Ju Guoli, Liu Shanhui, Feng Lei, Wang Chaoyue, Yang Kailin
Faculty of Printing, Packaging Engineering and Digital Media Technology, Xi'an University of Technology, Xi'an 710048, China.
Shaanxi Beiren Printing Machinery Co., Ltd., Weinan 714000, China.
Polymers (Basel). 2024 Dec 13;16(24):3479. doi: 10.3390/polym16243479.
This paper addresses the issue of the high-precision control of substrate tension in an accumulator during the roll-to-roll coating process. First, a coupling model for tension errors in the substrate within the accumulator is established, along with dynamic models for the input-output rollers, carriage, and the thrust model of the ball screw. Based on these models, a simulation model is built in MATLAB/Simulink to analyze the main causes of substrate tension errors in the accumulator under uncontrolled conditions. Next, to tackle the tension errors caused by carriage displacement, a nonlinear proportional-integral-derivative (PID) controller is proposed, and a control strategy for substrate tension in the accumulator is designed. Finally, based on the established simulation model, experiments are conducted using the proposed nonlinear PID controller and the designed tension control strategy, and their performance is compared with that of a classical PID controller. The simulation results show that both the nonlinear PID controller and the classical PID controller, when combined with the proposed tension error control strategy, can reduce tension errors in the accumulator substrate. However, the nonlinear PID controller is more suitable for controlling substrate tension errors in the accumulator. On the one hand, the nonlinear PID controller has better anti-disturbance capability. In the anti-disturbance experiment, under PID control, the substrate tension error remains stable at around -1.6 N, with tension disturbances of ±0.2 N occurring at approximately 185 s and 135 s. On the other hand, the nonlinear PID controller demonstrates better robustness. In the robustness experiment, under the nonlinear PID controller, the substrate tension error fluctuates within the range of 0 to 0.02 N, showing excellent robustness.
本文探讨了卷对卷涂布过程中蓄料器内基材张力的高精度控制问题。首先，建立了蓄料器内基材张力误差的耦合模型，以及输入输出辊、滑架的动力学模型和滚珠丝杠的推力模型。基于这些模型，在MATLAB/Simulink中构建了仿真模型，以分析蓄料器在未控制条件下基材张力误差的主要原因。接下来，为了解决由滑架位移引起的张力误差，提出了一种非线性比例积分微分（PID）控制器，并设计了蓄料器内基材张力的控制策略。最后，基于所建立的仿真模型，使用所提出的非线性PID控制器和设计的张力控制策略进行实验，并将其性能与经典PID控制器的性能进行比较。仿真结果表明，非线性PID控制器和经典PID控制器与所提出的张力误差控制策略相结合时，均可降低蓄料器基材中的张力误差。然而，非线性PID控制器更适合于控制蓄料器中的基材张力误差。一方面，非线性PID控制器具有更好的抗干扰能力。在抗干扰实验中，在PID控制下，基材张力误差在约-1.6 N左右保持稳定，在大约185 s和135 s时出现±0.2 N的张力干扰。另一方面，非线性PID控制器表现出更好的鲁棒性。在鲁棒性实验中，在非线性PID控制器下，基材张力误差在0至0.02 N的范围内波动，显示出优异的鲁棒性。
