Web Tension Estimation by Local Contact Force Measurement in Roll-to-Roll Manufacturing
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International Journal of Precision Engineering and Manufacturing https://doi.org/10.1007/s12541-020-00387-9
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Web Tension Estimation by Local Contact Force Measurement in Roll‑to‑Roll Manufacturing Yiwei Jin1 · Jiankui Chen1 · Zhouping Yin1 Received: 9 December 2019 / Revised: 14 July 2020 / Accepted: 15 July 2020 © Korean Society for Precision Engineering 2020
Abstract Web tension and its distribution are key factors in the operation of web systems, the roll to roll (R2R) manufacturing of flexible electronics brings even higher requirements for it. To effectively get the web tension at any position on the R2R process line, a new web tension estimation method by measuring the local contact force is investigated in this paper, which can not only estimate the web tension, but also the web tension distribution. This study attempts to derive the approximate fitting formula between the local contact force and the web tension. Firstly, the schematic of web tension estimation method by local contact force measurement is presented; Then the mass spring model is used to derive the governing equations, which is discretized and solved by Improved Euler method. And approximate fitting formula of the local contact force with tension is derived based on the numerical results. Finally, to validate the fitting formula, the experiments are carried out to detect the local contact force and estimate both the web tension and its distribution. Keywords Web tension estimation · Roll-to-roll manufacturing · Mass-spring model · Force sensor
1 Introduction Flexible electronics, as an emerging and exciting research field, has brought great interest to the issue of large scale manufacturing. Roll-to-roll (R2R) processes have been widely used in manufacturing of flexible displays [1], thin film solar cells [2], RFID tags [3], flexible sensors [4], flexible circuits [5] and stretchable batteries [6], as shown in Fig. 1, by taking advantages of saving time, cost and increasing efficiency, throughput, performance, etc. Web tension and its distribution are key factors in the operation of web systems [7, 8], the R2R manufacturing of flexible electronics [9, 10] brings even higher requirements for them. To minimize the register error, vibration, wrinkle of the substrate and keep the thickness and roughness of printed devices in limits, a distribution control strategy [11] is usually adopted (see Fig. 2), which requires direct or indirect measurement of web tension at any position on the R2R process line. * Jiankui Chen [email protected] 1
State Key Laboratory of Digital Manufacturing Equipment and Technology, Huazhong University of Science and Technology, Wuhan 430074, People’s Republic of China
Several methods have been developed to measure web tension in R2R system, such as force measurement using load cell mounted on rollers, torque measurement of tracer roller or dancer cells [12–14], which is convenient and effectual. However, for requirement of either special or extra rollers, the application of load cells adds system
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