Sensor-Efficient Estimation of Roll Misalignment via Side-to-Side Tension Differences in Roll-to-Roll Polymer Film...

Area of Science:

• Materials Science
• Mechanical Engineering
• Process Control

Background:

• Roll misalignment in roll-to-roll (R2R) processes causes defects like lateral displacement and tension imbalance.
• Existing diagnostic methods often require complex calibration and additional sensors, limiting real-time application.

Purpose of the Study:

• To develop a simplified diagnostic approach for estimating web misalignment in R2R systems.
• To eliminate the need for complex calibration and additional sensors in misalignment detection.

Main Methods:

• Developed a method to estimate web misalignment using side-to-side tension differences.
• Experimentally established the correlation between tension imbalance, lateral displacement, and misalignment angle.
• Validated the approach across various process conditions and tensions.

Main Results:

• The tension-based approach accurately predicts web misalignment without extra sensors.
• Reducing tension fluctuations ('hunting') improves prediction stability.
• The method demonstrated effectiveness under different misalignment and tension levels.

Conclusions:

• The proposed tension-based method offers a practical alternative for diagnosing roll misalignment in R2R manufacturing.
• Simplifies alignment diagnostics, enhancing process setup and reducing downtime.
• Improves the uniformity of polymer films in continuous manufacturing.