• 한국정밀공학회지
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• 제26권6호
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• pp.81-89
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• 2009

Dancer systems are typical equipment for attenuation of tension disturbances. Lately, demands for high speed roll-to-roll machines are rising but it is prior to attenuate the tension variation on the web entering into the printing zone to achieve the speed increment. Maintaining a constant tension before the first printing cylinder is the key of high speed, high quality printing. Dancer has been researched in two ways, whether it is controlled or not. The first one is active dancer and the other one is passive dancer. In the active dancer, a position of idle roll of dancer is measured and the roll is moved by external hydraulic cylinder to control tension disturbances. While the passive one composed with spring, damper and idle roll has no external actuator to position the idle roll. The tension disturbance causes movement of dancer roll and the displacement of the roll regulates the tension variation. On the other hand a composite type of dancer is applied for roll-to-roll printing machines. It has same apparatus as passive dancer. The displacement of roll is measured and front(or rear) driven roller is controlled to position the roll. In this paper, it is presented an analysis of pendulum dancer including position feedback PI control and logic for PI gain tuning in roll-to-roll machines. Pole-zero map and root locus with varying system parameters gives a design method for control of the dancer.

• 실천공학교육논문지
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• 제15권1호
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• pp.127-132
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• 2023

Roll to Roll (이하 RTR)로 연결된 유연회로기판(이하 FPCB)에서 일정한 장력을 유지하여 안정적인 홀 가공이 가능하게 하는 Dancer Roll System를 경량화하고 서보모터를 활용한 토크 제어를 통해 기존 방식 FPCB RTR에서는 대응 불가능하였던 중력가속도의 2배가 되는(이하 2.0G) 가속도의 고속 가공이 가능하도록 요소기술과 성능 지표를 제시한다. 기존 마그넷 클러치 방식 RTR에서는 달성이 불가능하였던 높은 회전수와 발열 문제, 낮은 토크 문제등을 마그네슘 소재를 이용한 Roll의 경량 가공법 개발과 서보모터의 토크 제어 알고리즘 개발을 통하여 해결하여 FPCB에 균일한 장력을 제공하고 토크 안정성을 높인다. 본 연구에서 개발한 요소 기술로 인해 Dancer Roll의 반응속도가 개선되어 목표한 고속화를 달성하였다.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2008년도 추계학술대회 논문집
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• pp.173-174
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• 2008

• 대한기계학회:학술대회논문집
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• 대한기계학회 2007년도 춘계학술대회A
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• pp.873-878
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• 2007

Stability of high-speed roll-to-roll printing machines is one of the most important factors that are required for the printing machines to operate properly and to obtain reasonable printing performance. This paper proposes a new model for the web-tension system of a high-speed gravure printing machine considering span-length variations due to dancer rollers, and analyzes the stability of plant dynamics of the printing machine using the proposed model. Span-length variations due to dancer motions are considered for the modeling of plant dynamics in two ways; one is to include the effect of span-length variations without considering dancer inertias and viscous frictions, and the other is to include the effect of span-length variations with considering dancer inertias and viscous frictions. The stability of the plant model is analyzed for various web-speeds using the eigenvalues of the linearized model about operating points.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2006년도 춘계학술대회 논문집
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• pp.65-66
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• 2006

Dancer systems are most widely used mechanism for attenuation of tension disturbances. Lately, demands fur high speed converting machines over 500mpm(m/min) are raising but domestic converting industries can not come up with the machines because capacities for a designing of the converting machine are restricted lower than 300mpm. Moreover roll-to-roll is attracted flexible display manufacturer's attention as a effective method for productivity. A constant tension level in the span before the first printing cylinder is the key of high speed quality printing. This paper presents a modeling and simulations of dancer systems on converting machines.

• 대한기계학회논문집A
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• 제33권5호
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• pp.482-488
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• 2009

Dancer system is typically used equipment for attenuation of tension disturbances. In industrial converting machines, a composite type of dancer system is applied which is mixture of active and passive dancer. It includes feedback position control loop of roll with pendulum dancer and its characteristics is different from passive and active one. In this paper, a mathematical model of the pendulum dancer was derived including PI position feedback controller and it was analyzed by using a pole-zero map and bode plot under various conditions. It was found out that velocity, length of span and inertia were associated with the performance of regulation. It was suggested that the length of upstream span should be greater than that of the downstream and the inertia should be smaller for improvement of the performance. The results can be used for design guidelines of the industrial dancer system.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2007년도 춘계학술대회 논문집
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• pp.439-440
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• 2007

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2006년도 춘계학술대회 논문집
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• pp.281-282
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• 2006

Tension control performance is very important in high-speed printing machine. One of the major factors that effect to tension control performance is the process of roll changing. Even if the turret arm moves during roll changing process and the span length of the unwinding system varies, it is customary to neglect it in motion and tension control and to consider it as a disturbance. In this paper, its effect is modeled nonlinearly and compared with linear model, and an effect of an infeeder dancer is analyzed under the condition with no unwinder dancer. We verify the performance of the proposed method via simulation in the high-speed printing machine.

• 한국정밀공학회지
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• 제26권10호
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• pp.65-73
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• 2009

For mass production of printed electronics in roll-to-roll fashion, precision tension control is important to reduce register errors. Register error should be minimized within several to tens of microns for many electronic devices to be manufactured through printing technology. In order to achieve this goal, tension disturbance must be attenuated before printing process within a certain range. In this paper, a certain tension range which allows maintaining register error within 10 micron was defined with specific operating conditions. A LQG controller was proposed instead of the conventional PI controller for precision tension control using a multivariable feedback. A guideline to determine design parameters for calculating LQ gain was proposed. The proposed LQG controller was compared to both PI controller and LQ regulator with white noise by numerical simulations. Results showed that the proposed LQG controller was effective for attenuating tension disturbance with white noise.

• 한국정밀공학회지
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• 제26권11호
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• pp.70-76
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• 2009

Web tension control system recently have been applied to OLED(Organic Light-Emitting Diode), RFID of flexible material, e-Paper and PLED(Polymeric LED) and various web control algorithms have being developed for higher productivity and product quality These system need an accuracy model to design and implement controller. In this paper, the web tension control system with dancer roll is mathematically modeled. Mathematical model consists of 8 subsystems and each subsystems can be described as impedance structure which connected by velocity and tension. Mathematical model is different from the estimated model at high frequency range because of structure dynamics which is ignored on mathematical model. The estimated model is derived using ARMAX model. The controller is designed using the estimated model. The step response of the estimated model are compared with that of physical model for a validation of estimated model. The experimental results show a good match between them.