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Abstract
Winding is an integral operation in almost every roll-to-roll system and the center-wound roll is one of the suitable and general schemes in a winding mechanism. The quality and performance of a center-wound roll are known to be related to the winding tension. In this paper, a novel optimization design method for winding tension using a special network structure is proposed. Firstly, based on the elasticity theory, the correlations between winding tension in the winding section and hoop stress distribution within a center-wound roll are analyzed. In addition, an analysis model for the residual stress due to the winding tension profile is developed. Then, according to the analysis model, the special network structure with back propagation training is developed to minimize the error of lateral residual stress, namely isostress-distribution. Finally, the experimental prototype of a roll-to-roll packaging system for glass-fiber fabric that can measure and control the winding tension is described, and actual experiments were carried out. Results show that the proposed method is very useful for determining the desirable taper-tension profile during the winding process and preventing defects of the center-wound roll.
Keywords
winding tension profile, center-wound roll, hoop stress, residual stress, isostress
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The web is defined as a material that is thin, continu- ous, long, and easily bent. Web products can be easily found in our daily lives, such as paper, tissue, and alu- minum foil.1 As a typical web product, glass-fiber fabric either exists as rolls in its final shape or at least exists in the form of rolls at the transporting stages. Nowadays, the center-wound roll form is the most efficient and convenient storage format for glass-fiber fabric packaging.
The process of transforming the web into the form of center-wound rolls is called the winding process. The important manufacturing specifications in the process are the control of winding tension and transport vel- ocity. The existing researches for such a winding pro- cess are mainly in the design of the tension controller (TC) to increase the web transport speed as much as possible.2
It is common practice in industrial web unwinder- winder systems (also called roll-to-roll systems) to use decentralized proportional-integral (PI)-type control- lers. Overviews of problems, solutions, and perspectives on the topic of web...