Abstract
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.
Highlights
Roll-to-roll (R2R) technology has recently attracted a great deal of attention for the mass production of electronic devices in the field of display and battery [1]
We propose a tension controller design based the Kalman filter (KF)
Unlike low pass filter (LPF), which has a limitation in lowering the cutoff frequency due to the phase delay, on a model expression and FF controller with excellent tracking performance in the transient section
Summary
Roll-to-roll (R2R) technology has recently attracted a great deal of attention for the mass production of electronic devices in the field of display and battery [1]. The R2R machine is composed of rewinder, unwinder, and feeder motors. The rewinder motor is used to wind the web made in roll form with the desired tension. The feeder motor is used for web transfer motions at the proper speed. In the R2R system, tension control is usually achieved by using a load cell or dancer roll. In R2R processing, robust and precise tension control is essential because it affects the quality of the web materials. The web has flexible substrates including metal foils, glass, and ceramics. These substrates used in electronic devices require precise tension control because coating and printing thickness variation occurs despite minute tension changes, resulting in changes in electrical properties
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