Analysis of current system problems
1. Tension fluctuations cause the material to stretch or relax
2. Insufficient slitting accuracy leads to edge waste
3. High material loss during the start/stop phase
4. Insufficient adaptability to different material properties
Optimize the solution
1. Tension control system upgrade
• Multi-stage closed-loop control: Tension detection points are set up in the unwinding, traction and rewinding links
• Adaptive PID algorithm: Automatically adjusts control parameters based on material properties and operating speed
• Dynamic compensation mechanism: real-time compensation for inertial forces in the process of acceleration and deceleration
2. Hardware improvements
• Replacement of high-precision tension transducer (±0.1% accuracy)
• Install a brushless motor drive system to improve the response speed
• Add edge position detection CCD to achieve automatic deviation correction
3. Material property database
• Create a database of tension-elongation curves for different gold foil materials
• Automatically recall the optimal tension parameter according to the material batch
• Recording of production data and continuous optimization of parameter settings
4. Operational optimization
• Develop automatic feeding programs to reduce manual intervention
• Optimized acceleration/deceleration curves to reduce impact
• Realize automatic splicing function to reduce downtime
What to expect
• 30-45% reduction in material waste
• The product qualification rate has increased to more than 99.2%.
• 40% reduction in changeover time
• 15% reduction in system energy consumption
Implementation steps
1. Evaluation of existing systems and data collection (1-2 weeks)
2. Hardware Upgrade & Installation (1 week)
3. Control system software update and debugging (2 weeks)
4. Operator training (3 days)
5. Commissioning and fine-tuning of parameters (1 week)
6. Formal production and continuous optimization
If more detailed information or specific technical parameters are needed, further explanations can be made.