Tension Controller Design Considering Periodic Disturbance Suppression in Roll-to-Roll Web Handling Systems

Abstract

This paper presents a modeling and tension controller design approach for web handling systems. In these systems, the web handling technology is a key component in the high-precision manufacturing of web products such as thin films and papers. However, periodic disturbances in the synchronization with the rotational frequencies of the roller deteriorate the tension control performance during web transportation. In this study, the web transportation system is modeled considering the motor control systems and web dynamics including viscoelasticity. Based on the constructed model, resonant filters are designed and used as an additional feedback compensator to shape the sensitivity characteristics for the disturbances. By using the compensator, the sensitivity gain of the tension control system can be reduced at specific frequencies, including the rotational frequencies of the rollers. The effectiveness of the designed tension controller is evaluated by conducting experiments using a prototype of the basic roll-to-roll web handling system.