Abstract
Roll-to-roll (R2R) system can be found and applied in various fields, such as paper manufacture and printing process. The matter regarding tension control is still a challenge because this tends to rely on elasticity of web materials with its elasticity and roll inertia which change. Additionally, another issue is limited stiffness shafts connecting the web handling system and driving motor. Due to non-rigid nature of the shafts, un-wanted vibration can be released, and this impact to the system. Therefore, the tension control is more complicated. In this paper, a control solution for a roll-to-roll web-transport system with flexible couplings will be performed. The connection of this system coupled with motors through non-rigid driving shaft is formed as a two-mass system. Moreover, the paper shows that the thickness of web material is assumed to be conscious in order to achieve a simple calculation of roll inertia momentum. By using backstepping control technique, control laws for unwinding and rewinding roll are defined. The control schemes ensure a linear velocity and tension tracking performance of the system. Extensive numerical simulations are carried out to verify the feasibility of the proposed control strategy. The simulation results indicate the effectiveness of the proposed control, web tension and position are driven to desired values.
Highlights
Roll-to-roll processing, or R2R, is a fabrication method used in manufacturing that embeds, coats, prints or laminates varying applications onto a flexible rolled substrate material [1], [2], and [3]
In order to create a suitable controller for this system, a mathematical model and a proper control need to be obtained
Tension control is essential in web-handling systems
Summary
Roll-to-roll processing, or R2R, is a fabrication method used in manufacturing that embeds, coats, prints or laminates varying applications onto a flexible rolled substrate material [1], [2], and [3]. Classical PID control is widely used in tension regulation [7] and [8], the approach presents several drawbacks in dealing with nonlinear systems with varying parameters such as the web-handling system. The shaft connecting a drive motor and a load machine is considered to be rigid when designing the industrial drive of R2R system [18]–[20]. This omission is acceptable in case of the small roll inertia and the short shaft, but not in the cases that characteristics of mechanical parts are considered. The obtained mathematical model used to design the control law for web position in a comprehensive procedure. Based on the backstepping method, this paper shows a simple approach that can be separately applied to the unwinder and rewinder
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