Control methodology for tensioned web considering thermal behavior in roll-to-roll manufacturing systems

The roll-to-roll manufacturing system is utilized for processing flexible webs into functional films, offering high productivity through continuous multi-stage processing. In the converting span, which encompasses coating, printing, and drying processes, precise tension control and appropriate tension settings are crucial to ensure the quality of the final product. Particularly during the drying process, where solvent removal occurs, thermal deformation of the web induces additional elongation, amplifying the impact of tension on coating layer quality and printing patterns. Consequently, the drying process necessitates more accurate tension control compared to other span, necessitating the application of feedforward control that considers web thermal deformation. However, the current tension control logic employs an imprecise temperature distribution within the dry span as an input, resulting in inadequate tension control performance and defects such as uneven coating layers and registration errors. This research presents the development of a feedforward tension controller that employs Finite Element Method (FEM)-based web temperature distribution inputs to enhance tension control performance during the drying span. The tension control performance was compared and analyzed based on the drying span web temperature prediction method, affirming that higher accuracy in predicting the web temperature distribution leads to improved tension control performance. Experimental results from an industrial-scale roll-to roll system demonstrate that the proposed model enhances tension control accuracy during the drying process by 27.76% compared to the existing control logic. Furthermore, the effectiveness of the tension control logic in enhancing the surface quality of functional layers was confirmed through surface quality analysis using solid oxide fuel cell (SOFC) electrolyte layers.