Control of web tension is crucial for maintaining quality of products processed on roll-to-roll (R2R) system. An R2R system can be divided into different tension spans which interact with each other. But converting industries tend to neglect these interactions and use decentralized single-input–single-output (SISO) control approaches to deal with tension control. Multi-input–multi-output approaches have been reported in literatures but are practically not in use. Interaction between the various tension spans is unavoidable as they are all connected by a single web. Disturbances produced in a span tend to travel further downstream along the direction of web travel. When the number of spans is less or the disturbance amplitudes are small, this does not present a big challenge and simple SISO control is sufficient. But when the amplitudes of disturbances produced in processing is large—as is the case with printed electronics—or the number of spans is large or both, then the interactions cannot be neglected. R2R-based offset printers have the potential for mass production of precision-printed electronics. In this paper, a fuzzy logic-based hybrid approach has been followed that specifically targets the printed electronics industry and this method considerably reduces the interactions. The algorithm has been designed such that it takes information from previous span to reduce the propagation of tension disturbances to the given span. This has been achieved through online computation of correlation coefficient and reducing the interaction through fuzzy feedback control.
This is a preview of subscription content, log in to check access.
Buy single article
Instant unlimited access to the full article PDF.
Price includes VAT for USA
Subscribe to journal
Immediate online access to all issues from 2019. Subscription will auto renew annually.
This is the net price. Taxes to be calculated in checkout.
Chen C (2004) Modeling and control of a web-fed machine. Appl Math Model 28(10):863–876
Dwivedula R, Zhu Y, Pagilla P (2006) Characteristics of active and passive dancers: a comparative study. Control Eng Pract 14(4):409–423
Lin KC (2003) Observer-based tension feedback control with friction and inertia compensation. IEEE Trans Control Syst Technol 11(1):109–118
Okada K, Sakamoto T (1998) An adaptive fuzzy control for web tension control system. Control Eng 3:1762–1767
Sakamoto T. (1999) Decentralized controller design of web tension control system in terms of interactions. ISIE ’99. Proc IEEE Int Symp Ind Electron (Cat. No.99TH8465) 3:1466–1471
Liu W, Davison EJ (2003) Servomechanism controller design of web handling systems. IEEE Trans Control Syst Technol 11(4):555–564
Pagilla PR, Siraskar NB, Dwivedula RV (2007) Decentralized control of web processing lines. IEEE Trans Control Syst Technol 15(1):106–117
Pudas M (2004) Gravure offset printing of polymer inks for conductors. Prog Org Coat 49(4):324–335
Ahmed DH, Sung HJ, Kim D-S (2011) Simulation of non-Newtonian ink transfer between two separating plates for gravure-offset printing. Int J Heat Fluid Flow 32(1):298–307
Ghadiri F, Ahmed DH, Sung HJ, Shirani E (2011) Non-Newtonian ink transfer in gravure-offset printing. Int J Heat Fluid Flow 32(1):308–317
Kim S, Na Y (2010) Study on the web deformation in ink transfer process for R2R printing application. Int J Heat Fluid Flow 11(6):945–954
Lee S, Na Y (2010) Analysis on the ink transfer mechanism in R2R application. J Mech Sci Technol 24(1):293–296
Lee C, Kang H, Kim C, Shin K (2010) A novel method to guarantee the specified thickness and surface roughness of the roll-to-roll printed patterns using the tension of a moving substrate. J Microelectromech Syst 19(5):1243–1253
Shin K-H, Kwon S-O (2007) The effect of tension on the lateral dynamics and control of a moving web. IEEE Trans Ind Appl 43(2):403–411
Lee T-M, Noh J-H, Kim CH, Jo J, Kim D-S (2010) Development of a gravure offset printing system for the printing electrodes of flat panel display. Thin Solid Films 518(12):3355–3359
Lee T-M, Noh J-H, Kim I, Kim D-S, Chun S (2010) Reliability of gravure offset printing under various printing conditions. J Appl Phys 108(10):102802
Lee CC (1990) Fuzzy logic in control systems: fuzzy logic controller. II. IEEE Trans Syst Man Cybern 20(2):419–435
Kang H-K, Lee C-W, Lee J-M, Shin K-H (2010) Cross direction register modeling and control in a multi-layer gravure printing. J Mech Sci Technol 24(1):391–397
Yoshida T, Takagi S, Muto Y, Shen T (2008) Register control of sectional drive rotogravure printing press. Design 417–420, doi:10.1007/978-1-84800-267-8_85
Anderson RG, Meyer AJ, Valenzuela MA, Lorenz RD (2001) Web machine coordinated motion control via electronic line-shafting. IEEE Trans Ind Appl 37(1):247–254
Volynskii AL, Bazhenov S, Lebedeva OV, Bakeev NF (2000) Mechanical buckling instability of thin coatings deposited on soft polymer substrates. Physics 5:547–554
Electronic supplementary material
About this article
Cite this article
Ponniah, G., Zubair, M., Doh, Y. et al. Fuzzy decoupling to reduce propagation of tension disturbances in roll-to-roll system. Int J Adv Manuf Technol 71, 153–163 (2014) doi:10.1007/s00170-013-5400-4
- Roll-to-roll system
- Offset printed electronics
- Fuzzy tension control
- Disturbance propagation