Robust constrained tension control for high-precision roll-to-roll processes

Chen, Zhiyi; Qu, Boning; Jiang, Baoyang; Forrest, Stephen R.; Ni, Jun

doi:10.1016/j.isatra.2022.11.020

Robust constrained tension control for high-precision roll-to-roll processes

Journal Article · Sat Nov 26 00:00:00 EST 2022 · ISA Transactions

DOI:https://doi.org/10.1016/j.isatra.2022.11.020· OSTI ID:1993003

^[1]; Qu, Boning ^[2]; Jiang, Baoyang ^[3]; Forrest, Stephen R. ^[4]; Ni, Jun ^[4]

University of Michigan, Ann Arbor, MI (United States); University of Michigan
University of Michigan, Ann Arbor, MI (United States)
Foxconn Industrial Internet, Guangdong Province (China)
University of Michigan, Ann Arbor, MI (United States)

Tension control is critical for maintaining good product quality in most roll-to-roll (R2R) production systems. Previous work has primarily focused on improving the disturbance rejection performance of tension controllers. Here, a robust linear parameter-varying model predictive control (LPV-MPC) scheme is designed to enhance the tension tracking performance of a pilot R2R system for deposition of materials used in flexible thin film applications. The performance of a tension controller may degrade due to disturbances associated with model uncertainties and the slowly-changing dynamics in R2R systems. We introduce a method that separately treats these two sources of disturbance. The controller utilizes an incremental model to eliminate the errors caused by the mismatch between the nominal model and the actual system. A tube-based MPC formulation combined with scheduled parameters adequately updates models and corrects for the time-varying dynamics. Constraints on the rated motor torque are incorporated in the MPC to maintain the controller reliability and avoid machine failures. We illustrate the operation of our control algorithm through simulation of an actual R2R system. The controller outperforms the benchmarks in terms of fast transient response and offset-free tension tracking. Furthermore, it also demonstrates immunity from variations due to parametric uncertainties.

View Accepted Manuscript (DOE)

Research Organization:: University of Michigan, Ann Arbor, MI (United States)

Sponsoring Organization:: USDOE; USDOE Office of Energy Efficiency and Renewable Energy (EERE)

Grant/Contract Number:: EE0008723

OSTI ID:: 1993003

Alternate ID(s):: OSTI ID: 1973546

Journal Information:: ISA Transactions, Journal Name: ISA Transactions Vol. 136; ISSN 0019-0578

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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Robust constrained tension control for high-precision roll-to-roll processes

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