CN118618978B - Winding method and system based on artificial intelligence - Google Patents
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- 238000000034 method Methods 0.000 title claims abstract description 77
- 238000004804 winding Methods 0.000 title claims abstract description 71
- 238000013473 artificial intelligence Methods 0.000 title claims abstract description 19
- 230000008569 process Effects 0.000 claims abstract description 33
- 238000007781 pre-processing Methods 0.000 claims abstract description 10
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- WHXSMMKQMYFTQS-UHFFFAOYSA-N Lithium Chemical compound [Li] WHXSMMKQMYFTQS-UHFFFAOYSA-N 0.000 description 5
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- 101100012902 Saccharomyces cerevisiae (strain ATCC 204508 / S288c) FIG2 gene Proteins 0.000 description 1
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- 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
- B65H26/02—Warning or safety devices, e.g. automatic fault detectors, stop-motions, for web-advancing mechanisms responsive to presence of irregularities in running webs
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H2511/00—Dimensions; Position; Numbers; Identification; Occurrences
- B65H2511/10—Size; Dimensions
- B65H2511/14—Diameter, e.g. of roll or package
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H2515/00—Physical entities not provided for in groups B65H2511/00 or B65H2513/00
- B65H2515/30—Forces; Stresses
- B65H2515/31—Tensile forces
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H2557/00—Means for control not provided for in groups B65H2551/00 - B65H2555/00
- B65H2557/20—Calculating means; Controlling methods
- B65H2557/264—Calculating means; Controlling methods with key characteristics based on closed loop control
- B65H2557/2644—Calculating means; Controlling methods with key characteristics based on closed loop control characterised by PID control
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Abstract
Description
技术领域Technical Field
本发明涉及电池隔膜制备领域,具体涉及一种基于人工智能的收卷方法和系统。The present invention relates to the field of battery separator preparation, and in particular to an artificial intelligence-based winding method and system.
背景技术Background Art
收卷机是一种用于将电池薄膜等卷状产品进行收卷的设备,其主要功能是通过卷取薄膜或片材来形成紧凑的卷筒结构,以便于后续的加工和应用。A winder is a device used to wind up roll products such as battery films. Its main function is to form a compact roll structure by winding up the film or sheet to facilitate subsequent processing and application.
传统收卷方法通常没有充分考虑到薄膜特性和卷径等因素,导致了张力设置不合理,进而导致薄膜在收卷过程中出现皱纹、暴筋、褶皱、滑膜等各种问题,影响电池隔膜的性能和品质。Traditional winding methods usually do not fully consider factors such as film characteristics and roll diameter, resulting in unreasonable tension settings, which in turn causes various problems such as wrinkles, ribs, folds, and slippage in the film during the winding process, affecting the performance and quality of the battery separator.
另外,一些方案虽然尝试实时调整张力,但使用的PID(比例-积分-微分)系统难以精确地控制张力输出。设定过于精细的目标张力可能导致PID系统实时输出的张力难以准确跟随目标张力的变化,导致超调和波动的情况,进而影响收卷的稳定性和品质。In addition, although some solutions try to adjust the tension in real time, the PID (proportional-integral-differential) system used is difficult to accurately control the tension output. Setting too precise target tension may cause the tension output of the PID system in real time to be difficult to accurately follow the changes in the target tension, resulting in overshoot and fluctuations, which in turn affects the stability and quality of winding.
发明内容Summary of the invention
有鉴于此,本发明旨在提供一种基于人工智能的收卷方法和系统,旨在解决传统收卷方法未充分考虑薄膜特性、卷径与PID系统的能力,导致的收卷效果不佳的问题。In view of this, the present invention aims to provide an artificial intelligence-based winding method and system, aiming to solve the problem that the traditional winding method does not fully consider the film characteristics, roll diameter and the capabilities of the PID system, resulting in poor winding effect.
一种基于人工智能的收卷方法,包括以下步骤:A method for collecting rolls based on artificial intelligence comprises the following steps:
S1:收集薄膜密度数据、薄膜厚度数据,以及薄膜收卷过程中薄膜卷的卷径数据、收卷过程中的薄膜张力数据,并对薄膜张力数据进行预处理,得到预处理后的薄膜张力数据;S1: collecting film density data, film thickness data, roll diameter data of the film roll during film winding, and film tension data during film winding, and preprocessing the film tension data to obtain preprocessed film tension data;
S2:将薄膜密度数据、薄膜厚度数据与卷径数据进行融合,同时构建张力预测模型,进行薄膜张力数据缺失值填补,生成卷径-张力曲线;S2: Fusing the film density data, film thickness data and roll diameter data, and constructing a tension prediction model to fill in the missing values of film tension data and generate a roll diameter-tension curve;
所述张力预测模型首先提出位置缺失编码、缺失距离编码,分别对缺失值的位置以及缺失值与真值的距离进行标识,再将位置缺失编码、缺失距离编码与薄膜张力数据进行融合,输入门控循环单元,对薄膜张力数据进行预测并填补;The tension prediction model first proposes position missing coding and missing distance coding to mark the position of the missing value and the distance between the missing value and the true value respectively, and then integrates the position missing coding and missing distance coding with the film tension data, inputs them into the gated recurrent unit, and predicts and fills the film tension data;
S3:计算PID系统每一次调整薄膜张力产生的超调幅度和波动时间,进而计算出超调惩罚项;S3: Calculate the overshoot amplitude and fluctuation time generated by each adjustment of the film tension by the PID system, and then calculate the overshoot penalty term;
S4:构建张力等级划分模型,根据最大卷径,输出张力等级数量和对应张力;S4: construct a tension level classification model, and output the number of tension levels and corresponding tension according to the maximum roll diameter;
所述张力等级划分模型的奖励函数采用定积分的方式计算卷径-张力曲线拟合度,张力等级划分模型的值函数采用Q-learning的方式进行计算,并采用ε-greedy策略,对张力等级划分模型进行更新;The reward function of the tension level classification model uses a definite integral method to calculate the coil diameter-tension curve fitting degree, and the value function of the tension level classification model is calculated by a Q-learning method, and an ε-greedy strategy is used to update the tension level classification model;
S5:根据张力等级数量和对应张力,通过PID系统控制收卷过程中的薄膜张力。S5: The film tension during the winding process is controlled by the PID system according to the number of tension levels and the corresponding tension.
进一步地,所述步骤S1中,所述卷径数据为离散时序数据,薄膜张力数据与卷径数据一一对应;Further, in the step S1, the roll diameter data is discrete time series data, and the film tension data corresponds to the roll diameter data one by one;
薄膜数据中的密度和厚度是锂电池隔膜的基本属性,直接影响张力大小;The density and thickness in the film data are the basic properties of lithium battery separators, which directly affect the tension;
所述对薄膜张力数据进行预处理包括以下步骤:采用样条插值法,对不同卷径下的薄膜张力数据进行单次插值,得到插值后的薄膜张力数据,计算方式为:The preprocessing of the film tension data comprises the following steps: using the spline interpolation method, performing a single interpolation on the film tension data under different roll diameters to obtain the interpolated film tension data, and the calculation method is:
; ;
; ;
; ;
; ;
其中,为三次样条函数输出的插值后的薄膜张力数据,为三次样条函数的输入,i为区间索引,为求解系数,为第i个区间左端点的卷径,为第i个区间左端点的对应的薄膜张力数据;为三次样条函数在第i个区间左端点的一阶导数,为三次样条函数在第i个区间左端点的二阶导数,为三次样条函数在第i+1个区间左端点的一阶导数,为三次样条函数在第i+1个区间左端点的二阶导数。in, is the interpolated film tension data output by the cubic spline function. is the input of the cubic spline function, i is the interval index, To solve for the coefficients, is the curl diameter of the left endpoint of the i-th interval, is the film tension data corresponding to the left endpoint of the i-th interval; is the first-order derivative of the cubic spline function at the left endpoint of the i-th interval, is the second-order derivative of the cubic spline function at the left endpoint of the ith interval, is the first-order derivative of the cubic spline function at the left endpoint of the i+1th interval, is the second-order derivative of the cubic spline function at the left endpoint of the i+1th interval.
薄膜张力数据通常是离散的,且数据点较少,无法充分反映出张力与卷径之间的细微变化;因此,采用样条插值法对离散的薄膜张力数据进行插值,能够得到更多的数据点,提高数据密度,有助于后续得到更加连续和平滑的张力-卷径曲线,也为后续的张力预测模型提供足够的数据点用于模型训练。Film tension data is usually discrete and has fewer data points, which cannot fully reflect the subtle changes between tension and roll diameter. Therefore, using spline interpolation to interpolate discrete film tension data can obtain more data points and improve data density, which will help to obtain a more continuous and smooth tension-roll diameter curve in the future, and also provide sufficient data points for the subsequent tension prediction model for model training.
进一步地,所述S2步骤包括:Furthermore, the S2 step includes:
S21:将薄膜密度数据、薄膜厚度数据与卷径数据进行融合,计算方式为:S21: The film density data, film thickness data and roll diameter data are integrated and calculated as follows:
; ;
; ;
其中,为融合后的数据,为拼接操作,分别为薄膜密度数据与薄膜厚度数据,为融合后的特征,为全连接层操作;in, is the fused data, For splicing operation, They are film density data and film thickness data, is the fused feature, It is a fully connected layer operation;
传统方法往往将张力设定为固定值,或只考虑卷径变化对张力的影响;相比之下,步骤S21结合了薄膜密度与薄膜厚度,在特征扩展之后再进行融合,考虑了更多的参数,能够更全面地捕捉张力的变化规律,使得收卷机在调整张力时能够更加精确地控制张力的变化,避免在收卷过程中出现的皱纹、暴筋等问题,提高锂电池隔膜的收卷效果;尤其是在面对不同厚度或密度的薄膜时,这种设计更能够适应不同的工艺要求,保证收卷效果的稳定性和品质;Traditional methods often set the tension to a fixed value, or only consider the effect of the change in roll diameter on the tension; in contrast, step S21 combines the film density and film thickness, and then fuses them after feature expansion, taking into account more parameters, and can more comprehensively capture the change law of tension, so that the winder can more accurately control the change of tension when adjusting the tension, avoiding wrinkles, ribs and other problems during the winding process, and improving the winding effect of lithium battery separators; especially when facing films of different thicknesses or densities, this design can better adapt to different process requirements and ensure the stability and quality of the winding effect;
S22:构建张力预测模型,预测薄膜张力数据的缺失值,并进行薄膜张力数据缺失值填补,计算方式为:S22: Construct a tension prediction model to predict the missing values of the film tension data and fill in the missing values of the film tension data. The calculation method is:
; ;
; ;
; ;
; ;
; ;
其中,为张力预测模型的输入,为第i个区间索引左端点的缺失编码,为第i-1个区间索引左端点的缺失编码,为第i个区间索引左端点的缺失距离编码,为第i-1个区间索引左端点的缺失距离编码,为衰减编码,为第i个区间索引左端点处的薄膜张力数据缺失值的预测结果,为第i-1个区间索引左端点处的薄膜张力数据缺失值的预测结果,为取自然常数的指数操作,为取最大值操作,为衰减参数权重,为衰减偏置向量,为循环神经网络操作;in, is the input of the tension prediction model, is the missing code of the left endpoint of the i-th interval index, is the missing code of the left endpoint of the i-1th interval index, is the missing distance code for the left endpoint of the i-th interval index, is the missing distance code for the left endpoint of the i-1th interval index, is the attenuation code, is the prediction result of the missing value of the film tension data at the left endpoint of the i-th interval index, is the prediction result of the missing value of the film tension data at the left endpoint of the i-1th interval index, To take the exponential operation of a natural constant, To obtain the maximum value, is the attenuation parameter weight, is the attenuation bias vector, Operate for recurrent neural networks;
与传统的循环神经网络对比,传统循环神经网络只考虑了数据之间的时序关系,而本发明通过显式编码为循环神经网络提供了一个信号,让循环神经网络注意到数据的缺失位置,同时注意到缺失值与最邻近非缺失值之间的时间步长,使得模型能更容易地利用薄膜张力数据的时序信息,从而提高了模型的预测精度和鲁棒性,进而提高收卷机的收卷效果;Compared with the traditional recurrent neural network, which only considers the temporal relationship between data, the present invention provides a signal to the recurrent neural network through explicit coding, so that the recurrent neural network pays attention to the missing position of the data and the time step between the missing value and the nearest non-missing value, so that the model can more easily use the temporal information of the film tension data, thereby improving the prediction accuracy and robustness of the model, and further improving the winding effect of the winder;
S23:根据预测结果,统计各个时刻的卷径数据、薄膜张力数据,生成卷径-张力曲线。S23: According to the prediction results, the roll diameter data and film tension data at each moment are counted to generate a roll diameter-tension curve.
进一步地,所述S3步骤包括:Furthermore, the S3 step includes:
S31:记录PID系统每一次调整薄膜张力的过程中产生的超调幅度;S31: recording the overshoot amplitude generated by each adjustment of the film tension by the PID system;
S32:当PID系统输出产生振荡时,记录振荡开始时间;S32: When the PID system output oscillates, the oscillation start time is recorded;
S33:当振荡幅度回到稳定范围内时,记录振荡停止时间,并与振荡开始时间作差,得到该次调整的波动时间;S33: When the oscillation amplitude returns to the stable range, the oscillation stop time is recorded and subtracted from the oscillation start time to obtain the fluctuation time of this adjustment;
S34:计算超调惩罚项,计算方式为:S34: Calculate the overshoot penalty term, the calculation method is:
; ;
其中,P为超调惩罚项,为超调幅度,为波动时间,为该次调整的总时间,为超调幅度权重,为时间权重。Among them, P is the overshoot penalty term, is the overshoot amplitude, is the fluctuation time, is the total time of this adjustment, is the overshoot amplitude weight, is the time weight.
设定过于精细的目标张力会导致PID系统在实时调整过程中,难以准确跟随目标张力的变化,经常出现超调和波动的情况,这些误差会随着调整次数的增加而累积,最终影响到收卷效果的稳定性;Setting too precise target tension will make it difficult for the PID system to accurately follow the changes in target tension during real-time adjustment, and overshoot and fluctuations will often occur. These errors will accumulate as the number of adjustments increases, ultimately affecting the stability of the winding effect.
此步骤引入了超调惩罚项,通过量化超调幅度和波动时间,对超调行为进行惩罚;对于S4步骤的基于强化学习的张力等级划分模型来说,这一惩罚机制能够有效降低频繁调整张力所带来的系统误差,使得张力等级划分模型更倾向于稳定的张力调整策略,而不是追求过度精细的目标张力,进而减少张力调整过程中的波动,提高了收卷过程的稳定性和品质。This step introduces an overshoot penalty term, which penalizes overshoot behavior by quantifying the overshoot amplitude and fluctuation time. For the tension level division model based on reinforcement learning in step S4, this penalty mechanism can effectively reduce the system error caused by frequent tension adjustment, making the tension level division model more inclined to a stable tension adjustment strategy rather than pursuing overly fine target tension, thereby reducing fluctuations in the tension adjustment process and improving the stability and quality of the winding process.
进一步地,所述S4步骤包括:Furthermore, the S4 step includes:
S41:设计张力等级划分模型的状态空间为:卷径-张力曲线分段后的张力值序列;动作空间为:对当前张力等级进行合并、在当前张力等级添加新的分段点;所述张力值序列以0为序列中的第一个数值,以最大卷径为序列中的最后一个数值;S41: The state space of the tension level division model is designed as: the tension value sequence after the coil diameter-tension curve is segmented; the action space is: merging the current tension level and adding a new segmentation point to the current tension level; the tension value sequence takes 0 as the first value in the sequence and the maximum coil diameter as the last value in the sequence;
S42:设计张力等级划分模型的奖励函数,计算方式为:S42: Design the reward function of the tension level classification model, which is calculated as follows:
; ;
; ;
其中,为张力等级划分模型的奖励值,为超调惩罚项的影响权重,为卷径-张力曲线拟合度,为卷径-张力曲线拟合度的影响权重,为取绝对值,为张力在卷径从变化到时的定积分;in, The reward value of the model divided into tension levels, is the influence weight of the overshoot penalty term, is the roll diameter-tension curve fitting degree, is the influence weight of the coil diameter-tension curve fitting, To take the absolute value, The tension is in the coil diameter from Change to The definite integral when
S43:设计张力等级划分模型的值函数,计算方式为:S43: The value function of the design tension level classification model is calculated as follows:
; ;
其中,为当前状态s和当前动作a下的值函数,为学习率,为下一个状态,为下一个动作,为使得下一步Q值最大时对应的下一步动作,为折扣因子,为更新符号;in, is the value function under the current state s and the current action a , is the learning rate, For the next state, For the next action, In order to make the next step corresponding to the maximum Q value, is the discount factor, To update the symbol;
S44:采用ε-greedy策略,对张力等级划分模型进行更新,并输出张力等级数量和各张力等级的对应张力。S44: Adopting the ε-greedy strategy, updating the tension level division model, and outputting the number of tension levels and the corresponding tension of each tension level.
S4步骤通过强化学习的方式,在给定最大卷径的情况下,计算分段点数量和分段后的张力值序列;以曲线拟合度中的面积的绝对值之差,来表示调整后的曲线与原卷径-张力曲线的拟合程度,但一味地追求拟合程度,会导致分段点数量过多,而每一次分段在将来PID系统进行控制时,都会产生超调和波动的误差;因此,奖励函数中还设计了超调惩罚项,这会使得模型在选择更多的分段次数时,得到较大的惩罚;In step S4, the number of segmentation points and the tension value sequence after segmentation are calculated by reinforcement learning under the condition of a given maximum coil diameter. The difference in the absolute value of the area in the curve fitting degree is used to indicate the degree of fit between the adjusted curve and the original coil diameter-tension curve. However, blindly pursuing the degree of fit will lead to too many segmentation points, and each segmentation will produce overshoot and fluctuation errors when the PID system is controlled in the future. Therefore, an overshoot penalty term is also designed in the reward function, which will cause the model to receive a larger penalty when selecting more segmentation times.
超调惩罚项可以约束系统的调整过程,避免频繁调整和误差累积,而曲线拟合度则能够评估张力曲线与卷径变化的匹配程度,进一步优化了奖励函数的设计,两者协同运行,共同提高了张力等级划分模型的性能,从而实现更加智能化、实用化的张力控制方式。The overshoot penalty term can constrain the system's adjustment process, avoiding frequent adjustments and error accumulation, while the curve fitting degree can evaluate the matching degree between the tension curve and the change in roll diameter, further optimizing the design of the reward function. The two work together to improve the performance of the tension level division model, thereby achieving a more intelligent and practical tension control method.
进一步地,所述S5步骤包括:Furthermore, the step S5 includes:
S51:初始化PID系统的比例、积分和微分参数;S51: Initialize the proportional, integral and differential parameters of the PID system;
S52:实时监测收卷过程中的薄膜张力和卷径;S52: Real-time monitoring of film tension and roll diameter during the winding process;
S53:根据张力等级数量和各张力等级的对应张力,通过PID系统调整收卷过程中的薄膜张力。S53: According to the number of tension levels and the corresponding tension of each tension level, the film tension during the winding process is adjusted through the PID system.
为实现上述基于人工智能的收卷方法,本发明还提供了一种基于人工智能的收卷系统, 包括:In order to realize the above-mentioned artificial intelligence-based winding method, the present invention also provides an artificial intelligence-based winding system, comprising:
数据采集与预处理模块:收集薄膜密度数据、薄膜厚度数据,以及薄膜收卷过程中薄膜卷的卷径数据、收卷过程中的薄膜张力数据,并对薄膜张力数据进行预处理,得到预处理后的薄膜张力数据;Data acquisition and preprocessing module: collects film density data, film thickness data, film roll diameter data during film winding, and film tension data during film winding, and preprocesses the film tension data to obtain preprocessed film tension data;
张力预测模型构建模块:将薄膜密度数据、薄膜厚度数据与卷径数据进行融合,同时构建张力预测模型,进行薄膜张力数据缺失值填补,生成卷径-张力曲线;Tension prediction model building module: integrates film density data, film thickness data and roll diameter data, builds a tension prediction model, fills in missing values of film tension data, and generates a roll diameter-tension curve;
超调惩罚项计算模块:计算PID系统每一次调整薄膜张力产生的超调幅度和波动时间,进而计算出超调惩罚项;Overshoot penalty calculation module: calculates the overshoot amplitude and fluctuation time generated by each adjustment of the film tension by the PID system, and then calculates the overshoot penalty term;
张力等级划分模型构建模块:构建张力等级划分模型,根据最大卷径,输出张力等级数量和对应张力;Tension level classification model construction module: constructs a tension level classification model, and outputs the number of tension levels and corresponding tensions according to the maximum roll diameter;
PID控制模块:根据张力等级数量和对应张力,通过PID系统控制收卷过程中的薄膜张力。PID control module: According to the number of tension levels and the corresponding tension, the film tension during the winding process is controlled by the PID system.
与现有技术相比,本发明的优点在于:Compared with the prior art, the advantages of the present invention are:
(1)在整体方案上,本发明构建张力预测模型,结合薄膜厚度数据、薄膜密度数据,对薄膜张力数据进行缺失值补全,计算出卷径-张力曲线;其次,通过强化学习的方式,构建张力等级划分模型,计算得到合适的张力等级数量和各等级的对应张力,然后据此进行实际张力调整,实现张力调整次数和效果的平衡,根据不同卷径计算出合理的张力调整次数对收卷机进行控制,提高了锂电池收卷效果,减少收卷过程中的皱纹、暴筋等问题。(1) In terms of the overall solution, the present invention constructs a tension prediction model, combines the film thickness data and the film density data, completes the missing values of the film tension data, and calculates the roll diameter-tension curve; secondly, through the reinforcement learning method, a tension level classification model is constructed to calculate the appropriate number of tension levels and the corresponding tension of each level, and then the actual tension is adjusted based on this to achieve a balance between the number of tension adjustments and the effect. According to different roll diameters, a reasonable number of tension adjustments is calculated to control the winder, thereby improving the lithium battery winding effect and reducing wrinkles, ribs and other problems during the winding process.
(2)在算法改进上,本发明首先对薄膜厚度数据、薄膜密度数据以及薄膜张力数据进行特征扩展,增强向量的表示能力;其次,在循环神经网络的基础上,对缺失位置、缺失值与临近非缺失值的时间步长以及衰减方式进行显式建模,提高了薄膜张力数据缺失值填补的效果,得到卷径-张力曲线。(2) In terms of algorithm improvement, the present invention first expands the features of film thickness data, film density data and film tension data to enhance the representation ability of vectors; secondly, based on the recurrent neural network, the missing position, the time step between the missing value and the adjacent non-missing value, and the attenuation method are explicitly modeled, thereby improving the effect of filling the missing values of the film tension data and obtaining the roll diameter-tension curve.
(3)本发明考虑到实际情况中PID系统每次进行张力调整带来的误差累积,引入强化学习思想,根据最大卷径计算出合理的张力分段数量和对应目标张力,使得张力分段控制方案更合理,降低了频繁调整张力所带来的系统误差,进而减少张力调整过程中的波动,提高了收卷过程的稳定性和品质。(3) The present invention takes into account the error accumulation caused by each tension adjustment of the PID system in actual situations, introduces the idea of reinforcement learning, and calculates the reasonable number of tension segments and the corresponding target tension according to the maximum roll diameter, so that the tension segment control scheme is more reasonable, reduces the system error caused by frequent tension adjustment, and thus reduces the fluctuation in the tension adjustment process, thereby improving the stability and quality of the winding process.
附图说明BRIEF DESCRIPTION OF THE DRAWINGS
图1为本发明提供的基于人工智能的收卷方法的流程示意图。FIG1 is a schematic flow chart of the artificial intelligence-based winding method provided by the present invention.
图2为本发明提供的张力预测模型的算法结构示意图。FIG. 2 is a schematic diagram of the algorithm structure of the tension prediction model provided by the present invention.
具体实施方式DETAILED DESCRIPTION
下面结合附图对本发明作进一步的说明,但不以任何方式对本发明加以限制,基于本发明教导所作的任何变换或替换,均属于本发明的保护范围。The present invention is further described below in conjunction with the accompanying drawings, but the present invention is not limited in any way. Any changes or substitutions made based on the teachings of the present invention belong to the protection scope of the present invention.
实施例1:Embodiment 1:
一种基于人工智能的收卷方法,如图1所示,包括以下步骤:An artificial intelligence-based winding method, as shown in FIG1 , comprises the following steps:
S1:收集薄膜密度数据、薄膜厚度数据,以及薄膜收卷过程中薄膜卷的卷径数据、收卷过程中的薄膜张力数据,并对薄膜张力数据进行预处理,得到预处理后的薄膜张力数据;S1: collecting film density data, film thickness data, roll diameter data of the film roll during film winding, and film tension data during film winding, and preprocessing the film tension data to obtain preprocessed film tension data;
所述卷径数据为离散时序数据,薄膜张力数据与卷径数据一一对应;薄膜数据中的密度和厚度是锂电池隔膜的基本属性,直接影响张力大小;The roll diameter data is discrete time series data, and the film tension data corresponds to the roll diameter data one by one; the density and thickness in the film data are the basic properties of the lithium battery separator, which directly affect the tension;
所述对薄膜张力数据进行预处理包括以下步骤:采用样条插值法,对不同卷径下的薄膜张力数据进行单次插值,得到插值后的薄膜张力数据,计算方式为:The preprocessing of the film tension data comprises the following steps: using the spline interpolation method, performing a single interpolation on the film tension data under different roll diameters to obtain the interpolated film tension data, and the calculation method is:
; ;
; ;
; ;
; ;
其中,为三次样条函数输出的插值后的薄膜张力数据,为三次样条函数的输入,i为区间索引,为求解系数,为第i个区间左端点的卷径,为第i个区间左端点的对应的薄膜张力数据;为三次样条函数在第i个区间左端点的一阶导数,为三次样条函数在第i个区间左端点的二阶导数,为三次样条函数在第i+1个区间左端点的一阶导数,为三次样条函数在第i+1个区间左端点的二阶导数。in, is the interpolated film tension data output by the cubic spline function. is the input of the cubic spline function, i is the interval index, To solve for the coefficients, is the curl diameter of the left endpoint of the i-th interval, is the film tension data corresponding to the left endpoint of the i-th interval; is the first-order derivative of the cubic spline function at the left endpoint of the i-th interval, is the second-order derivative of the cubic spline function at the left endpoint of the ith interval, is the first-order derivative of the cubic spline function at the left endpoint of the i+1th interval, is the second-order derivative of the cubic spline function at the left endpoint of the i+1th interval.
薄膜张力数据通常是离散的,且数据点较少,无法充分反映出张力与卷径之间的细微变化;因此,采用样条插值法对离散的薄膜张力数据进行插值,能够得到更多的数据点,提高数据密度,有助于后续得到更加连续和平滑的张力-卷径曲线,也为后续的张力预测模型提供足够的数据点用于模型训练。Film tension data is usually discrete and has fewer data points, which cannot fully reflect the subtle changes between tension and roll diameter. Therefore, using spline interpolation to interpolate discrete film tension data can obtain more data points and improve data density, which will help to obtain a more continuous and smooth tension-roll diameter curve in the future, and also provide sufficient data points for the subsequent tension prediction model for model training.
例如,For example,
插值前:Before interpolation:
插值后:After interpolation:
插值并非要填补所有数据,而是通过三次样条函数的拟合能力,将已知数据点之间的趋势进行初步处理,为后续的张力预测模型提供更多数据点,从而增强模型的预测性能和稳健性;在实时性和易用性方面,采用插值的方法相对于其他缺失值填补方法具有明显优势。Interpolation does not mean to fill in all the data, but to preliminarily process the trends between known data points through the fitting ability of the cubic spline function, so as to provide more data points for the subsequent tension prediction model, thereby enhancing the prediction performance and robustness of the model; in terms of real-time and ease of use, the interpolation method has obvious advantages over other missing value filling methods.
S2:将薄膜密度数据、薄膜厚度数据与卷径数据进行融合,同时构建张力预测模型,进行薄膜张力数据缺失值填补,生成卷径-张力曲线,如图2所示;S2: Fusing the film density data, film thickness data and roll diameter data, and constructing a tension prediction model to fill in the missing values of the film tension data and generate a roll diameter-tension curve, as shown in FIG2 ;
张力预测模型首先提出位置缺失编码、缺失距离编码,分别对缺失值的位置以及缺失值与真值的距离进行标识,再将位置缺失编码、缺失距离编码与薄膜张力数据进行融合,输入门控循环单元,对薄膜张力数据进行预测并填补;The tension prediction model first proposes position missing coding and missing distance coding to mark the position of the missing value and the distance between the missing value and the true value respectively, and then integrates the position missing coding and missing distance coding with the film tension data and inputs them into the gated recurrent unit to predict and fill the film tension data.
步骤S2包括:Step S2 includes:
S21:将薄膜密度数据、薄膜厚度数据与卷径数据进行融合,计算方式为:S21: The film density data, film thickness data and roll diameter data are integrated and calculated as follows:
; ;
; ;
其中,为融合后的数据,为拼接操作,分别为薄膜密度数据与薄膜厚度数据,为融合后的特征,为全连接层操作;in, is the fused data, For splicing operation, They are film density data and film thickness data, is the fused feature, It is a fully connected layer operation;
传统方法往往将张力设定为固定值,或只考虑卷径变化对张力的影响;相比之下,步骤S21结合了薄膜密度与薄膜厚度,在特征扩展之后再进行融合,考虑了更多的参数,能够更全面地捕捉张力的变化规律,使得收卷机在调整张力时能够更加精确地控制张力的变化,避免在收卷过程中出现的皱纹、暴筋等问题,提高锂电池隔膜的收卷效果;尤其是在面对不同厚度或密度的薄膜时,这种设计更能够适应不同的工艺要求,保证收卷效果的稳定性和品质;Traditional methods often set the tension to a fixed value, or only consider the effect of the change in roll diameter on the tension; in contrast, step S21 combines the film density and film thickness, and then fuses them after feature expansion, taking into account more parameters, and can more comprehensively capture the change law of tension, so that the winder can more accurately control the change of tension when adjusting the tension, avoiding wrinkles, ribs and other problems during the winding process, and improving the winding effect of lithium battery separators; especially when facing films of different thicknesses or densities, this design can better adapt to different process requirements and ensure the stability and quality of the winding effect;
S22:构建张力预测模型,预测薄膜张力数据的缺失值,并进行薄膜张力数据缺失值填补,计算方式为:S22: Construct a tension prediction model to predict the missing values of the film tension data and fill in the missing values of the film tension data. The calculation method is:
; ;
; ;
; ;
; ;
; ;
其中,为张力预测模型的输入,为第i个区间索引左端点的缺失编码,为第i-1个区间索引左端点的缺失编码,为第i个区间索引左端点的缺失距离编码,为第i-1个区间索引左端点的缺失距离编码,为衰减编码,为第i个区间索引左端点处的薄膜张力数据缺失值的预测结果,为第i-1个区间索引左端点处的薄膜张力数据缺失值的预测结果,为取自然常数的指数操作,为取最大值操作,为衰减参数权重,为衰减偏置向量,为循环神经网络操作;in, is the input of the tension prediction model, is the missing code of the left endpoint of the i-th interval index, is the missing code of the left endpoint of the i-1th interval index, is the missing distance code for the left endpoint of the i-th interval index, is the missing distance code for the left endpoint of the i-1th interval index, is the attenuation code, is the prediction result of the missing value of the film tension data at the left endpoint of the i-th interval index, is the prediction result of the missing value of the film tension data at the left endpoint of the i-1th interval index, To take the exponential operation of a natural constant, To obtain the maximum value, is the attenuation parameter weight, is the attenuation bias vector, Operate for recurrent neural networks;
与传统的循环神经网络对比,传统循环神经网络只考虑了数据之间的时序关系,而本发明通过显式编码为循环神经网络提供了一个信号,让循环神经网络注意到数据的缺失位置,同时注意到缺失值与最邻近非缺失值之间的时间步长,使得模型能更容易地利用薄膜张力数据的时序信息,从而提高了模型的预测精度和鲁棒性,进而提高收卷机的收卷效果;Compared with the traditional recurrent neural network, which only considers the temporal relationship between data, the present invention provides a signal to the recurrent neural network through explicit coding, so that the recurrent neural network pays attention to the missing position of the data and the time step between the missing value and the nearest non-missing value, so that the model can more easily use the temporal information of the film tension data, thereby improving the prediction accuracy and robustness of the model, and further improving the winding effect of the winder;
例如,For example,
传统循环神经网络的输入为单层的向量:The input of a traditional recurrent neural network is a single-layer vector:
[13.5N, 14.755N, _, 15.525N, 16.290N, _, _, 16.875N][13.5N, 14.755N, _, 15.525N, 16.290N, _, _, 16.875N]
经过显式编码后的输入为三层的矩阵:The input after explicit encoding is a three-layer matrix:
[13.5N, 14.755N, _, 15.525N, 16.290N, _, _, 16.875N][13.5N, 14.755N, _, 15.525N, 16.290N, _, _, 16.875N]
[1, 1, 0, 1, 1, 0, 0, 1][1, 1, 0, 1, 1, 0, 0, 1]
[0, 0, 1, 0, 0, 1, 2, 0][0, 0, 1, 0, 0, 1, 2, 0]
第二层与第三层分别对缺失值位置和缺失值距离上一个非缺失值的距离进行显式编码,使得循环神经网络更加明确应当重点关注哪些位置的信息,进而提高了薄膜张力数据缺失值填补的效果;The second and third layers explicitly encode the missing value position and the distance between the missing value and the previous non-missing value, respectively, so that the recurrent neural network can more clearly know which positions should be focused on, thereby improving the effect of missing value filling in film tension data.
S23:根据预测结果,统计各个时刻的卷径数据、薄膜张力数据,生成卷径-张力曲线。S23: According to the prediction results, the roll diameter data and film tension data at each moment are counted to generate a roll diameter-tension curve.
S3:计算PID系统每一次调整张力产生的超调幅度和波动时间,进而计算出超调惩罚项;S3: Calculate the overshoot amplitude and fluctuation time generated by each tension adjustment of the PID system, and then calculate the overshoot penalty term;
S31:记录PID系统每一次调整薄膜张力的过程中产生的超调幅度;S31: recording the overshoot amplitude generated by each adjustment of the film tension by the PID system;
S32:当PID系统输出产生振荡时,记录振荡开始时间;S32: When the PID system output oscillates, the oscillation start time is recorded;
S33:当振荡幅度回到稳定范围内时,记录振荡停止时间,并与振荡开始时间作差,得到该次调整的波动时间;S33: When the oscillation amplitude returns to the stable range, the oscillation stop time is recorded and subtracted from the oscillation start time to obtain the fluctuation time of this adjustment;
S34:计算超调惩罚项,计算方式为:S34: Calculate the overshoot penalty term, the calculation method is:
; ;
其中,P为超调惩罚项,为超调幅度,为波动时间,为该次调整的总时间,为超调幅度权重,为时间权重。Among them, P is the overshoot penalty term, is the overshoot amplitude, is the fluctuation time, is the total time of this adjustment, is the overshoot amplitude weight, is the time weight.
设定过于精细的目标张力会导致PID系统在实时调整过程中,难以准确跟随目标张力的变化,经常出现超调和波动的情况,这些误差会随着调整次数的增加而累积,最终影响到收卷效果的稳定性;Setting too precise target tension will make it difficult for the PID system to accurately follow the changes in target tension during real-time adjustment, and overshoot and fluctuations will often occur. These errors will accumulate as the number of adjustments increases, ultimately affecting the stability of the winding effect.
此步骤引入了超调惩罚项,通过量化超调幅度和波动时间,对超调行为进行惩罚;对于S4步骤的基于强化学习的张力等级划分模型来说,这一惩罚机制能够有效降低频繁调整张力所带来的系统误差,使得张力等级划分模型更倾向于稳定的张力调整策略,而不是追求过度精细的目标张力,进而减少张力调整过程中的波动,提高了收卷过程的稳定性和品质。This step introduces an overshoot penalty term, which penalizes overshoot behavior by quantifying the overshoot amplitude and fluctuation time. For the tension level division model based on reinforcement learning in step S4, this penalty mechanism can effectively reduce the system error caused by frequent tension adjustment, making the tension level division model more inclined to a stable tension adjustment strategy rather than pursuing overly fine target tension, thereby reducing fluctuations in the tension adjustment process and improving the stability and quality of the winding process.
S4:构建张力等级划分模型,根据最大卷径,输出张力等级数量和对应张力;S4: construct a tension level classification model, and output the number of tension levels and corresponding tension according to the maximum roll diameter;
张力等级划分模型的奖励函数采用定积分的方式计算卷径-张力曲线拟合度,张力等级划分模型的值函数采用Q-learning的方式进行计算,并采用ε-greedy策略,对张力等级划分模型进行更新;The reward function of the tension level classification model uses a definite integral method to calculate the coil diameter-tension curve fitting degree, and the value function of the tension level classification model is calculated using the Q-learning method, and the ε-greedy strategy is used to update the tension level classification model.
步骤S4包括:Step S4 includes:
S41:设计张力等级划分模型的状态空间为:卷径-张力曲线分段后的张力值序列;动作空间为:对当前张力等级进行合并、在当前张力等级添加新的分段点;所述张力值序列以0为序列中的第一个数值,以最大卷径为序列中的最后一个数值;S41: The state space of the tension level division model is designed as: the tension value sequence after the coil diameter-tension curve is segmented; the action space is: merging the current tension level and adding a new segmentation point to the current tension level; the tension value sequence takes 0 as the first value in the sequence and the maximum coil diameter as the last value in the sequence;
S42:设计张力等级划分模型的奖励函数,计算方式为:S42: Design the reward function of the tension level classification model, which is calculated as follows:
; ;
; ;
其中,为张力等级划分模型的奖励值,为超调惩罚项的影响权重,为卷径-张力曲线拟合度,为卷径-张力曲线拟合度的影响权重,为取绝对值,为张力在卷径从变化到时的定积分;例如,若最大卷径为60厘米,模型在训练开始阶段,将分段点数量设定为100,即卷径每变化0.6厘米,PID系统就要调整一次目标张力,频次过高,因此根据超调惩罚项,模型会受到更大的惩罚,减少分段点数量;in, The reward value of the model divided into tension levels, is the influence weight of the overshoot penalty term, is the roll diameter-tension curve fitting degree, is the influence weight of the coil diameter-tension curve fitting, To take the absolute value, The tension is in the coil diameter from Change to For example, if the maximum roll diameter is 60 cm, the number of segmentation points is set to 100 at the beginning of the model training. That is, the PID system has to adjust the target tension once for every 0.6 cm change in roll diameter. The frequency is too high. Therefore, according to the overshoot penalty term, the model will be punished more severely and the number of segmentation points will be reduced.
在训练中期,模型将分段点数量设定为6,即卷径每变化10厘米,PID系统进行一次目标张力的调整,频次过低,与卷径-张力曲线的面积的绝对值较大,拟合程度较差,因此根据曲线拟合度,模型仍然会受到惩罚,提高分段点数量;In the middle of the training, the model sets the number of segmentation points to 6, that is, the PID system adjusts the target tension once for every 10 cm change in the roll diameter. The frequency is too low, and the absolute value of the area of the roll diameter-tension curve is large, and the degree of fit is poor. Therefore, according to the curve fit, the model will still be penalized and the number of segmentation points will be increased;
在训练后期,模型经过双向的惩罚后,计算出较为合适的分段点数量为20,即卷径每变化3厘米,PID系统进行一次目标张力的调整,频次适中,保证了在不产生过多的超调和波动的前提下,对卷径-张力曲线的拟合程度;In the later stage of training, after two-way punishment, the model calculated that the number of segmentation points was more appropriate to be 20, that is, the PID system adjusted the target tension once for every 3 cm change in the roll diameter, with a moderate frequency, ensuring the degree of fitting of the roll diameter-tension curve without excessive overshoot and fluctuation.
S43:设计张力等级划分模型的值函数,计算方式为:S43: The value function of the design tension level classification model is calculated as follows:
; ;
其中,为当前状态s和当前动作a下的值函数,为学习率,为下一个状态,为下一个动作,为使得下一步Q值最大时对应的下一步动作,为折扣因子,为更新符号;in, is the value function under the current state s and the current action a , is the learning rate, For the next state, For the next action, In order to make the next step corresponding to the maximum Q value, is the discount factor, To update the symbol;
S44:采用ε-greedy策略,对张力等级划分模型进行更新,并输出张力等级数量和各张力等级的对应张力。S44: Adopting the ε-greedy strategy, updating the tension level division model, and outputting the number of tension levels and the corresponding tension of each tension level.
S4步骤通过强化学习的方式,在给定最大卷径的情况下,计算分段点数量和分段后的张力值序列;以曲线拟合度中的面积的绝对值之差,来表示调整后的曲线与原卷径-张力曲线的拟合程度,但一味地追求拟合程度,会导致分段点数量过多,而每一次分段在将来PID系统进行控制时,都会产生超调和波动的误差;因此,奖励函数中还设计了超调惩罚项,这会使得模型在选择更多的分段次数时,得到较大的惩罚;In step S4, the number of segmentation points and the tension value sequence after segmentation are calculated by reinforcement learning under the condition of a given maximum coil diameter. The difference in the absolute value of the area in the curve fitting degree is used to indicate the degree of fit between the adjusted curve and the original coil diameter-tension curve. However, blindly pursuing the degree of fit will lead to too many segmentation points, and each segmentation will produce overshoot and fluctuation errors when the PID system is controlled in the future. Therefore, an overshoot penalty term is also designed in the reward function, which will cause the model to receive a larger penalty when selecting more segmentation times.
超调惩罚项可以约束系统的调整过程,避免频繁调整和误差累积,而曲线拟合度则能够评估张力曲线与卷径变化的匹配程度,进一步优化了奖励函数的设计,两者协同运行,共同提高了张力等级划分模型的性能,从而实现更加智能化、实用化的张力控制方式。The overshoot penalty term can constrain the system's adjustment process, avoiding frequent adjustments and error accumulation, while the curve fitting degree can evaluate the matching degree between the tension curve and the change in roll diameter, further optimizing the design of the reward function. The two work together to improve the performance of the tension level division model, thereby achieving a more intelligent and practical tension control method.
S5:根据张力等级数量和对应张力,通过PID系统控制收卷过程中的薄膜张力;S5: Control the film tension during the winding process through the PID system according to the number of tension levels and the corresponding tension;
S51:初始化PID系统的比例、积分和微分参数;S51: Initialize the proportional, integral and differential parameters of the PID system;
S52:实时监测收卷过程中的薄膜张力和卷径;S52: Real-time monitoring of film tension and roll diameter during the winding process;
S53:根据张力等级数量和各张力等级的对应张力,通过PID系统调整收卷过程中的薄膜张力。S53: According to the number of tension levels and the corresponding tension of each tension level, the film tension during the winding process is adjusted through the PID system.
本发明尤其适用于对收卷效果要求较高的生产场景,特别是在需要频繁调整张力的情况下;本发明能够充分考虑薄膜特性、卷径与PID系统的能力,解决传统收卷方法在调整张力过程中出现的误差累积、超调和波动等问题,改善收卷效果。The present invention is particularly suitable for production scenarios with high requirements for winding effects, especially when frequent tension adjustment is required; the present invention can fully consider the film characteristics, roll diameter and the capabilities of the PID system, solve the problems of error accumulation, overshoot and fluctuation that occur in the traditional winding method during the tension adjustment process, and improve the winding effect.
实施例2Example 2
一种基于人工智能的收卷系统,用于实现上述基于人工智能的收卷方法,包括:An artificial intelligence-based winding system, used to implement the artificial intelligence-based winding method, comprises:
数据采集与预处理模块:收集薄膜密度数据、薄膜厚度数据,以及薄膜收卷过程中薄膜卷的卷径数据、收卷过程中的薄膜张力数据,并对薄膜张力数据进行预处理,得到预处理后的薄膜张力数据;Data acquisition and preprocessing module: collects film density data, film thickness data, film roll diameter data during film winding, and film tension data during film winding, and preprocesses the film tension data to obtain preprocessed film tension data;
张力预测模型构建模块:将薄膜密度数据、薄膜厚度数据与卷径数据进行融合,同时构建张力预测模型,进行薄膜张力数据缺失值填补,生成卷径-张力曲线;Tension prediction model building module: integrates film density data, film thickness data and roll diameter data, builds a tension prediction model, fills in missing values of film tension data, and generates a roll diameter-tension curve;
超调惩罚项计算模块:计算PID系统每一次调整薄膜张力产生的超调幅度和波动时间,进而计算出超调惩罚项;Overshoot penalty calculation module: calculates the overshoot amplitude and fluctuation time generated by each adjustment of the film tension by the PID system, and then calculates the overshoot penalty term;
张力等级划分模型构建模块:构建张力等级划分模型,根据最大卷径,输出张力等级数量和对应张力;Tension level classification model construction module: constructs a tension level classification model, and outputs the number of tension levels and corresponding tensions according to the maximum roll diameter;
PID控制模块:根据张力等级数量和对应张力,通过PID系统,控制收卷过程中的薄膜张力。PID control module: According to the number of tension levels and the corresponding tension, the film tension during the winding process is controlled through the PID system.
需要说明的是,上述本发明实施例序号仅仅为了描述,不代表实施例的优劣。并且本文中的术语“包括”、“包含”或者其任何其他变体意在涵盖非排他性的包含,从而使得包括一系列要素的过程、装置、物品或者方法不仅包括那些要素,而且还包括没有明确列出的其他要素,或者是还包括为这种过程、装置、物品或者方法所固有的要素。在没有更多限制的情况下,由语句“包括一个……”限定的要素,并不排除在包括该要素的过程、装置、物品或者方法中还存在另外的相同要素。It should be noted that the serial numbers of the above embodiments of the present invention are only for description and do not represent the advantages and disadvantages of the embodiments. And the terms "including", "comprising" or any other variants thereof in this article are intended to cover non-exclusive inclusion, so that a process, device, article or method including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, device, article or method. In the absence of further restrictions, an element defined by the sentence "including a ..." does not exclude the presence of other identical elements in the process, device, article or method including the element.
通过以上的实施方式的描述,本领域的技术人员可以清楚地了解到上述实施例方法可借助软件加必需的通用硬件平台的方式来实现,当然也可以通过硬件,但很多情况下前者是更佳的实施方式。基于这样的理解,本发明的技术方案本质上或者说对现有技术做出贡献的部分可以以软件产品的形式体现出来,该计算机软件产品存储在如上所述的一个存储介质(如ROM/RAM、磁碟、光盘)中,包括若干指令用以使得一台终端设备(可以是手机,计算机,服务器,或者网络设备等)执行本发明各个实施例所述的方法。Through the description of the above implementation methods, those skilled in the art can clearly understand that the above-mentioned embodiment methods can be implemented by means of software plus a necessary general hardware platform, and of course by hardware, but in many cases the former is a better implementation method. Based on such an understanding, the technical solution of the present invention is essentially or the part that contributes to the prior art can be embodied in the form of a software product, which is stored in a storage medium (such as ROM/RAM, magnetic disk, optical disk) as described above, and includes a number of instructions for a terminal device (which can be a mobile phone, a computer, a server, or a network device, etc.) to execute the methods described in each embodiment of the present invention.
以上仅为本发明的优选实施例,并非因此限制本发明的专利范围,凡是利用本发明说明书及附图内容所作的等效结构或等效流程变换,或直接或间接运用在其他相关的技术领域,均同理包括在本发明的专利保护范围内。The above are only preferred embodiments of the present invention, and are not intended to limit the patent scope of the present invention. Any equivalent structure or equivalent process transformation made using the contents of the present invention specification and drawings, or directly or indirectly applied in other related technical fields, are also included in the patent protection scope of the present invention.
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