Advertisement

Improvement of a Splicing Machine to Decrease Abrupt Tension Changes and Tail Defects during the Roll Exchange Process in a Roll-to-Roll Manufacturing System

  • Jongsu Lee
  • Changwoo Lee
Regular Paper
  • 38 Downloads

Abstract

The use of the splicing system is necessary to exchange a fully unwound roll to a new one without stopping the roll-to-roll manufacturing machine. However, abrupt tension changes and tail defects, which is an overlap of completely unwound films with films in the process of being unwound, could occur during the roll exchange phase causing film loss and deterioration of product quality. Herein, we improved the splicing machine in an industrial scale R2R manufacturing system to decrease abrupt tension errors and tail defects. First, the effects of the factors generating the tail defects in the splicing machine on the net tail lengths were analyzed using designed mathematical models. Furthermore, the reason for the abrupt tension disturbance in the roll exchange process was determined. Based on the analyses, a passive dancer system was applied to the unwinding section to attenuate the tension error, and the time interval between the pressing and cutting phases was decreased by changing the signal processing method of the previous version of the splicing machine. Experimental results showed that the abrupt tension change was decreased by an average of 46.5%, while tail lengths were decreased by more than 2.5 times, thereby verifying the superior performance of the upgraded splicing machine.

Keywords

Roll-to-roll Winding Splicing machine Signal processing Tail Tension 

NOMENCLATURE

TLd

tail length generated by the distance between the nip roll and knife

TLa

tail length in the attaching phase

TLc

tail length in the cutting phase

TLt

net tail length in the splicing process

Dnk

distance between nip-roll and knife

Rn

the radius of the new roll

Rd

the radius of the dancer roll

b

bearing friction coefficient of dancer roll

bd

bearing friction coefficient of hinge

v

web moving velocity

l1

rod length of dancer arm to pneumatic cylinder

l2

length of dancer arm

Jeq

equivalent moment of inertia of dancer

Jd

moment of inertia of dancer roll

L2

length of unwinder to the dancer roll

L3

length of dancer roll to the infeed roll

T1

tension of unwinder to LC#1

T2

tension of LC#1 to passive dancer

T3

tension after passive dancer

V2

velocity variation of film before dancer

V3

velocity variation of film after dancer

tpc

time interval between pressing and cutting phases

tac

time interval between attaching and cutting phases

tp

time period between the start and end of pressing

to

period of one cycle rotation of unwinding roll

ts

scan time of unwinding tension controller

A

cross-sectional area of substrate

E

elastic modulus of substrate

θan

difference of the angular positions of the adhesive tape at the attaching and nipping phases

A(s)

L3s + v

B(s)

AERd2 / (Jds + bd)

C(s)

AEl22s / (Jeqs2 + bs + 3.077l1)

D(s)

A(s) + B(s) + C(s)

E(s)

(B(s) + v - C(s)) / D(s)

F(s)

(B(s) - C(s)) / D(s)

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

References

  1. 1.
    Homenick, C. M., James, R., Lopinski, G. P., Dunford, J., et al., “Fully Printed and Encapsulated SWCNT-Based Thin Film Transistors via a Combination of R2R Gravure and Inkjet Printing,” ACS Applied Materials & Interfaces, Vol. 8, No. 41, pp. 27900–27910, 2016.CrossRefGoogle Scholar
  2. 2.
    Chu, W.-S., Kim, M.-S., Jang, K.-H., Song, J.-H., Rodrigue, H., et al., “From Design for Manufacturing (DFM) to Manufacturing for Design (MFD) via Hybrid Manufacturing and Smart Factory: A Review and Perspective of Paradigm Shift,” International Journal of Precision Engineering and Manufacturing-Green Technology, Vol. 3, No. 2, pp. 209–222, 2016.CrossRefGoogle Scholar
  3. 3.
    Nguyen, H. A. D., Shin, K., and Lee, C., “Multi-Response Optimization of R2R Gravure Printing Using Orthogonal Array and Principal Component Analysis as a Weighting Factor,” The International Journal of Advanced Manufacturing Technology, Vol. 90, Nos. 9–12, pp. 3595–3606, 2017.CrossRefGoogle Scholar
  4. 4.
    Lee, J., Park, S., Park, J., Cho, Y.S., Shin, K.-H., and Lee, D., “Analysis of Adhesion Strength of Laminated Copper Layers in Roll-to-Roll Lamination Process,” International Journal of Precision Engineering and Manufacturing, Vol. 16, No. 9, pp. 2013–2020, 2015.CrossRefGoogle Scholar
  5. 5.
    Yu, J. H., Rho, Y., Kang, H., Jung, H. S., and Kang, K.-T., “Electrical Behavior of Laser-Sintered Cu Based Metal-Organic Decomposition Ink in Air Environment and Application as Current Collectors in Supercapacitor,” International Journal of Precision Engineering and Manufacturing-Green Technology, Vol. 2, No. 4, pp. 333–337, 2015.CrossRefGoogle Scholar
  6. 6.
    Park, J., Shin, K., and Lee, C., “Roll-to-Roll Coating Technology and Its Applications: A Review,” International Journal of Precision Engineering and Manufacturing, Vol. 17, No. 4, pp. 537–550, 2016.CrossRefGoogle Scholar
  7. 7.
    Woo, J. Y., Oh, J. H., Han, H., Kim, J.-W., Jo, S., and Han, C.-S., “Ultraclean Contact Transfer of Patterned Ag Electrodes by Thermal Release Tape for Transparent Conductive Electrode,” International Journal of Precision Engineering and Manufacturing, Vol. 17, No. 4, pp. 461–466, 2016.CrossRefGoogle Scholar
  8. 8.
    Yu, W., Lee, Y., Lee, Y. H., Cho, G. Y., Park, T., et al., “Performance Enhancement of Thin Film LSCF Cathodes by Gold Current Collecting Layer,” International Journal of Precision Engineering and Manufacturing-Green Technology, Vol. 3, No. 2, pp. 185–188, 2016.CrossRefGoogle Scholar
  9. 9.
    Lee, C., Kang, H., Kim, C., and Shin, K., “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,” Journal of Microelectromechanical Systems, Vol. 19, No. 5, pp. 1243–1253, 2010.CrossRefGoogle Scholar
  10. 10.
    Lee, J., Park, J., Jeong, H., Shin, K.-H., and Lee, D., “Optimization of Printing Conditions for Microscale Multiline Printing in Continuous Roll-to-Roll Gravure Printing,” Journal of Industrial and Engineering Chemistry, Vol. 42, pp. 131–141, 2016.CrossRefGoogle Scholar
  11. 11.
    Park, S.-I., Quan, Y.-J., Kim, S.-H., Kim, H., Kim, S., et al., “A Review on Fabrication Processes for Electrochromic Devices,” International Journal of Precision Engineering and Manufacturing-Green Technology, Vol. 3, No. 4, pp. 397–421, 2016.CrossRefGoogle Scholar
  12. 12.
    Pham, M. Lee, C., “Novel Approach to Predict the Varying Thicknesses of a PVA Film during a Roll-To-Roll Process,” International Journal of Mechanical Sciences, Vol. 92, pp. 52–69, 2015.CrossRefGoogle Scholar
  13. 13.
    Lee, C., Lee, J., Kang, H., and Shin, K., “A Study on the Tension Estimator by Using Register Error in a Printing Section of Roll to Roll E-Printing Systems,” Journal of Mechanical Science and Technology, Vol. 23, No. 1, pp. 212–220, 2009.CrossRefGoogle Scholar
  14. 14.
    Wan, L., Zhu, N., Li, X., Zhang, R.-y., and Mei, T., “Optimization for Solid Polymer Microstructure Replication Using Gas-Assisted Hot Embossing under Low Pressure,” International Journal of Precision Engineering and Manufacturing, Vol. 17, No. 8, pp. 1067–1072, 2016.CrossRefGoogle Scholar
  15. 15.
    Lee, J., Isto, P., Jeong, H., Park, J., Lee, D., and Shin, K.-H., “Register Mark Measurement Errors in High-Precision Roll-to-Roll Continuous Systems: The Effect of Register Mark Geometry on Measurement Error,” Applied Physics Letters, Vol. 109, No. 14, Paper No. 141602, 2016.Google Scholar
  16. 16.
    Peng, Y., Li, H., Wang, R., Zhong, Q., Han, X., et al., “Self-Calibration Three-Dimensional Light Field Display Based on Scalable Multi-LCDS,” Journal of the Society for Information Display, Vol. 20, No. 12, pp. 653–660, 2012.CrossRefGoogle Scholar
  17. 17.
    Randolph, M. A., “Commercial Assessment of Roll to Roll Manufacturing of Electronic Displays,” M.Sc. Thesis, Massachusetts Institute of Technology, 2006.Google Scholar
  18. 18.
    Brandenburg, G., “New Mathematical Models for Web Tension and Register Error,” Proc. of International IFAC Conference on Instrumentation and Automation in the Paper, Rubber and Plastics Industry, pp. 411–438, 1976.Google Scholar
  19. 19.
    Lin, K. C., “Observer-Based Tension Feedback Control with Friction and Inertia Compensation,” IEEE Transactions on Control Systems Technology, Vol. 11, No. 1, pp. 109–118, 2003.MathSciNetCrossRefGoogle Scholar
  20. 20.
    Lynch, A. F., Bortoff, S. A., and Röbenack, K., “Nonlinear Tension Observers for Web Machines,” Automatica, Vol. 40, No. 9, pp. 1517–1524, 2004.MathSciNetCrossRefzbMATHGoogle Scholar
  21. 21.
    Kuhm, D., Knittel, D., and Bueno, M.-A., “Robust Control Strategies for an Electric Motor Driven Accumulator with Elastic Webs,” ISA Transactions, Vol. 51, No. 6, pp. 732–742, 2012.CrossRefGoogle Scholar
  22. 22.
    Lee, C., Kang, H., and Shin, K., “A Study on Tension Behavior Considering Thermal Effects in Roll-to-Roll E-Printing,” Journal of Mechanical Science and Technology, Vol. 24, No. 5, pp. 1097–1103, 2010.CrossRefGoogle Scholar
  23. 23.
    Lee, J., Shin, K., and Lee, C., “Analysis of Dynamic Thermal Characteristic of Register of Roll-to-Roll Multi-Layer Printing Systems,” Robotics and Computer-Integrated Manufacturing, Vol. 35, pp. 77–83, 2015.CrossRefGoogle Scholar
  24. 24.
    Kang, H., Lee, C., and Shin, K., “Modeling and Compensation of the Machine Directional Register in Roll-to-Roll Printing,” Control Engineering Practice, Vol. 21, No. 5, pp. 645–654, 2013.CrossRefGoogle Scholar
  25. 25.
    Giannoccaro, N. I., Nishida, T., and Sakamoto, T., “Decentralized Control Performances of an Experimental Web Handling System,” International Journal of Advanced Robotic Systems, Vol. 9, No. 4, Paper No. 141, 2012. (DOI:10.5772/51481)Google Scholar
  26. 26.
    Lee, J., Seong, J., Park, J., Park, S., Lee, D., and Shin, K.-H., “Register Control Algorithm for High Resolution Multilayer Printing in the Roll-to-Roll Process,” Mechanical Systems and Signal Processing, Vol. 60, pp. 706–714, 2015.CrossRefGoogle Scholar
  27. 27.
    Altmann, H. C., “Formulas for Computing the Stresses in Center-Wound Rolls,” Tappi Journal, Vol. 51, No. 4, pp. 176–179, 1968.Google Scholar
  28. 28.
    Qualls, W. and Good, J., “An Orthotropic Viscoelastic Winding Model Including a Nonlinear Radial Stiffness,” Journal of Applied Mechanics, Vol. 64, No. 1, pp. 201–208, 1997.CrossRefzbMATHGoogle Scholar
  29. 29.
    Burns, S., Meehan, R. R., and Lambropoulos, J., “Strain-Based Formulas for Stresses in Profiled Center-Wound Rolls,” Tappi Journal, Vol. 82, No. 7, pp. 159–167, 1999.Google Scholar
  30. 30.
    Lee, J. and Lee, C., “An Advanced Model for the Numerical Analysis of the Radial Stress in Center-Wound Rolls,” International Journal of Mechanical Sciences, Vol. 105, pp. 360–368, 2016.CrossRefGoogle Scholar
  31. 31.
    Hu, J., Jiang, Z., and Lu, H., “Research on Taper Tension Control Theory Apply in Material Rolling up Procedure,” in: Communications and Information Processing, Zhao, M., Sha, J., (Eds.), Springer, pp. 1–8, 2012.Google Scholar
  32. 32.
    Dehui, W., Chen, C., Xiumiao, Y., Xuesong, L., and Yimin, H., “Optimization of Taper Winding Tension in Roll-to-Roll Web Systems,” Textile Research Journal, Vol. 84, No. 20, pp. 2175–2183, 2014.CrossRefGoogle Scholar
  33. 33.
    Lee, C., Kang, H., and Shin, K., “Advanced Taper Tension Method for the Performance Improvement of a Roll-to-Roll Printing Production Line with a Winding Process,” International Journal of Mechanical Sciences, Vol. 59, No. 1, pp. 61–72, 2012.CrossRefGoogle Scholar
  34. 34.
    Seshadri, A. and Pagilla, P.R., “Modeling and Control of a Rotating Turret Winder Used in Roll-to-Roll Manufacturing,” Control Engineering Practice, Vol. 41, pp. 164–175, 2015.CrossRefGoogle Scholar
  35. 35.
    Kang, H.-K., Lee, C.-W., Shin, K.-H., and Kim, S.-C., “Modeling and Matching Design of a Tension Controller Using Pendulum Dancer in Roll-to-Roll Systems,” IEEE Transactions on Industry Applications, Vol. 47, No. 4, pp. 1558–1566, 2011.CrossRefGoogle Scholar

Copyright information

© Korean Society for Precision Engineering and Springer-Verlag GmbH Germany, part of Springer Nature 2018

Authors and Affiliations

  1. 1.Department of Mechanical Design and Production EngineeringKonkuk UniversitySeoulRepublic of Korea
  2. 2.School of Mechanical EngineeringChangwon National UniversityGyeongsangnam-doRepublic of Korea

Personalised recommendations