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Abstract—Tension control and precise conveyance in nonuniform web. Thus, the tension control is extremely
web-handling machines are critical to ensure product quality. important for flexible web-conveyed system. Current trends
This paper is focused on actualizing a hybrid control method of in the development of electronics systems show that the
tension and position for a discontinuous web transport system. roll-to-roll processes of web system may be the choice as a
First, the simplified algebraic dynamical models of the
very economic production method and will most probably
unwind/rewind section and feed section are presented, which
plays an important role for the moving control of flexible web. play an important part in the future. Electronic elements, like
Second, the hybrid control method, the PID tension control, the sensors, flexible batteries, displays, labels, or ICs are etched
synchronous position control and the hybrid control, are or printed on the web. These new jobsites usually need the
introduced, respectively. Finally, based on the mathematical flexible web to be transported in a discontinuous way, which
model and control strategies, an experiment platform is brings new requirements for tension control and position
established. Several experiments have been performed to show
control because of frequent acceleration and deceleration to
the efficiency and feasibility of this hybrid control method for
discontinuous web transport system. the web transport system. This intermittent oscillation
requires more strict tension control to be implemented. The
Index Terms—PID tension control, synchronous position tension fluctuation may damage the elements’ electronic,
control, discontinuous web transport system, radio frequency magnetic or optical properties. The position precision in
identification (RFID). discontinuous web transport systems has been more and more
exigent in chip integrated industry.
I. INTRODUCTION Due to their difficulty and importance in industry, web
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J 0 t n 02 J m 0 J c 0 J Z 0 t . (1) oscillation, special control must be made to eliminate the
tension disturbance for the precise transport position. Using
where Jc0 is the inertia of the driven unwind/rewind roller, the proposed dynamic model, a suitable control strategy will
Jm0 is the inertia of all the rotating elements on the motor side, be spread out in the following section to achieve both the
including inertia of the motor armature, driving shafts of the steady tension and the position precision in the discontinuous
motor and the reducer, driving gears of the reducer, etc., and web-conveyed system.
J0(t) is the inertia of the rotating web material. Both Jc0 and
Jm0 are constants. But J0(t) is changing, which is given by:
III. HYBRID CONTROL METHOD
S
J Z 0 t
2
W U R 04 t r04 . (2)
In the discontinuous web transport process, the primary
aim of tension control is to ensure the web’s position
where W is the web width, p is the density of the web precision. All operations for the tension control and position
material. R0(t) is the changing radius of the roller. control are completed by the Turbo PMAC-PCI board, which
Synthesizing (1) and (2) gives: is provided by the Delta Tau Data Systems Inc. This card
makes it possible for users to compile individualized
J
. . programs to the card directly and modify the control structure.
J 0 R0 v v 2S W U R 04 v 0 R 0 T0 R 03 Special software programs for the web-fed are achieved to
0 0 (3)
n 0W 0 R f 0 R 0 v 0 .
2 modify the control system.
0
PID controller has a widespread field acceptance, which
has been effective and reliable in most situations when
Nip rollers are special thin-film-driven components in adequately tuned. In the dynamic control system of the
many devices which transport dielectric webs or other motors, decentralized PID control, is used to endow the
materials in the form of sheets. In the RFID tag packaging motors with excellent dynamical performances. In this
equipment, the space between the master nip rollers and the conveyance process, the PID tension control is used to keep
slave nip rollers is the work space. The two nip rollers are the system with stable tension.
endowed with the same tangential velocity to keep precision In modern manufacturing, multi-axis motion control
web-conveyed. Both the nip rollers will be analyzed as one theories are applied to minimize the tracking error. In
part. addition to precision motion control of individual motors to
According to the Newton’s law of motion and the law of track the desired motion trajectories, efficient
energy conservation, the relation between the nip roller synchronization among them is crucially important to
torque and the web tensions can be represented as: minimize the positional offsets between the axes. These
offsets can arise due to different drive and motor
J1 J 2 § . .
· 2 n1 r1 f characteristics, nonuniform load distribution and so on. The
¨ v1 v 2 ¸ T3 T1 rc W 1 v1 v 2 . (4)
n1 rc © ¹ rc rc synchronized position control scheme, with the timely
position feedback from CCD vision systems, is adopted to the
Colligating (3) and (4), and simplifying the interim slave and master nip motors of the feed section to get the
parameters gives: invariance tension and feeding position precision.
In this discontinuous web transport system, the hybrid
J 0 . J1 J 2 § . control method is designed to achieve precise feeding
.
· J3 . n3 2n r
v
2 0 ¨ v1 v 2 ¸ 2 v 3 W 3 12 1 W 1 position while maintaining satisfactory web tension. The
R0 n1 rc ©
2
¹ R3 R3 rc
structure of this hybrid control is integrated with: 1) PID
n0 J v 2S W U R 04 v 0 . J 0 v 3 2S W U R 34 v 3 . (5) tension control; 2) synchronous position control; 3)
W0 0 0 R0 R3
R0 R 03 R 33 feed-forward control; 4) feedback control.
f0 f f
v 0 21 v1 v 2 02 v 3 . A. Tension Control
R 02 rc R3 The block diagram of the proposed PID tension control
scheme is shown in Fig.4. Both the reference position and the
In this simplified multi-input multi-output drive model, (5) reference tension are input values in the unwind/rewind
illuminates the interaction between the constants and the section. In this method, the tension data are detected,
variables in the web transport system. It can be seen that the analyzed and disposed to control the tension, and the
unwind/rewind roller radii R0 and R3 directly correlated with feedback of the tension data from the load cell is used to
web tension, and the speeds v0, v1, v2 and v3 are the main modify the input value at the same time. The closed-loop
controlled variables. Considering the relationship between tension control sub-system is composed of the load cell, the
roll radii and tension difference due to the tangential velocity unwind/rewind motor and the PMAC. In the unwind and the
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rewind sections, the position control can be looked as known quantity into parameters.
position feed-forward control. The feedback data is coming This control scheme assigns one motor as the master and
from the CCD vision system. Both the position feedback and the other as the slave. Although the command signal is
the changing encoder output are used to calculate a transmitted to the two motors at the same time, the slave also
compensation for the next step’s feeding distance. The tracks the motion of the master. It works just as if a single
dynamic model of the unwind/rewind section can be acquired motor were driving the web feeding. It can also be used
from (3) based on the rated parameters in the experiment. The during jogging and homing moves.
PID tension control in both the unwind section and the rewind The feeding position is modified by the CCD feedback,
section supply stable tension and stationary web length to the and the position compensations can be computed by (6) and
feeding section. (7) as follows,
Pm Pr K 0 Pa . (6)
Pa K 1 Pc1 K 2 Pc 2 . (7)
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controllers insure the four motors have the same linear the torques. The web material used in the experiments is PET
velocity and the same web conveyance length in one feeding (Ploy-ethylene Terephthalate). PET is considered as one of
cycle. the best organic-web candidates for RFID applications, while
This method possesses several important and useful it features the industrial ability to be processed in a roll-roll
features. First, it incorporates two PID tension controllers to
stabilize the web tension. PID control is intended to provide
optimal command response and stability properties. Second,
synchronized position controller and uniform CCD vision
feedback control are designed to achieve precise web feeding
position. This feature is special since uncertainty disturbances
affect the position control performance, especially when the
frequent start-stop causes obvious tension fluctuation in the
web. Third, the hybrid control structure of tension and
position is to supply the discontinuous web transport system
with both tension control and position control in the same
web feeding process. Experimental results are duly presented
Fig. 7. The rear part of the experimental web process line
to illustrate the competitive advantages.
In the hybrid controllers, the feeding positions of the
unwind and rewind motors, Pu and Pw , can be represented
using (9) and (10) as follows:
n 0 rc (9)
Pu K5 Pm .
n1 R 0
n 3 rc (10)
Pw K6 Pm .
n1 R 3
Width 334 mm
Thickness 50 μm
IV. IMPLEMENTING RESULTS
Elastic modulus 400 kg/mm2
In order to verify the performance of the hybrid control
method, a large experimental web line has been built to mimic correct the lateral position error as the flexible web runs
most of the features of an industrial web transport system. through a process. The web properties are shown in Table I.
The web line is divided into two parts by the long workspace Extensive experiments were conducted with the proposed
span, as shown in Fig.7 and Fig.8. The fore part consists the hybrid control strategy. Experiment results for the following
unwind section, the lateral guider I, the load cells I and the cases are shown as follows.
slave nip feeding parts. The rear part contains the rewind Case 1): Reference velocity vmax=0.13m/s; the acceleration
section, the load cell II, the lateral guider II and the master nip time ta=250ms; the deceleration time td=250ms; the reference
feeding parts. Both the unwind roller and the rewind roller are tension tr1=28N.
cover by the flat tables in the figures. For conducting the Case 2): Reference velocity vmax=0.38m/s; the acceleration
experiments, the web is threaded through four driven rollers time ta=150ms; the deceleration time td=150ms; the reference
and many other idle rollers to facilitate transport of the web tension tr1=26N.
from the unwind to the rewind. The parameters’ values, selected in the experiments, are:
Four three-phase induction motors, with 750w capacity, K0 = 1; K1 = 0.6; K2 = 0.4; K3 = 0; K4 = 1; K5 = 1.02; K6 = 0.97.
are used to drive the unwind/rewind rollers and two nip Results of the experiments for case 1) are shown in Fig. 9
rollers. Each motor is equipped with one reducer to augment and Fig. 10. The tension data in Fig. 9 is captured in a
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single-step feeding. The selected sampling interval is 0.005s. of tension and position for a discontinuous web transport
Fig. 9. Tension plot in low speed single-step feeding Fig. 11. Tension plot in high speed single-step feeding
Fig. 10. Position error plot in low speed feeding Fig. 12. Position error plot in high speed feeding
A record of more than 2000 samples was collected. It can be system adapted to RFID-tag integrated equipments. Not only
seen that the tension keeps benignly steady in an acceptable the precise synchronous position control and the PID tension
confined scope except in the time of ta and td. While starting control but also the feedback compensation control and
and stopping of the web conveying, the tension is changed feed-forward control are synthesized adopted in this system.
obviously and has some confusing oscillations. The The implementing results show that the system has high
acceleration of the web generates positive damping while tension stability and precise feeding position, which means
deceleration generates a negative or destabilizing damping. that the proposed hybrid control method is a successful case
Fig. 10 shows the position error results for case 1). The in the discontinuous web-conveyed jobsites. It is important to
sampling interval is 10s. The data are captured by the vision note that there exists biggish tension fluctuation in the
system in the discontinuous feeding process. Some special starting and stopping of feeding process, and that there is
marks have been printed on the web for the CCD’s graphics some uncertain steady error in the tension control. Future
disposal system. The graph data, jumping in limited domain, work will focus on solving these problems.
indicates that this web transport system works well on the
performance of the precise feeding. The well tuned tension
controllers keep the web being transported with little REFERENCES
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V. CONCLUSIONS
no. 1, pp. 106-117, Jan. 2007.
This paper outlined the design of a hybrid control method
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