Advanced Motion Control Design for Longitudinal Web Dynamics in Roll-to-Roll Systems: Velocity or Position Control?

2013 ◽  
Author(s):  
Y. Martz ◽  
J. Frechard ◽  
D. Knittel
Keyword(s):  
Control Strategy ◽  
Position Control ◽  
Tension Control ◽  
Web Handling ◽  
Reference Tracking ◽  
External Loop ◽  
Roll To Roll ◽  
Processing Line ◽  
The Web ◽  
Web Tension

Roll-to-Roll systems handling web material such as papers, polymers, textiles or metals are very common in the industry. One of the main objectives in web handling plant is to reach an expected web speed while maintaining the web tension within an acceptable range around the tension reference in the entire processing line. In the recent years, several works have focused on the topic of web tension control using H∞ approaches. In the traditional way, each motor driven roller is controlled in speed and the web tension control is ensured by an external loop. This paper proposes to compare, for the first time, the traditional control strategy with a control strategy including position control rather than speed control. In fact, position control is commonly used in printing industry. The comparison will be ensured in frequency and time domain and take into account the reference tracking performances and the robustness to web elasticity variations.

A Nonlinear Tension Control Scheme for Web Transport Through Heating Processes

2015 ◽  
Author(s):  
Youwei Lu ◽  
Prabhakar R. Pagilla
Keyword(s):  
Heat Transfer ◽  
Thermal Effects ◽  
Tension Control ◽  
Web Based ◽  
Transfer Processes ◽  
Roll To Roll ◽  
Flexible Material ◽  
Control Scheme ◽  
The Web ◽  
Web Tension

In this paper we develop a model-based nonlinear tension control scheme for transport of flexible materials (webs) through heating processes. Heat transfer processes are widely employed in Roll-to-Roll (R2R) process machines that are used to perform processing operations on a moving web on rollers. Heat transfer processes induce thermal expansion/contraction of the flexible material during transport. Because web strain and elastic modulus are functions of temperature distribution in the web, web tension resulting from elastic strain is affected by heating/cooling of the web. Based on a web tension governing equation that includes both elastic and thermal effects, a nonlinear tension control scheme is developed for control of tension in each tension zone of an R2R system. The control scheme is implemented on an R2R experimental platform containing two heat transfer rollers, one for heating the web and one for subsequently cooling the web prior to winding of the web. Experimental results are presented and discussed.

Register control of roll-to-roll gravure-offset printing equipment considering time difference between measurement and actuation

2012 ◽  
Vol 226 (11) ◽  
pp. 2726-2738 ◽  
Author(s):  
Chung Hwan Kim ◽  
Ha-Il You ◽  
Seung-Hyun Lee
Keyword(s):  
Measurement System ◽  
Position Control ◽  
Printed Electronics ◽  
Control Method ◽  
Axial Direction ◽  
Time Difference ◽  
Offset Printing ◽  
Drying Time ◽  
Roll To Roll ◽  
The Web

The manufacture of printed electronics by roll-to-roll printing machine requires more accurate register performance than conventional media printing technology. Moreover, high drying temperature and long drying time to sinter the inks can induce the substantial changes in the length of the substrate and consequently register errors. Among the roll-to-roll printing methods, the gravure one, despite its relatively fast productivity and fine-line printing capacity, has difficulty in achieving the required register specifications for printed electronics because of the dependence of the register control on web dynamics. This study proposes a roll-to-roll gravure-offset printing equipment, including the register measurement system designed to enhance register performance and the related register control method for the application of printed electronics. Each cylinder constituting the printing unit is driven independently by an individual servomotor. Moreover, the printing patterns of the plate cylinder can move in the axial direction by position control, as well as in the web transport direction by a phase shift of the plate cylinder, without affecting the dynamics of the web. The time difference between the measurement and the actual control action is considered and modeled. The register measurement system, including selections of sensors and marks is also proposed to consider the effect of the time difference. The simulation results and the experiments of the register control are shown to verify the effect of the time difference on the control performances. It is found that a proper estimation of time difference should be obtained in order to guarantee more accurate and stable control performances.

Advanced Optimization of Industrial Large-Scale Roll-to-Roll Systems Under Parametric Uncertainties

2012 ◽  
Author(s):  
J. Frechard ◽  
D. Knittel
Keyword(s):  
Young’S Modulus ◽  
Large Scale ◽  
Young's Modulus ◽  
Robust Design Optimization ◽  
Parametric Uncertainties ◽  
Optimization Approach ◽  
Roll To Roll ◽  
Polymer Metal ◽  
The Web ◽  
Web Tension

In industrial plants some parameters can not be evaluated properly or they are varying with time. These parametric uncertainties has to be taken into account during the design process of industrial systems. In this work, the developped optimization approach is applied on an industrial roll-to-roll sytem. Such systems are commonly used to handle materials as polymer, metal, paper and textile. The key challenge is to move the web at the expected speed while maintaining the web tension in an acceptable range around its reference. Moreover, the Young’s modulus of the web is difficult to evaluate and it is varying with time due to temperature and moisture variations. This paper deals with the web tension controller synthesis on a large-scale roll-to-roll system with uncertain Young’s modulus. To synthesize web tension controllers, an H∞ approach is applied and adapted to the system with parametric uncertainties using multi-objective robust design optimization.

Bahnzugkraftregelung in der Batteriezellfertigung*/Web tension control in battery cell production

2018 ◽  
Vol 108 (07-08) ◽  
pp. 519-524
Author(s):  
H. Weinmann ◽  
F. Lang ◽  
J. Hofmann ◽  
J. Fleischer
Keyword(s):  
Dimensional Accuracy ◽  
Tension Control ◽  
Selection Function ◽  
Battery Cell ◽  
Cell Production ◽  
Material Parameters ◽  
Single Sheet ◽  
The Web ◽  
Web Tension

Viele Maschinen- und Materialparameter sind für die Qualität eines Elektroden-Einzelblattes verantwortlich. Relevant für Vereinzelung und Stapelbildung ist etwa die Bahnzugkraft, mit der die Elektrodenbahn während des Stanzvorgangs beaufschlagt wird. Diese wurde in der Versuchsanlage des wbk Institut für Produktionstechnik regelbar ausgeführt, um Zusammenhänge bei der Einzelblattstapelbildung zu untersuchen. Dieser Artikel stellt Auswahl und Funktion sowie die Integration der Lösung in die Versuchsanlage und die Auswirkung verschiedener Bahnzugkräfte auf die Maßhaltigkeit der gestanzten Einzelblätter vor.   The quality of an electrode single-sheet is affected by a multitude of machine and material parameters, such as the web tension force for separating and stacking applied to the electrode web during die cutting. As an adjustable force it was analyzed in a demonstrator at the wbk Institute of Production Science to identify interdependencies during single-sheet-stacking. This article presents the selection, function and integration of the solution into a demonstrator and how different web tension forces affect the dimensional accuracy of die-cut sheets.

scholarly journals Kalman-Filter-Based Tension Control Design for Industrial Roll-to-Roll System

Algorithms ◽  
2019 ◽  
Vol 12 (4) ◽  
pp. 86 ◽  
Author(s):  
Hyeongjin Hwang ◽  
Jehwon Lee ◽  
Sangjune Eum ◽  
Kanghyun Nam
Keyword(s):  
Kalman Filter ◽  
Control Method ◽  
Tracking Error ◽  
Tension Control ◽  
External Disturbances ◽  
Roll To Roll ◽  
Control Scheme ◽  
Roll System ◽  
The Web

This paper presents a robust and precise tension control method for a roll-to-roll (R2R) system. In R2R processing, robust and precise tension control is very important because improper web tension control leads to deterioration in the quality of web material. However, tension control is not easy because the R2R system has a model variation in which the inertia of the web in roll form is changed and external disturbances caused by web slip and crumpled web. Therefore, a disturbance observer (DOB) was proposed to achieve robustness against model variations and external disturbances. DOB is a robust control method widely used in various fields because of its simple structure and excellent performance. Moreover, the web passes through various process steps to achieve the finished product in the R2R process. Particularly, it is important to track the tension when magnitude of the tension varies during process. Feedforward (FF) controller was applied to minimize the tracking error in the transient section where tension changes. Moreover, the signal processing of a sensor using the Kalman filter (KF) in the R2R system greatly improved control performance. Finally, the effectiveness of the proposed control scheme is discussed using experimental results.

scholarly journals Roll-to-roll infrared and hot-air sintering of gravure-printed Ag layer based on in situ tension measuring and analysis

2016 ◽  
Vol 4 (38) ◽  
pp. 8884-8888 ◽  
Author(s):  
Janghoon Park ◽  
Hyi Jae Kang ◽  
Hyogeun Gil ◽  
Kee-Hyun Shin ◽  
Hyunkyoo Kang
Keyword(s):  
Hot Air ◽  
Roll To Roll ◽  
The Web ◽  
Web Tension

The sintering energy was quantified and evaluated based on theoretical and experimental calculations. Moreover, the effect of the sintering energy on the web tension was simultaneously considered.

System for Automatic Web Guiding for Roll-to-Roll Machine Working in a Start-Stop Mode

2014 ◽  
Vol 223 ◽  
pp. 374-382
Author(s):  
Mirosław Neska ◽  
Andrzej Majcher
Keyword(s):  
Material Processing ◽  
Control System ◽  
Processing Machine ◽  
Processing Machinery ◽  
Roll To Roll ◽  
Transport Velocity ◽  
The Web ◽  
Selection Of ◽  
Web Tension ◽  
Hardware Structure

Web guiding used in roll-to-roll material processing machinery is connected with a number of issues including the maintenance of the web tension, the precision of the lateral web displacement, the accuracy of transport positioning of the web, and the selection of web transport velocity. The article presents the precision of the lateral web displacement issue during the start-stop work mode of the web transport. A model of a system for automatic web guiding is shown. The requirements of the lateral web guiding for transporting material over rollers in a processing machine working in a start-stop mode are presented. The control system is discussed, particularly its hardware structure and behaviour. The obtained functionality of the control system enables its application in roll-to-roll material processing machines, working either in the start-stop mode or continuously.

Modeling Web Tension Dynamics Considering Thermal and Viscoelastic Effects: Simulations and Experiments

2014 ◽  
Author(s):  
Kadhim A. Jabbar ◽  
Prabhakar R. Pagilla
Keyword(s):  
Thermal Strain ◽  
Viscoelastic Model ◽  
Model Simulations ◽  
Viscoelastic Parameters ◽  
Viscoelastic Effects ◽  
Processing Line ◽  
Materials Used ◽  
Creep And Stress Relaxation ◽  
The Web ◽  
Web Tension

In this paper, a governing equation for web tension considering thermal and viscoelastic effects in a multi-span system is developed. The thermal effect is included in the web tension dynamics by considering the thermal strain induced by temperature distribution in the web span. The viscoelastic effect is introduced by using a standard linear solid (SLS) model from which a relationship between the applied stress and the resulting strain is obtained. Elevated temperature creep and stress relaxation experiments are conducted on several web materials used in an industrial web processing line to determine the viscoelastic parameters of the utilized viscoelastic model. Model simulations are conducted with the same control systems as those used in an industrial web processing line. Data from model simulations are compared with measured data obtained from the industrial web processing line.

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