Cắt chính xác, trao quyền cho tương lai: Tiết lộ công nghệ cốt lõi của thế hệ máy cắt màng quang học mới

With the increasing popularity of smartphones, tablets, LCD TVs, new energy vehicle displays, and even VR/AR devices, we have long been accustomed to colorful, clear and realistic visual experiences. Behind all this, it is inseparable from layers of seemingly inconspicuous but crucial materials - optical films.

Optical films, such as brightening films, diffusion films, reflective films, quantum dot films, etc., are the "nerves" and "souls" of the display panel, which directly affects the brightness, contrast, color gamut and viewing angle of the device. These high-value, delicate and fragile optical films must go through a crucial process - slitting before leaving the factory. That is, the master roll is accurately cut into finished rolls of different widths according to customer needs.

"Precise cutting" is no easy task, and the difference between heaven and hell is the difference between burrs, drawings, wrinkles, and tearing crystal dots...... Any micro-defects can lead to the scrapping of the entire roll of material, resulting in significant losses. Therefore, the new generation of optical film slitting machine is no longer a simple "cutting" tool, but a high-end intelligent manufacturing equipment integrating precision machinery, intelligent control and machine vision. How does it achieve its mission of "empowering the future"? Where is the mystery of its core technology?

1. The ultimate precision "surgical scalpel": cutting system technology

Cutting is at the heart of all slitting machines, and the evolution of new generations of equipment in this regard is nothing short of revolutionary.

1. High rigidity & precision frame and rails: This is the basis of all precision. The frame is made of natural granite or high-strength alloy steel, with precision preloaded linear guides, to ensure that the equipment is rock-stable when running at high speed, fundamentally eliminating cutting jitter caused by vibration, and providing physical guarantee for micron-level accuracy.

2. Autonomous constant tension control system:

◦ Core challenge: Optical film materials are soft and malleable, and any small tension fluctuations during high-speed slitting can cause the film to be stretched, wrinkled, or even broken.

◦ Technological breakthrough: The new generation of slitting machine adopts a full closed-loop servo tension control system. The high-precision tension sensor monitors the coil tension in real time and feeds back the data to the central processing unit (PLC), which instantly adjusts the torque and speed of the unwinding and rewinding servo motors, and sets multiple damping rollers and floating rollers in the traction and slitting sections to form a dynamically balanced "tension pool" to ensure that the film is under the preset optimal and constant tension at every step from unwinding to unwinding, just like gliding on a calm lake.

3. Non-contact (air floating) support and transmission: For high-end optical films (such as MLCC release film, CPI film), any contact may cause scratches. The new generation of slitting machine adopts air suspension technology, replacing the traditional metal rollers with air cushions to support and transfer the film, achieving "zero contact" throughout the process and perfectly protecting the film surface.

2. The "eye of wisdom" with insight: visual inspection and correction system

It is not enough to have a stable "hand", but also a bright "eye" and a smart "brain".

1. High-resolution CCD online inspection system: During the slitting process, the high-speed camera continuously scans the film surface, detecting and marking defects such as stains, scratches, foreign objects, and streaks in real time. The system can automatically record the location, size and type of defects, and generate quality reports to provide a basis for product quality traceability and big data analysis.

2. High-precision CPC/EPC automatic deviation correction system:

◦ Why is it needed? The film is very prone to lateral deviation at high speeds, and once the edge deviates from the preset cutting path, the consequences are unimaginable.

◦ How does it work? The edge of the film or the pre-printed line sensor is tracked in real time through the edge sensor or line array CCD, and the position signal is transmitted to the controller, which then drives the correction actuator (usually a complete set of swing arm units) to fine-tune it in milliseconds to ensure that the film always moves along the precise path, and the slitting error is controlled within ±0.1mm or even ±0.05mm.

3. The "digital brain" of strategizing: intelligent control and data analysis

The new generation of slitting machines is the practitioner of Industry 4.0, and its "brain" is highly intelligent.

1. Full servo motor drive system: Replacing traditional mechanical long shafts and variable frequency motors, each key unit (unwinding, traction, winding) is driven by an independent servo motor. This makes the control more flexible and precise, and the process parameters (such as speed, tension, taper) can be freely set and quickly switched through software to adapt to the flexible production needs of small batches and multiple varieties.

2. Digital Twins and Intelligent Algorithms:

◦ The operator can preset all the slitting parameters on the HMI (human-machine interface), and the system will automatically calculate and simulate the operation effect.

◦ The intelligent winding algorithm can automatically calculate and optimize the winding pressure and taper according to the material characteristics, effectively avoiding common problems such as uneven winding and "cabbage heart" collapse.

◦ The system can record and learn the massive data of each production, and continuously optimize itself through AI algorithms to improve the yield and efficiency.

3. Internet of Things (IoT) and remote operation and maintenance: Devices are connected to the industrial Internet platform to support remote monitoring, troubleshooting, and program updates. Engineers can view equipment status and analyze problems on the other side of the world, greatly improving after-sales response speed and equipment utilization.

Empowering the future: from display to new energy

The value of the new generation of optical film slitting machine has long surpassed the traditional display field. In the booming new energy vehicle industry, it is used for precise slitting of lithium battery separators and aluminum-plastic encapsulation films; in the field of photovoltaic power generation, it is used to slit solar backsheet films; in the field of flexible electronics, it is an indispensable core equipment for processing special films such as PI and CPI.

Phần kết luận

Precision is the eternal pursuit of the manufacturing industry. The new generation of optical film slitting machine has achieved a leap from "capable cutting" to "smart cutting" by deeply integrating precision mechanical engineering, intelligent sensing technology, and digital control algorithms. It is not only the key to ensuring the quality of high-end film materials, but also the cornerstone of promoting the innovation and development of strategic emerging industries such as display technology, new energy, and flexible electronics. It is this precise "digital scalpel" that is silently cutting out a clearer, more brilliant and intelligent picture of the future.