描述中，“多个”的含义是两个以上，除非另有明确具体的限定。
在本文中提及“实施例”意味着，结合实施例描述的特定特征、结构或特性可以包含在本申请的至少一个实施例中。在说明书中的各个位置出现该短语并不一定均是指相同的实施例，也不是与其它实施例互斥的独立 的或备选的实施例。本领域技术人员显式地和隐式地理解的是，本文所描述的实施例可以与其它实施例相结合。
在本申请实施例的描述中，术语“和/或”仅仅是一种描述关联对象的关联关系，表示可以存在三种关系，例如A和/或B，可以表示：单独存在A，同时存在A和B，单独存在B这三种情况。另外，本文中字符“/”，一般表示前后关联对象是一种“或”的关系。
在本申请实施例的描述中，术语“多个”指的是两个以上(包括两个)，同理，“多组”指的是两组以上(包括两组)，“多片”指的是两片以上(包括两片)。
在本申请实施例的描述中，技术术语“中心”“纵向”“横向”“长度”“宽度”“厚度”“上”“下”“前”“后”“左”“右”“竖直”“水平”“顶”“底”“内”“外”“顺时针”“逆时针”“轴向”“径向”“周向”等指示的方位或位置关系为基于附图所示的方位或位置关系，仅是为了便于描述本申请实施例和简化描述，而不是指示或暗示所指的装置或元件必须具有特定的方位、以特定的方位构造和操作，因此不能理解为对本申请实施例的限制。
在本申请实施例的描述中，除非另有明确的规定和限定，技术术语“安装”“相连”“连接”“固定”等术语应做广义理解，例如，可以是固定连接，也可以是可拆卸连接，或成一体；也可以是机械连接，也可以是电连接；可以是直接相连，也可以通过中间媒介间接相连，可以是两个元件内部的连通或两个元件的相互作用关系。对于本领域的普通技术人员而言，可以根据具体情况理解上述术语在本申请实施例中的具体含义。
目前，从市场形势的发展来看，动力电池的应用越加广泛。动力电池不仅被应用于水力、火力、风力和太阳能电站等储能电源系统，而且还被广泛应用于电动自行车、电动摩托车、电动汽车等电动交通工具，以及军事装备和航空航天等多个领域。随着动力电池应用领域的不断扩大，其市场的需求量也在不断地扩增。
动力电池在生产过程中，对极片进行涂布是必不可少的工序，其中收卷机构是涂布工序的最后组成部分，涂布工序之后是对极片进行冷压处理 的工序。发明人注意到涂布工序的收卷机构完成的膜卷出现异常时，会影响后续的冷压处理工序，进而直接影响动力电池的产出质量。在涂布工序中，收卷机构完成的膜卷最常见的异常是“炮筒”现象。“炮筒”现象也即部分极片沿膜卷的轴向往一端偏移，沿膜卷径向上的多层极片的宽度(极片的宽度方向与膜卷的轴向一致)中心错位，膜卷的端面平齐度较差的现象。发明人发现，涂布工序完成的膜卷出现轻微“炮筒”时，会影响冷压处理工序的生产速度，但不会造成实际损失；涂布工序完成的膜卷出现严重“炮筒”时，冷压处理工序的设备受纠偏可调区间的限位影响，无法对膜卷释放的极片进行纠偏，往往会导致冷压处理工序无法生产。
针对于膜卷出现严重“炮筒”的情况，需要对这些异常膜卷进行处理。现有技术在处理异常膜卷的过程中，容易出现极耳打皱，且处理完成的极片进行冷压时，也容易出现断带，费时、费力、占用生产资源，对产品优率和生产效率影响极大。因此，无论是新工厂或成熟稳定的工厂，涂布工序的收卷机构都要尽可能的避免产生严重炮筒，以避免由此带来的沉重损失。
当前涂布工序主要通过调整收卷张力、调整锥度系数、调整起始卷径、调整过辊水平度来改善“炮筒”现象，但不同极片对以上影响因子(影响因子也即收卷张力、锥度系数、起始卷径和过辊水平度)的要求有所不同，加上涂布工序中的其他异常，使膜卷中间不可避免的夹杂摩擦系数较小的基材，导致收卷时极片容易发生滑动，涂布工序中膜卷出现“炮筒”的风险一直存在，且不可避免。在新工厂的新设备的调试阶段，由于不可预知的风险，更是大大增加了异常发生的可能性。
目前对于膜卷“炮筒”现象的监管，主要依靠操作人员在收卷机构收卷的过程中，实时观察膜卷是否发生“炮筒”，可靠性较低，且操作人员的劳动强度较大。针对于此，发明人经过深入研究，提出了一种收卷预警方法，该收卷预警方法通过获取预警时间段内的膜卷的轴向的实际边缘信息，根据实际边缘信息对应的边缘位置超出膜卷的预设边缘范围，控制显示设备作出预警反应。这样，在膜卷的边缘位置超出膜卷预设边缘范围时，也即存在出现“炮筒”风险时，显示设备可作出预警反应，操作人员可根 据显示设备的预警反应，查看收卷过程的膜卷是否出现“炮筒”现象。“炮筒”现象预警不再依靠人工实时观察，可在涂布工序的膜卷形成“炮筒”的初期阶段即可作出预警，及时遏制膜卷“炮筒”恶化，避免造成实际损失，降低了操作人员的劳动强度，且可靠性提高。
本申请实施例公开的收卷预警方法可以但不限于用于涂布工序中对收卷机构收卷形成的膜卷进行预警。可以使用本申请实施例公开的收卷预警方法对其他工序，例如但不限于，冷压处理工序、模切分条工序中的收卷机构形成的膜卷进行预警，以能够及时发现工序收卷过程中的“炮筒”，避免膜卷发生严重“炮筒”。
其中，涂布工序是向基材上涂覆活性物质以形成极片的过程。极片包括正极极片和负极极片，加工正极极片的涂布工序所使用的基材为正极基材，涂覆的活性物质为正极活性物质；加工负极极片的涂布工序所使用的基材为负极基材，涂覆的活性物质为负极活性物质。以锂离子电池为例，正极基材可为铝箔，正极活性物质可以为钴酸锂、磷酸铁锂、三元锂或锰酸锂等；负极基材可为铜箔，负极活性物质层包括负极活性物质，负极活性物质可以为碳或硅等。涂布工序形成的极片的边缘会存在留白区，也即涂布工序在向基材涂覆活性物质时，会预留基材的边缘不涂覆活性物质。极片涂覆有活性物质的部分形成极片的主体部，留白区用于形成极耳，极耳用于连接转接片或电极端子。在电池的充放电过程中，正极活性物质和负极活性物质与电解液发生反应，极耳连接电极端子以形成电流回路。
冷压处理工序是在涂布工序之后的极片加工步骤，其主要用于对涂布完成的极片进行冷压，以减少极片的体积，同时可对极片进行预分切。模切分条工序在冷压处理工序之后，模切分条工序主要是将极片从宽度方向的中部进行分切，使形成的极片仅一侧具有极耳，为后续极片卷绕或叠放形成电池单体做准备。
以下实施例为了方便说明，以本申请一实施例的收卷预警方法应用于涂布工序为例进行说明。
本实施例提供一种能够执行上述收卷预警方法的收卷预警系统，该收卷预警系统应用于收卷机构中，收卷机构上设置有收卷轴和驱动收卷轴转 动的电机及传动组件。收卷机构可应用于涂布机。
收卷机构是用于完成极片收卷的设备，也即用于将极片卷绕形成膜卷1的设备。在当前收卷过程开始前，先将卷筒2安装到收卷轴上，然后将极片的端部粘贴到卷筒2上，通过电机驱动收卷轴带动卷筒2转动，卷筒2上卷绕极片，最终形成膜卷1。
其中，电机也称为电动机，其是收卷的动力设备。电机能够将电能转化为机械能，电机的工作原理是依靠磁场对电流受力的作用使电机转动。
收卷轴是带动卷筒2转动的轴，其通过传动组件与电机连接，在电机转动作用下，收卷轴能够自转。
卷筒2是用于卷绕极片的筒体，其通常为空心的圆柱形，卷筒2的两端用于与收卷轴连接，且与收卷轴同轴设置，卷筒2的周向用于卷绕极片。
膜卷1指的是卷筒2上的极片在持续卷绕过程中形成的筒状结构，膜卷1上的极片的宽度方向与膜卷1的轴向一致，膜卷1的径向上包括有多层连续卷绕的极片。
涂布机是用于完成极片的涂布工序的设备。
根据本申请的一些实施例，参照图1所示，图1为本申请一些实施例提供的收卷预警方法的流程图。本申请提供了一种收卷预警方法，包括：
步骤S1：获取预警时间段内的膜卷的轴向的实际边缘信息。其中预警时间段是当前膜卷的收卷过程对应的局部时间或全部时间。
步骤S2：根据实际边缘信息对应的边缘位置超出膜卷的预设边缘范围，控制显示设备作出预警反应。
该收卷预警方法应用于控制器3，控制器3是具有信号处理、运算等功能的控制单元，其具体可以是PLC(PLC指可编程逻辑控制器)控制系统。
当前膜卷指的是处于收卷过程中的膜卷1，该膜卷1处于被监控状态。当前膜卷的收卷过程也即当前膜卷从开始收卷至收卷完成的过程。当前膜卷的收卷过程对应的局部时间或全部时间，也即当前膜卷从开始收卷至收卷完成的部分时间段或者整个时间段。
通常，预警时间段是从开始收卷后的一定时间开始。这是因为，在收卷的初始阶段，膜卷1刚刚开始形成，膜卷1的直径较小，膜卷1在卷筒 2上形成初始位置，基本不会产生“炮筒”。同时，初始阶段的膜卷1的边缘位置实际上也是膜卷1形成的基础位置，其可作为后续预警时间段的膜卷1的参照边缘位置。
膜卷1的轴向的实际边缘信息指的是膜卷1上的所有极片在膜卷1的轴向上的实际边缘信息，在涂布工序中，膜卷1的实际边缘信息也即留白区的实际边缘信息。膜卷1的轴向有两端，所以膜卷1的轴向的实际边缘信息可包括膜卷1的轴向的两端的实际边缘信息。步骤S1中，获取预警时间段内的膜卷1的轴向的实际边缘信息，该实际边缘信息可在控制器处理后对应于量化的数据信息。
预设边缘范围是预先设置在控制器3内的参照边缘范围，该预设边缘范围可通过与控制器3连接的输入装置(输入装置可以是带有触屏输入功能的显示面板等)输入至控制器3，并可通过输入装置进行更改。该预设边缘范围也可以是相应的位置信息，其也是可量化的数据信息。在预设边缘范围内，一般认为膜卷1不会发生严重炮筒，生产完成的膜卷1不会对生产造成影响；超出预设边缘范围时，可认为膜卷1的极片沿膜卷1的轴向发生偏移较大，此时具有发生严重“炮筒”现象的风险。
显示设备是能够做出报警反应的设备，具体可以是显示预警信息的显示屏6、能够发出声音报警的报警器8、能够发出光电报警的报警器8等。
显示设备作出的预警反应是能够对操作人员进行提醒的反应，例如，显示屏6上显示预警信息，报警器8发出声音或光等，对操作人员进行提醒。
通过获取预警时间段内的膜卷1的轴向的实际边缘信息，在实际边缘信息对应的边缘位置超出膜卷1的预设边缘范围时，控制显示设备作出预警反应。这样，在膜卷1的边缘位置超出膜卷1预设边缘范围时，也即存在出现严重“炮筒”风险时，显示设备可作出预警反应，操作人员可根据显示设备的预警反应，查看收卷过程的膜卷1是否出现“炮筒”现象。“炮筒”现象预警不再依靠人工实时观察，可在涂布工序的膜卷1形成“炮筒”的初期阶段即可作出预警，及时遏制膜卷1“炮筒”恶化，避免造成实际损失，降低了操作人员的劳动强度，且可靠性提高。
根据本申请的一些实施例，本实施例膜卷预警方法包括在预警时间段内，分别获取膜卷的轴向两端的实际边缘信息；根据膜卷的轴向两端的实际边缘信息中，至少一端的实际边缘信息对应的边缘位置超出该端对应的预设边缘范围时，控制显示设备作出预警反应。
具体的，膜卷1轴向的两端分别为第一端和第二端，可通过与控制器3连接的输入装置(输入装置可以是带有触屏输入功能的显示面板等)针对第一端和第二端分别向控制器3输入相应的预设边缘范围。分别获取膜卷1的轴向两端的实际边缘信息也即是分别获取膜卷1的轴向第一端的实际边缘信息和膜卷1的轴向第二端的实际边缘信息。控制器3用于将获取的第一端的实际边缘信息对应的边缘位置与第一端的预设边缘范围进行比较，将获取的第二端的实际边缘信息对应的边缘位置与第二端的预设边缘范围进行比较。在第一端的实际边缘信息对应的边缘位置超出第一端的预设边缘范围时，和/或，第二端的实际边缘信息对应的边缘位置超出第二端的预设边缘范围时，控制器3控制显示设备作出预警反应。
本申请实施例的收卷预警方法通过获取膜卷1的轴向两端的实际边缘信息，在膜卷1的轴向的两端中的任意一端的实际边缘信息对应的边缘位置超出该端对应的预设边缘范围时控制显示设备作出预警反应，从而能够在膜卷1的任意一端出现异常时，及时提醒操作人员，进一步提高了对“炮筒”预警的可靠性。
根据本申请的一些实施例，本实施例膜卷预警方法包括：在预警时间段内，分别获取膜卷的轴向两端的实时的实际边缘信息；根据膜卷的轴向两端的实时的实际边缘信息中，至少一端的实时的实际边缘信息对应的边缘位置超出该端对应的预设边缘范围时，控制显示设备作出预警反应。
轴向两端的实时的实际边缘信息，也即是在预警时间段内，任意时间点的第一端的实际边缘信息和第二端的实际边缘信息。
通过获取膜卷1的轴向两端的实时的实际边缘信息，并在两端的实时的实际边缘信息中的一者对应的边缘位置超出该端对应的预设边缘范围时，控制显示设备作出预警反应，从而通过实时监控，可在膜卷1发生“炮筒”现象的初期即可作出预警提示，有利于避免严重“炮筒”的形成。
根据本申请的一些实施例，参照图2所示，图2为本申请一些实施例的根据实际边缘信息对应的边缘位置超出膜卷的预设边缘范围，控制显示设备作出预警反应的流程图，步骤S2包括：
步骤S21：基于膜卷的轴向两端的实际边缘信息对应的边缘位置和膜卷的轴向两端的参照边缘位置，分别得到膜卷1的轴向两端的实际偏移量。
步骤S22：根据膜卷的轴向两端的实际偏移量中的至少一端的实际偏移量大于预设偏移量，控制显示设备作出预警反应。
参照边缘位置可理解为膜卷1在收卷过程中的基准位置，该位置可以是人为通过输入装置(输入装置可以是带有触屏输入功能的显示面板等)设定到控制器3内的位置参数，也可以是通过获取当前收卷过程中膜卷1形成初期的边缘位置而确定。膜卷1的边缘位置与参照边缘位置一致时，认为膜卷1处于最理想的卷绕状态，其形成的膜卷1的端面为垂直于膜卷1轴向的平面。
膜卷1的第一端和第二端分别对应相应的参照边缘位置。将第一端的实际边缘信息对应的边缘位置与第一端的参照边缘位置进行比较，也即是第一端的实际边缘信息对应的位置参数与第一端的参照边缘位置对应的参数作差而得到第一端的实际偏移量。将第二端的实际边缘信息对应的边缘位置与第二端的参照边缘位置进行比较，也即是第二端的实际边缘信息对应的位置参数与第二端的参照边缘位置对应的参数作差而得到第二端的实际偏移量。
预设偏移量是预先通过输入装置(输入装置可以是带有触屏输入功能的显示面板等)输入至控制器3内的位移参数，其是膜卷1的边缘位置相对参照边缘位置允许的最大偏移量。第一端的预设偏移量是膜卷1第一端的边缘位置可以相对第一端的参照边缘位置偏移的最大偏移量，第二端的预设偏移量是膜卷1第二端的边缘位置可以相对第二端的参照边缘位置偏移的最大偏移量。在膜卷1的第一端的实际偏移量大于预设偏移量时，可认为膜卷1的第一端超出预设边缘范围，同理，在膜卷1的第二端的实际偏移量大于预设偏移量时，可认为膜卷1的第二端超出预设边缘范围。
第一端和第二端的预设偏移量可以相同也可不同。在本实施例中，第 一端和第二端的预设偏移量相同。预设偏移量可在0-15毫米范围内进行设定，具体可以是1毫米、2毫米、5毫米、10毫米、15毫米等。
通过基于膜卷1的轴向两端的实际边缘信息对应的边缘位置和膜卷1的轴向两端的参照边缘位置，分别得到膜卷1的轴向两端的实际偏移量，在至少一端的实际偏移量大于预设偏移量时，控制显示设备作出预警反应。其中，参照边缘位置可以是当前收卷过程中膜卷1形成初期的边缘位置，实际偏移量通过实际边缘信息对应的边缘位置和参照边缘位置关联得出，并将实际偏移量作为是否发生“炮筒”的参考值，其准确性较高，膜卷1的异常检测更加准确，降低了误预警的几率。
根据本申请的一些实施例，参照图3所示，图3为本申请一些实施例的膜卷1的轴向两端的参照边缘位置的获取流程图，本实施例膜卷预警方法还包括:膜卷1的轴向两端的参照边缘位置的获取，具体该步骤包括：
步骤S31：在预定时间段内，分别获取膜卷的轴向的两端的实际边缘信息。其中，预定时间段和预警时间段处于同一个收卷过程中，且预定时间段处于预警时间段之前。
步骤S32：基于预定时间段内获取的膜卷的轴向两端中第一端的实际边缘信息对应的边缘位置，计算膜卷的第一端在预定时间段内的平均位置，膜卷在预定时间段内的第一端的平均位置为膜卷的第一端的参照边缘位置；基于预定时间段内获取的膜卷的轴向两端中第二端的实际边缘信息对应的边缘位置，计算膜卷的第二端在预定时间段内的平均位置，膜卷在预定时间段内的第二端的平均位置为膜卷1的第二端的参照边缘位置。
其中，预定时间段是当前膜卷的收卷过程中的一个时间段，其通常是收卷过程的初始阶段的一个时间段。
预定时间段内的膜卷1的轴向的两端的实际边缘信息对应的位置信息，通常以位置数据进行显示。预定时间段内实时对膜卷1的第一端的实际边缘信息和第二端的实际边缘信息进行获取，每端的实际边缘信息对应的边缘位置在预定时间段内可能是不变的，也可能是微变的。
膜卷1的第一端在预定时间段内的平均位置，也即在预定时间段内，获取到的膜卷1的第一端的实际边缘信息对应的位置数据的平均值。膜卷 1的第二端在预定时间段内的平均位置，也即在预定时间段内，获取到的膜卷1的第二端的实际边缘信息对应的位置数据的平均值。
预定时间段与预警时间段可以是连续的，也即预定时间段结束后预警时间段即开始。
通过将预警时间段之前的预定时间段内的膜卷1的轴向两端的边缘位置的平均值，分别作为膜卷1的轴向两端的参照边缘位置，由于预定时间段和预警时间段处于同一个收卷过程中，且预定时间段处于预警时间段之前，所以预定时间段的边缘位置可认为是当前膜卷形成初期的边缘位置位置，以当前膜卷形成初期的边缘位置的平均值作为参照边缘位置，来计算当前膜卷预警时间段内的膜卷1的两端的实际偏移量，准确度较高，膜卷1的异常检测更加准确，降低了误预警的几率；且不需要对不同收卷过程的膜卷1的位置进行校准，操作更加方便。
根据本申请的一些实施例，预定时间段为当前收卷过程开始后的60秒-120秒；和/或预警时间段为收卷过程开始后的120秒至该收卷过程结束的时间。
预定时间段为当前收卷过程开始后的60秒-120秒，也即收卷轴开始带动卷筒2转动，以进行收卷后的60秒到120秒的时间为预定时间。
可以理解的是，在收卷过程刚开始的60秒之内完成的膜卷1的直径较小，膜卷1在卷筒2上的位置稳定性较差，膜卷1的端面对齐度较差，也即，膜卷的轴向两端的边缘位置稳定性较差；在60秒到120秒的时间段内，膜卷1的端面平齐度较为稳定，所以以收卷过程开始的60秒到120秒作为预定时间获取的参照边缘位置，对整体膜卷1的参照意义较好，从而可准确预警后续膜卷1的“炮筒”现象。
以当前收卷过程开始后的120秒作为预警时间段的起始时间，能够在收卷过程中尽可能早的发现“炮筒”现象，避免发生严重“炮筒”。
根据本申请的一些实施例，本实施例收卷预警方法还包括：获取自动换卷作业的上一收卷过程的切带信息，根据接收到切带信息的时间作为当前收卷过程的开始时间。或获取收卷机构开启后的开始走带信息，根据接收到开始走带信息的时间作为当前收卷过程的开始时间。
一个膜卷1收卷完成后，需要将极片切断，然后再将极片接入新的卷筒2开始新的膜卷1的收卷，该过程也即是换卷作业。换卷作业可以自动完成，也可以手动完成，其中，自动完成换卷作业的过程可称为自动换卷作业，手动完成换卷作业的过程可称为手动换卷作业。
自动换卷作业的收卷机构通常包括两根交替使用的收卷轴。在一根收卷轴执行收卷作业时，另一根收卷轴执行准备作业(准备作业包括将卷筒2安装到收卷轴上，向卷筒2上贴双面胶等准备工作)，执行收卷作业的收卷轴上的膜卷1准备出货时，操作人员通过点击收卷机构上的自动换卷按钮，控制切刀升起到指定位置，并控制准备接入极片的卷筒2(也即执行准备作业的收卷轴上的卷筒2)开始空转至线速度和涂布工序的生产速度保持一致；而后切刀执行裁切动作，将极片切断的同时，上一膜卷收卷完成、新接入极片的收卷轴开始收卷作业，切刀缓慢下降至初始位置后，一个自动收卷过程完成。操作人员利用相应的机械设备，将收卷完成的膜卷1从收卷轴上拆卸下来，并在该收卷轴上更换上新的卷筒2，再次开始做该收卷轴收卷前的准备工作。在涂布工序中，自动换卷作业使得涂布工序可连续生产，不需要频繁停机。
切带信息是切刀切断极片的信息，也即，一个膜卷1收卷完成后，切刀执行裁切动作将极片切断，以使生产过程中的极片与膜卷1上的极片断开的信息。具体可将切刀执行裁切动作的信息作为切带信息，也即控制器获取到切刀执行裁切动作时，认为获取到了切带信息。
在自动换卷作业的收卷机构中，将获取到前一收卷过程的切带信息的时间作为当前收卷过程的开始时间，能够对连续生产的膜卷进行自动监控，实现每个收卷过程开始时间的智能判断，提高了收卷预警的自动化程度。
手动换卷作业的收卷机构，通常设置一根收卷轴，在收卷轴完成一个膜卷1的收卷作业时，需要暂停生产后，将极片切断，然后将收卷轴上的卷筒2和膜卷1拆卸下来，更换上新的卷筒2，而后再将极片接入新的卷筒2，重新开始生产。收卷过程与涂布工序的其他作业是连续进行的，在手动换卷暂停生产时，涂布工序的所有作业基本都会停止，也即涂布机停机，在换卷完成再次开始生产时，所有作业重新开启，也即涂布机开机。
收卷机构开启后的开始走带信息，也即涂布机由关闭状态至开启状态后，极片开始沿生产流程进行移动的信息。
在手动换卷作业的收卷机构中，将接收到收卷机构开启后的开始走带信息的时间作为当前收卷过程的开始时间，可实现对每个收卷过程开始时间的智能判断，提高了收卷预警的自动化程度。
需要说明的是，在其他工况下，涂布机也可能停机，例如：极片断裂需要接带的停机工况、临时缺少涂布工序使用的浆料导致的停机工况、操作人员下班或休息时的停机工况、设备异常的停机工况等。在这些工况下，涂布机的所有作业同样与收卷机构同步开启或关闭。所以，在涂布机的任意一种停机再开机的工况下，都可以将接收到收卷机构开启后的开始走带信息的时间作为当前收卷过程的开始时间，以对涂布机开机后的第一个膜卷的开始时间进行智能判断，提高了收卷预警的自动化程度。
根据本申请的一些实施例，收卷预警方法还包括控制自动巡边设备对膜卷的轴向的边缘位置进行自动巡边定位；获取自动巡边设备的位置信息，以自动巡边设备的位置信息作为膜卷1的轴向的实际边缘信息。
自动巡边设备是自动对膜卷的边缘进行定位巡边的设备，其可以自动定位膜卷1的边缘并能够实时输出位置信息。常见的自动巡边设备是激光自动巡边设备，激光自动巡边设备通过激光感应组件对膜卷1的边缘进行识别。具体的在涂布工序中，电机带动激光感应组件移动，激光感应组件对极片的留白区的边缘进行识别定位。激光感应组件携带有位置传感器等位移感应组件，通过位移感应组件可以实时获取激光感应组件的位置，而激光感应组件的位置与膜卷1的边缘位置是对应的，所以可通过获取自动巡边设备的位置信息作为膜卷1的轴向的实际边缘信息。
激光自动巡边设备可以通过电机正转和反转，控制激光感应组件的正向和反向移动。在实际应用时，分别将两电机配置成正转(或反转)时，两激光感应组件均向相互远离的方向移动，从而使激光感应组件向外移动的距离为正值。这样在自动巡边设备持续巡边的过程中，自动巡边设备逐渐向外巡边，其移动的位移是正向的，顺应于操作人员的正向思维习惯，便于换算自动巡边设备移动的位移。
激光自动巡边设备可在膜卷1的整个收卷过程中实时对膜卷1的边缘位置进行定位。也即在预定时间段和预警时间段内的膜卷1的轴向的实际边缘信息的获取均可通过自动巡边设备实现。
通过控制激光自动巡边设备对膜卷1的轴向的边缘位置进行自动定位，并以自动巡边设备的位置信息作为膜卷1的轴向的实际边缘信息，能够实现膜卷1的实际边缘信息的实时获取，膜卷1的实际边缘信息获取方便且准确性较高。
根据本申请的一些实施例，控制自动巡边设备对膜卷的轴向的边缘位置进行自动巡边定位，包括：控制膜卷两端的自动巡边设备分别对膜卷的轴向的两端的边缘位置进行自动巡边定位。
膜卷两端的自动巡边设备分别为第一自动巡边设备72和第二自动巡边设备73，第一自动巡边设备72用于对膜卷1的轴向的第一端的边缘位置进行自动巡边定位，第二自动巡边设备73用于对膜卷1的轴向的第二端的边缘位置进行自动巡边定位。
本申请实施例的收卷预警方法，通过控制膜卷两端的自动巡边设备分别对膜卷1的轴向的两端的边缘位置进行自动巡边定位，能够实时获取膜卷1的轴向的两端的膜卷1的实际边缘信息，信息获取准确且方便。
根据本申请的一些实施例，控制膜卷两端的自动巡边设备分别对膜卷1的轴向的两端的边缘位置进行自动巡边定位的步骤，包括：控制第一自动巡边设备72从第一初始位置52移动至检测到膜卷1的轴向的第一端的边缘位置的位置，控制第一自动巡边设备72对膜卷1的轴向的第一端的边缘位置进行自动巡边；控制第二自动巡边设备73从第二初始位置53移动至检测到膜卷1的轴向的第二端的边缘位置的位置，控制第二自动巡边设备73对膜卷1的轴向的第二端的边缘位置进行自动巡边。
其中，膜卷两端的自动巡边设备分别为第一自动巡边设备和第二自动巡边设备，第一端和第二端分别为膜卷1的轴向的两端，第一初始位置52位于第一端远离第二端的一侧，第二初始位置53位于第二端远离第一端的一侧。
第一初始位置52是第一自动巡边设备72在初始状态所处的位置，也 可理解为第一自动巡边设备72在非使用状态下所处的位置。第二初始位置53是第二自动巡边设备73在初始状态所处的位置，也可理解为第二自动巡边设备73在非使用状态下所处的位置。第一初始位置52位于第一端远离第二端的一侧，使得第一自动巡边设备72是从没有膜卷1的位置向膜卷1所在的位置移动，第一自动巡边设备72在检测到膜卷1的第一端的边缘位置时，开始自动巡边。第二初始位置53位于第二端远离第一端的一侧，使得第二自动巡边设备73是从没有膜卷1的位置向膜卷1所在的位置移动，第二自动巡边设备73在检测到膜卷1的第二端的边缘位置时，开始自动巡边。自动巡边的过程中，膜卷1的轴向边缘在极片卷绕过程中，只可能发生沿轴向背离中心的偏转，所以第一自动巡边设备72在自动巡边的过程中可能的移动是由首次检测到第一端的边缘位置向第一初始位置52移动，第二自动巡边设备73在自动巡边的过程中可能的移动是由首次检测到第二端的边缘位置向第二初始位置53移动。
本申请实施例的收卷预警方法，第一初始位置52位于第一端远离第二端的一侧，从而第一自动巡边设备72是从第一初始位置52向内巡边，以首次定位膜卷1轴向的第一端的边缘位置；第二初始位置53位于第二端远离第一端的一侧，第二自动巡边设备73是从远离膜卷1的第二初始位置53向内巡边，以首次定位膜卷1轴向的第二端的边缘位置。由于自动巡边设备时通过感应极片而进行定位，两自动巡边设备首次定位膜卷1的边缘位置不易受膜卷1的影响，定位更加准确。
根据本申请的一些实施例中，在控制显示设备作出预警反应之后，还包括：根据关闭操作指令，控制第一自动巡边设备72移动回第一初始位置52，控制第二自动巡边设备73移动回第二初始位置53。
关闭操作指令可以是操作人员手动输入的指令，也可以是控制器3基于其他情况发出的关闭操作指令。在本实施例中，关闭操作指令是操作人员手动输入。具体的，在显示设备作出预警反应后，操作人员通过在输入装置(输入装置可以是带有触屏输入功能的显示面板等)上进行操作，向控制器3输入关闭操作指令。
通过根据关闭操作指令控制第一自动巡边设备72移动回第一初始位 置52，控制第二自动巡边设备73移动回第二初始位置53，这样可避免自动巡边设备影响后续的作业，例如，避免自动巡边设备影响换卷过程。
根据本申请的一些实施例，根据实际边缘信息对应的边缘位置超出膜卷1的预设边缘范围，控制显示设备作出预警反应的步骤，也即步骤S2包括：根据实际边缘信息对应的边缘位置超出膜卷1的预设边缘范围，生成预警信息，将预警信息发给显示屏6进行显示；和/或，根据实际边缘信息对应的边缘位置超出膜卷1的预设边缘范围，向报警器8发出预警指令，控制报警器8报警。
预警信息可以是确认是否炮筒的提示信息，具体可以以弹窗的方式显示在显示屏6上。显示屏6是能够对信息进行显示的屏幕，具体可以是电脑的显示屏、PLC的显示界面等等。
预警指令是控制报警器8进行报警的控制指令。报警器8可以是蜂鸣报警器、光报警器或者声光报警器等等。
通过显示屏6显示预警信息，和/或通过控制报警器8报警，可使操作人员及时且直观的获取到预警信息，从而能够及时对膜卷1进行检查。
根据本申请的一些实施例，在控制显示设备作出预警反应之后，还包括：接收输入的关闭操作指令；根据输入的关闭操作指令，判断预警时间段结束，停止获取膜卷1的轴向的实际边缘信息，并控制显示设备停止预警反应。
关闭操作指令一般是操作人员输入，具体是在显示设备作出预警反应之后，操作人员手动通过输入装置(输入装置可以是带有触屏输入功能的显示面板等)输入关闭操作指令，控制器3接收到该关闭操作指令时，停止执行对膜卷1的预警程序。此时，操作人员可根据提醒，查看膜卷1是否出现“炮筒”现象，如果确认膜卷1出现炮筒，将膜卷1进行更换；如果未出现“炮筒”现象，可能是误预警，此时收卷过程正常进行。
通过根据关闭操作指令，停止获取膜卷1的轴向的实际边缘信息，并控制显示设备停止预警反应，从而在操作人员输入关闭操作指令后，能够及时关闭预警程序和显示设备，避免显示设备的预警反应持续开启，对操作人员造成困扰。
根据本申请的一些实施例，本实施例收卷预警方法还包括：在接收输入的关闭操作指令预设时长后，再次开始获取膜卷1的轴向的实际边缘信息，并根据实际边缘信息的边缘位置超出膜卷1的预设边缘范围，控制显示设备作出预警反应。
预设时长可以是通过输入装置(输入装置可以是带有触屏输入功能的显示面板等)输入，预先设置在控制器3内的时间，该预设时长可以是2分钟、3分钟、4分钟、5分钟或6分钟等，具体预设时长可根据实际操作工况进行确定。需要注意的是，预设时长首先要保证操作人员有足够的时间查看膜卷1是否发生炮筒。
判断接收输入的关闭操作指令是否达到预设时长的具体过程为：以控制器3接收到关闭操作指令时开始计时，在计时时长达到预设时长时，认为接收输入的关闭操作指令达到预设时长。控制器3响应于计时时长达到预设时长时，再次开始获取膜卷的轴向的实际边缘信息，也即再次控制重启收卷预警系统的预警程序，开始对膜卷1进行监控。
需要说明的是，控制器3在接收到关闭操作指令开始计时的过程中，如果出现更换膜卷1或停机情况时，计时停止。在停机的情况下，收卷预警系统的预警程序可根据涂布机开启后的开始走带信息进行启动；在自动换卷作业中，收卷预警系统的预警程序根据自动换卷作业中的上一收卷过程的切带信息进行启动。换言之，只有在当前膜卷未进行更换并继续生产的过程中，会在接收输入的关闭操作指令预设时长后，自动控制收卷预警系统重启。
本申请实施例的收卷预警方法，在接收到关闭操作指令预设时长后，再次开始获取膜卷1的轴向的实际边缘信息，并根据实际边缘信息对应的边缘位置超出膜卷1的预设边缘范围，控制显示设备作出预警反应，也即收卷预警系统的预警程序停止预设时长后，再次开启预警程序。在误预警时或者操作人员关闭预警程序后忘记观察膜卷等情况下，均可在预设时长后自动开启预警程序，再次对膜卷1进行监控，以提醒操作人员，提高了收卷预警方法的自动化程度和可靠性。
根据本申请的一些实施例，本实施例收卷预警方法还包括获取预存的 操作记录、操作记录对应的操作人标识、操作记录对应的膜卷1的膜卷1标识信息以及该膜卷1的收卷过程的预警信息、参照边缘位置及实际偏移量的最大值，将操作记录、操作人标识、膜卷1标识信息、预警信息、参照边缘位置、实际偏移量的最大值关联并存储至本地数据库。
操作记录是操作人员在收卷预警程序中执行的操作的记录，该操作记录包括但不限于输入关闭操作指令、出现“炮筒”现象时操作更换膜卷1的程序等。操作人标识也即是执行相应操作的人员对应的标识，该操作人标识可以是操作人的工牌工号、姓名等。膜卷的标识信息是对膜卷1进行区分的标识信息，该标识信息可以是膜卷号等。预警信息是控制器3在膜卷1收卷过程中，作出预警反应的信息，其包括但不限于是否发生预警、预警次数等。实际偏移量的最大值是膜卷1在收卷过程中，膜卷1的实际边缘信息对应的边缘位置相对于参照边缘位置偏移的最大值。
在使用双收卷轴的工况下，还可将膜卷1对应的收卷轴的信息一并关联后存储在本地数据库中。
通过将相关信息进行关联存储至本地数据库中，使得每个膜卷1的收卷过程的操作及监控信息可追溯。
根据本申请的一些实施例，参照图4所示，图4为本申请一些实施例的收卷预警系统的示意图。本实施例提供一种收卷预警系统，包括控制器3、检测构件和显示设备。检测构件用于检测膜卷1的轴向的实际边缘信息，并将实际边缘信息发送给控制器3；控制器3用于执行本申请实施例的收卷预警方法；显示设备用于根据控制器3的控制信息作出预警反应。
检测构件是能够检测膜卷1的实际边缘信息的构件，其可以是自动巡边设备，或者其他感应传感器、三维成像模组等。
通过检测构件检测膜卷1的实际边缘信息，并将该检测信息发给控制器3，控制器3通过获取预警时间段内的膜卷1的轴向的实际边缘信息，在实际边缘信息对应的边缘位置超出膜卷1的预设边缘范围时，控制显示设备作出预警反应，操作人员可根据显示设备的预警反应，查看收卷过程的膜卷1是否出现“炮筒”现象。“炮筒”现象预警不再依靠人工实时观察，降低了操作人员的劳动强度，且可靠性提高。
根据本申请的一些实施例，请继续参照图4，本实施例收卷预警系统还包括信号接收组件4。信号接收组件4与检测构件和控制器3连接，信号接收组件4用于接收检测构件发出的检测信息并将该检测信息发送给控制器3。
信号接收组件4主要是将检测构件中的信号接收下来，并将其变换成与发送时物理形式相同的信息,再传给控制器3，即完成所谓的译码过程。
本申请实施例的收卷预警系统通过信号接收组件4将检测构件的检测信息发送给控制器3，使得检测信息能够被控制器3及时接收，提高了检测信息的传输稳定性。
根据本申请的一些实施例，继续参照图4和图5，图5为图4所示的收卷预警系统的自动巡边设备处于自动巡边状态的示意图。本实施例检测构件包括两自动巡边设备。两自动巡边设备分别用于对膜卷1的轴向的两端进行自动巡边，以检测膜卷1的轴向的两端的实际边缘信息。
本申请实施例的收卷预警系统通过两自动巡边设备分别对膜卷1的轴向的两端进行自动巡边，膜卷1的实际边缘信息检测准确性高。
根据本申请的一些实施例，继续参照图4和图5所示，检测构件还包括导轨5，导轨5用于与收卷轴的轴向平行设置，两自动巡边设备均可滑动的安装在导轨5上。
导轨5是一根呈直线延伸的轨道。导轨5在设置时，与收卷轴的轴向平行，并位于收卷轴的一侧。导轨5能够为两自动巡边设备的移动提供导向作用。
通过导轨5与收卷轴的轴向平行设置，从而两自动巡边设备沿导轨5移动，也即是沿膜卷1的轴向移动，能够更准确的获知两自动巡边设备的移动距离，从而可更好的通过自动巡边设备获知膜卷1的边缘位置信息。
根据本申请的一些实施例，继续参照图4和图5，本实施例导轨5上设置有长度刻度线。
长度刻度线也即能够显示长度的刻度，长度刻度线沿导向轨的长度方向布置。长度刻度线可对应设置相应的数字，以便于操作人员读取长度数值。
通过在导轨5上设置长度刻度线，可方便于检测构件的安装，例如，在安装导轨5和自动巡边设备时，可通过长度刻度线定位导轨5的中心位置以及自动巡边设备的安装位置。
根据本申请的一些实施例，继续参照图4和图5，可选的，本实施例导轨5的中部为零刻度线，零刻度线两侧的刻度分别逐渐递增；两自动巡边设备分别为第一自动巡边设备72和第二自动巡边设备73，第一自动巡边设备72和第二自动巡边设备73分别设置在零刻度线的两侧。
零刻度线也是长度刻度的起点。在一个具体实现方式中，零刻度线两侧的长度刻度的量程分别为500毫米。导轨5的零刻度线位置可大致对应于卷筒2的轴向的中心设置，此时位于卷筒2的轴向中心的两侧的刻度大致一样。
涂布工序中的膜卷1的轴向长度也即极片的宽度通常不大于800毫米，通过在零刻度线两侧分别设置500毫米长的刻度，也即整个导轨5具有1000毫米的量程，可覆盖膜卷1在轴向上的长度，并可在膜卷1的两端预留出足够的拆卸膜卷1的空间。
通过将零刻度线设置在导轨5的中部，零刻度线两侧的刻度分别逐渐递增，这样零刻度线也即是导轨5的中心位置，在导轨5安装时，便于操作人员定位导轨5的位置；同时，导轨5两侧递增的刻度，方便于两自动巡边设备的定位安装。
根据本申请的一些实施例，本申请的导轨5的两端分别设置有第一初始位置52和第二初始位置53，第一初始位置52与第二初始位置53之间的距离大于膜卷1的轴向长度。在初始状态，第一自动巡边设备72位于第一初始位置52，第二自动巡边设备73位于第二初始位置53。
初始状态也即自动巡边设备不执行巡边工作时所处的状态。本实施例的第一初始位置52和第二初始位置53分别位于导轨5的两端，具体可以是两端的分别对应500毫米刻度的位置。
通过将导轨5上的第一初始位置52与第二初始位置53之间的距离大于膜卷1的轴向长度，这样，两自动巡边设备分别位于第一初始位置52和第二初始位置53时，可避免自动巡边设备对膜卷1造成干涉；并且在实际 收卷过程中，可将膜卷1置于第一初始位置52和第二初始位置53之间，如此，两自动巡边设备从远端向内移动以首次定位膜卷1的边缘，避免膜卷1对自动巡边设备的巡边准确性造成影响。
根据本申请的一些实施例，可选的，本申请的导轨5在零刻度线51的两侧分别设置有第一限位位置和第二限位位置，第一限位位置和第二限位位置位于第一初始位置52和第二初始位置53之间，第一限位位置和第一初始位置52位于零刻度线51的一侧，第二限位位置和第二初始位置53位于零刻度线51的另一侧，第一限位位置和第二限位位置均与零刻度线51间隔预设距离，预设距离大于零。第一自动巡边设备72配置为在第一初始位置52和第一限位位置之间移动，第二自动巡边设备73配置为在第二初始位置53和第二限位位置之间移动。
第一限位位置用于限定第一自动巡边设备72向内(也即向膜卷1所在的一侧)移动的最远距离，第二限位位置用于限定第二自动巡边设备73向内移动的最远距离。
在一些特殊情况下，第一自动巡边设备72或第二自动巡边设备73在执行巡边作业时，可能没有定位到相应端的膜卷1的边缘位置，此时第一自动巡边设备72或第二自动巡边设备73会沿着膜卷1的轴向继续向前移动，有可能出现第一自动巡边设备72与第二自动巡边设备73相碰撞的情况。本实施例通过将第一自动巡边设备72配置为在第一初始位置52和第一限位位置之间移动，第二自动巡边设备73配置为在第二初始位置53和第二限位位置之间移动，避免了在某些意外情况下，两自动巡边设备定位不到膜卷1的边缘位置而导致第二自动巡边设备73与第一自动巡边设备72相互碰撞的情况发生。
根据本申请的一些实施例，参照图4所示，本实施例收卷预警系统的显示设备包括显示屏6，显示屏6用于显示控制器3生成的预警信息。和/或显示设备包括报警器8，报警器8用于根据控制器3发出的预警指令进行报警。
本申请实施例的收卷预警系统，通过显示屏6显示预警信息，和/或通过控制报警器8报警，可使操作人员及时且直观的获取到预警信息，从 而能够及时对膜卷1进行检查。
根据本申请的一些实施例，本实施例还提供一种收卷机构，包括收卷轴和上述任一实施例提供的收卷预警系统，检测构件对应收卷轴设置。
通过检测构件检测膜卷1的实际边缘信息，并将该实际边缘信息发给控制器3，控制器3通过获取预警时间段内的膜卷1的轴向的实际边缘信息，在实际边缘信息对应的边缘位置超出膜卷1的预设边缘范围时，控制显示设备作出预警反应，操作人员可根据显示设备的预警反应，查看收卷过程的膜卷1是否出现“炮筒”现象。“炮筒”现象预警不再依靠人工实时观察，降低了操作人员的劳动强度，且可靠性提高。
根据本申请的一些实施例，可选的，本实施例收卷机构包括两收卷轴，两收卷轴分别对应设置一检测构件。
具体的，两收卷轴的任一一根收卷轴对应设置有两自动巡边设备。每根收卷轴对应的两自动巡边设备用于分别对当前收卷轴上的膜卷1的轴向两端的边缘位置进行检测。
两收卷轴通常交替使用，形成自动换卷作业。在一个收卷轴执行收卷作业时，另一个收卷轴执行准备作业；一个收卷轴收卷完成后，自动将极片从当前收卷轴切换到另一个收卷轴上，保证了生产过程的连续性。
两收卷轴对应的自动巡边设备跟随收卷轴的使用状态，交替开启。也即，在收卷轴上执行收卷作业时，该收卷轴对应的两自动巡边设备开启，并对收卷轴上的膜卷1进行巡边。
在实际作业时，自动巡边设备的切换，以极片切断为信号。也即控制器3接收到极片被切断的信息后，控制当前收卷轴对应的自动巡边设备停止巡边，当前收卷轴对应的自动巡边设备复位至初始位置，并控制另一收卷轴对应的自动巡边设备开始巡边。
本申请实施例的收卷机构的两收卷轴可交替使用进行收卷作业，以使收卷对应的作业工序连续生产。通过对应两个收卷轴分别设置检测构件，可对两根收卷轴上的膜卷1均进行检测，以提高连续生产过程的所有膜卷1的质量，避免膜卷“炮筒”现象的发生。
根据本申请的一些实施例，本实施例提供一种涂布机，涂布机包括上 述任一实施例提供的收卷机构。
通过在涂布机上设置本实施例提供的收卷机构，收卷机构的收卷预警系统可以对膜卷1的“炮筒”现象进行检测，避免了形成严重“炮筒”，方便了后续工序对膜卷1的极片进行加工，提高了电池生产的效率及良品率。
根据本申请的一些实施例，参照图4和图5，本实施例提供一种膜卷预警系统，包括控制器3、信号接收组件4、两激光自动巡边设备、导轨5、显示屏6和报警器8。导轨5两端的最远距离(导轨5的量程为1000毫米，零刻度线51居中，左/右各500毫米)为激光自动巡边设备默认的初始位置。控制器3针对于收卷预警系统的开启或关闭设置有权限，该权限的设定可通过输入装置进行输入或确认，避免监控失效的情况发生。也即只能是有权限的操作人员才能开启或关闭收卷预警系统。该具有权限的操作人员能够执行的是将收卷预警系统关闭或打开，但是收卷预警系统是否执行预警程序需要根据生产过程确定。换言之，具有权限的操作人员将收卷预警系统设置为“开”的状态，预警收卷系统才可能执行实际预警作业。本实施例预警收卷系统为“开”的状态下，首次以涂布工序开始走带为信号，激发预警收卷系统的预警程序，处于收卷过程的收卷轴对应的激光自动巡边设备同时检测膜卷1的左/右两侧的边缘留白区最大位移情况。当预警程序关闭后，激光自动巡边设备恢复到初始位置。在中间换卷过程中，如果是自动换卷作业，以上一个收卷轴执行的收卷过程的极片切断为信号，控制下一个收卷轴对应的激光自动巡边设备开启；如果是手动换卷作业，依然以涂布工序开始走带为信号，控制激光自动巡边设备执行巡边作业。
需要说明的是，图5中的膜卷1的右侧未形成“炮筒”现象，膜卷1的左侧形成有“炮筒”现象，炮筒”现象从炮筒起始位置13沿膜卷1的径向向外(图5向左的方向)延伸。炮筒起始位置13对应的极片的边缘位置是参照边缘位置11，膜卷1的左端的最外侧的极片的边缘位置是预警时间段内的实际边缘信息对应的边缘位置12，实际边缘信息对应的边缘位置12与参照边缘位置11之间的位置差为实际偏移量14，该实际偏移量也是膜卷1在该端的最大偏移量。
参照图6，图6为本申请一些实施例的收卷预警系统的实际监控过程图。该实际监控过程是收卷预警方法的体现。该实际监控过程在开始前，先在系统允许的0-15mm范围内，设定预设偏移量为某一特定数值。预设偏移量也即感应间距，感应间距为系统允许极片边缘留白区的最大偏移量，极片留白区的边缘的偏移量达到该感应间距即报警。
下面介绍下膜卷1的完整监控过程。
在控制器3接收到涂布工序中的极片的开始走带信息时，收卷预警系统的预警程序自动开启。涂布机的收卷机构根据被检测膜卷1的基材宽度，明确定义收卷卷筒2的位置。收卷预警系统的预警程序自动开启后，激光自动巡边设备即发射激光束71以设定的移动速度(移动速度范围为20±10毫米/秒)向内自动巡边，检测膜卷1的极片边缘留白区最外侧位置(为避免左/右激光自动巡边设备相撞，设置最大位移450毫米防呆)。为了避免膜卷1起始边缘留白区位置波动大影响到参照边缘位置(参照边缘位置也即预警程序默认的极片边缘留白区最外侧初始位置)的准确度，默认收卷预警系统开启后，第60秒-120秒时间段检测到的极片边缘最外侧位置的均值为参照边缘位置，也即预警程序的参照零点位置。其中，膜卷1的左侧留白区边缘和右侧留白区边缘，享有2个独立的零点位置。涂布走带过程中，极片两侧边缘留白区最外侧位置持续输出，通过与参照零点位置的对比，计算出实际偏移量。当极片左/右两侧留白区边缘，任意一个实际偏移量也即最大位移大于等于预设偏移量(也即感应间距)时，触发预警机制，显示设备作出预警反应，也即电脑的显示屏弹出对应预警信息，并伴随声光报警。当最大位移小于感应间距时，不会触发预警机制，正常生产至正常出货，当前膜卷监控结束。
在显示设备作出预警反应的情况下，操作人员通过点击关闭程序按钮临时手动(收卷预警系统只做“炮筒”预警，不会强制设备停机)向控制器3输入关闭操作指令，手动临时关闭收卷预警系统的预警程序，并确认是否发生“炮筒”。若发生“炮筒”，涂布工序的膜卷出货，当前膜卷炮筒监控结束。若未发生“炮筒”，正常生产至正常出货，当前膜卷监控结束。当前膜卷经操作人员确认未发生“炮筒”的情况下，也即持续生产状 态下，临时关闭程序按钮的有效时长为5分钟，5分钟后收卷预警系统自动开启(开启后的参照零点位置和临时关闭程序前的参照零点位置相同)。
涂布工序的膜卷出货后，控制器3能够接收到换卷信号。新的涂布工序的膜卷开始收卷后，第60-120秒时间段检测到的极片边缘留白区最外侧位置的均值为新膜卷1的零点位置，也即参照边缘位置。
其中，最大位移450毫米防呆，也即是设置第一激光自动巡边设备对应的第一预设距离和第二激光自动巡边设备对应的第二预设距离分别为450毫米，以避免两激光自动巡边设备发生碰撞。导轨5两端的最远距离，也即左右各500毫米的位置对应于第一初始位置52和第二初始位置53。以第一初始位置52向内移动450毫米，对应的50毫米的位置也即是第一限位位置。同理，以第二初始位置53向内移动450毫米，对应的50毫米的位置也即是第二限位位置。左右两侧对应于膜卷1的第一端和第二端。最大位移也即实际偏移量的最大值。
本实施例收卷预警方法及系统，能够在生产过程中极片边缘留白区水平偏移量达到感应间距后，及时识别异常，并弹出预警信息，提醒开机操作人员及时确认并处理异常，能够在“炮筒”产生的初期阶段，及时遏制炮筒恶化，避免造成实际损失。
最后应说明的是：以上各实施例仅用以说明本申请的技术方案，而非对其限制；尽管参照前述各实施例对本申请进行了详细的说明，本领域的普通技术人员应当理解：其依然可以对前述各实施例所记载的技术方案进行修改，或者对其中部分或者全部技术特征进行等同替换；而这些修改或者替换，并不使相应技术方案的本质脱离本申请各实施例技术方案的范围，其均应涵盖在本申请的权利要求和说明书的范围当中。尤其是，只要不存在结构冲突，各个实施例中所提到的各项技术特征均可以任意方式组合起来。本申请并不局限于文中公开的特定实施例，而是包括落入权利要求的范围内的所有技术方案。

Claims (28)

  1. 一种收卷预警方法，其中，包括：
    获取预警时间段内的膜卷的轴向的实际边缘信息，其中预警时间段是当前膜卷的收卷过程对应的局部时间或全部时间；
    根据所述实际边缘信息对应的边缘位置超出膜卷的预设边缘范围，控制显示设备作出预警反应。
  2. 根据权利要求1所述的收卷预警方法，其中，所述方法包括：
    在预警时间段内，分别获取膜卷的轴向两端的实际边缘信息；
    根据膜卷的轴向两端的实际边缘信息中，至少一端的实际边缘信息对应的边缘位置超出该至少一端对应的所述预设边缘范围时，控制显示设备作出预警反应。
  3. 根据权利要求2所述的收卷预警方法，其中，所述方法包括：
    在预警时间段内，分别获取膜卷的轴向两端的实时的实际边缘信息；
    根据膜卷的轴向两端的实时的实际边缘信息中，至少一端的实时的实际边缘信息对应的边缘位置超出该端对应的所述预设边缘范围时，控制显示设备作出预警反应。
  4. 根据权利要求2或3所述的收卷预警方法，其中，所述根据所述实际边缘信息对应的边缘位置超出膜卷的预设边缘范围，控制显示设备作出预警反应，包括：
    基于膜卷的轴向两端的实际边缘信息对应的边缘位置和膜卷的轴向两端的参照边缘位置，分别得到膜卷的轴向两端的实际偏移量；
    根据膜卷的轴向两端的实际偏移量中的至少一端的实际偏移量大于预设偏移量，控制显示设备作出预警反应。
  5. 根据权利要求4所述的收卷预警方法，其中，所述方法还包括所述膜卷的轴向两端的参照边缘位置的获取：
    在预定时间段内，分别获取膜卷的轴向的两端的实际边缘信息，其中，所述预定时间段和所述预警时间段处于同一个收卷过程中，且所述预定时间段处于所述预警时间段之前；
    基于所述预定时间段内获取的所述膜卷的轴向两端中第一端的实际 边缘信息对应的边缘位置，计算所述膜卷的第一端在所述预定时间段内的平均位置，所述膜卷在预定时间段内的第一端的平均位置为所述膜卷的第一端的参照边缘位置；
    基于所述预定时间段内获取的所述膜卷的轴向两端中第二端的实际边缘信息对应的边缘位置，计算所述膜卷的第二端在所述预定时间段内的平均位置，所述膜卷在预定时间段内的第二端的平均位置为所述膜卷的第二端的参照边缘位置。
  6. 根据权利要求5所述的收卷预警方法，其中，所述预定时间段为当前收卷过程开始后的60秒-120秒；
    和/或所述预警时间段为当前收卷过程开始后的120秒至该收卷过程结束的时间。
  7. 根据权利要求6所述的收卷预警方法，其中，所述方法还包括：
    获取自动换卷作业的上一收卷过程的切带信息，根据接收到所述切带信息的时间作为当前收卷过程的开始时间；
    或获取收卷机构开启后的开始走带信息，根据接收到所述开始走带信息的时间作为当前收卷过程的开始时间。
  8. 根据权利要求1-7任一项所述的收卷预警方法，其中，所述方法还包括：
    控制自动巡边设备对膜卷的轴向的边缘位置进行自动巡边定位；
    获取自动巡边设备的位置信息，以所述自动巡边设备的位置信息作为膜卷的轴向的实际边缘信息。
  9. 根据权利要求8所述的收卷预警方法，其中，所述控制自动巡边设备对膜卷的轴向的边缘位置进行自动巡边定位，包括：
    控制膜卷两端的自动巡边设备分别对膜卷的轴向的两端的边缘位置进行自动巡边定位。
  10. 根据权利要求9所述的收卷预警方法，其中，所述控制膜卷两端的自动巡边设备分别对膜卷的轴向的两端的边缘位置进行自动巡边定位，包括：
    控制第一自动巡边设备从第一初始位置移动至检测到膜卷的轴向的 第一端的边缘位置的位置，控制第一自动巡边设备对膜卷的轴向的第一端的边缘位置进行自动巡边；
    控制第二自动巡边设备从第二初始位置移动至检测到膜卷的轴向的第二端的边缘位置的位置，控制第二自动巡边设备对膜卷的轴向的第二端的边缘位置进行自动巡边；
    其中，膜卷两端的所述自动巡边设备分别为所述第一自动巡边设备和所述第二自动巡边设备，所述第一端和所述第二端分别为所述膜卷的轴向的两端，所述第一初始位置位于所述第一端远离所述第二端的一侧，所述第二初始位置位于所述第二端远离所述第一端的一侧。
  11. 根据权利要求10所述的收卷预警方法，其中，所述控制膜卷两端的自动巡边设备分别对膜卷的轴向的两端的边缘位置进行自动巡边定位，还包括：
    控制所述第一自动巡边设备从所述第一初始位置向所述第二初始位置沿直线在第一预设距离内移动，控制所述第二自动巡边设备从所述第二初始位置向所述第一初始位置沿直线在第二预设距离内移动；
    所述第一预设距离大于等于所述第一初始位置至所述膜卷的第一端的边缘位置之间的最大距离，所述第二预设距离大于等于所述第二初始位置至所述膜卷的第二端的边缘位置之间的最大距离，所述第一预设距离与所述第二预设距离的和小于第一初始位置至所述第二初始位置之间的距离。
  12. 根据权利要求10或11所述的收卷预警方法，其中，在控制显示设备作出预警反应之后，还包括：
    根据操作人员的关闭操作指令，控制所述第一自动巡边设备移动回所述第一初始位置，控制所述第二自动巡边设备移动回所述第二初始位置。
  13. 根据权利要求1-12任一项所述的收卷预警方法，其中，所述根据所述实际边缘信息对应的边缘位置超出膜卷的预设边缘范围，控制显示设备作出预警反应，包括：
    根据所述实际边缘信息对应的边缘位置超出膜卷的预设边缘范围，生成预警信息，将所述预警信息发给显示屏进行显示；
    和/或，根据所述实际边缘信息对应的边缘位置超出膜卷的预设边缘 范围，向报警器发出预警指令，控制报警器报警。
  14. 根据权利要求1-13任一项所述的收卷预警方法，其中，在控制显示设备作出预警反应之后，还包括：
    接收输入的关闭操作指令；
    根据输入的关闭操作指令，判断所述预警时间段结束，停止获取膜卷的轴向的实际边缘信息，并控制所述显示设备停止预警反应。
  15. 根据权利要求14所述的收卷预警方法，其中，所述方法还包括：
    在接收输入的关闭操作指令预设时长后，再次开始获取膜卷的轴向的实际边缘信息，并根据所述实际边缘信息对应的边缘位置超出膜卷的所述预设边缘范围，控制显示设备作出预警反应。
  16. 根据权利要求15所述的收卷预警方法，其中，所述方法还包括：
    获取预存的操作记录、所述操作记录对应的操作人标识、所述操作记录对应的膜卷的膜卷标识信息以及该膜卷的收卷过程的预警信息、参照边缘位置及实际偏移量的最大值，将所述操作记录、所述操作人标识、所述膜卷标识信息、所述预警信息、所述参照边缘位置、所述实际偏移量的最大值关联并存储至本地数据库。
  17. 一种收卷预警系统，其中，包括控制器、检测构件和显示设备；
    所述检测构件用于检测膜卷的轴向的实际边缘信息，并将所述实际边缘信息发送给所述控制器；
    所述控制器用于执行权利要求1-16任一项所述的收卷预警方法；
    所述显示设备用于根据控制器的控制信息作出预警反应。
  18. 根据权利要求17所述的收卷预警系统，其中，所述收卷预警系统还包括信号接收组件；
    所述信号接收组件与所述检测构件和所述控制器连接，所述信号接收组件用于接收所述检测构件发出的检测信息并将该所述检测信息发送给所述控制器。
  19. 根据权利要求17或18所述的收卷预警系统，其中，所述检测构件包括两自动巡边设备，所述两自动巡边设备分别用于对膜卷的轴向的两端进行自动巡边，以检测膜卷的轴向的两端的实际边缘信息。
  20. 根据权利要求19所述的收卷预警系统，其中，所述检测构件还包括导轨，所述导轨用于与收卷机构的收卷轴的轴向平行设置，所述两自动巡边设备均可滑动的安装在所述导轨上。
  21. 根据权利要求20所述的收卷预警系统，其中，所述导轨上设置有长度刻度线。
  22. 根据权利要求21所述的收卷预警系统，其中，所述导轨的中部为零刻度线，所述零刻度线两侧的刻度分别逐渐递增；
    两所述自动巡边设备分别为第一自动巡边设备和第二自动巡边设备，所述第一自动巡边设备和所述第二自动巡边设备分别设置在所述零刻度线的两侧。
  23. 根据权利要求22所述的收卷预警系统，其中，所述导轨的两端分别设置有第一初始位置和第二初始位置，所述第一初始位置与所述第二初始位置之间的距离大于膜卷的轴向长度；
    在初始状态，所述第一自动巡边设备位于所述第一初始位置，所述第二自动巡边设备位于所述第二初始位置。
  24. 根据权利要求23所述的收卷预警系统，其中，所述导轨在所述零刻度线的两侧分别设置有第一限位位置和第二限位位置，所述第一限位位置和第二限位位置位于所述第一初始位置和所述第二初始位置之间，所述第一限位位置和第一初始位置位于所述零刻度线的一侧，所述第二限位位置和所述第二初始位置位于所述零刻度线的另一侧，所述第一限位位置和所述第二限位位置均与所述零刻度线间隔预设距离，所述预设距离大于零；
    所述第一自动巡边设备配置为在所述第一初始位置和所述第一限位位置之间移动，所述第二自动巡边设备配置为在所述第二初始位置和所述第二限位位置之间移动。
  25. 根据权利要求17-24任一项所述的收卷预警系统，其中，所述显示设备包括显示屏，所述显示屏用于显示控制器生成的预警信息；
    和/或所述显示设备包括报警器，所述报警器用于根据控制器发出的预警指令进行报警。
  26. 一种收卷机构，其中，包括收卷轴和权利要求17-25任一项所述 的收卷预警系统，所述检测构件对应所述收卷轴设置。
  27. 根据权利要求26所述的收卷机构，其中，所述收卷机构包括两收卷轴，两所述收卷轴分别对应设置一所述检测构件。
  28. 一种涂布机，其中，包括权利要求26或27所述的收卷机构。
PCT/CN2023/088959 2022-08-02 2023-04-18 收卷机构、涂布机、收卷预警方法及系统 WO2024027204A1 (zh)

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