Digital roll-to-roll web processing revolutionizes printed electronic production

03/12/2013


In the Figure 2 example, the press uses two successive controllers. But now the step change signaled by the green section controller doesn’t create a cascade effect upstream. Along with decoupling to prevent feedback, the Rexroth controller initiates a re

The result can be seen in Figure 2. In this example, the press uses two successive controllers. But now the step change signaled by the green section controller doesn’t create a cascade effect upstream. Along with decoupling to prevent feedback, the controller initiates a response to step reduction in tension control in one-fourth the time compared to typical controllers.

With the solution described, tension can be controlled for up to eight axes. One or multiple points can be selected to be left uncontrolled. At the selected axis, line speed is held constant. At a standstill, web tension can be maintained. In fact, multi-axis tension control increases standstill web tension accuracy by a factor of two to four. Achieving the desired standstill web tension is also much faster. Without decoupling, a setpoint can be achieved in 13-14 seconds; with decoupling, it takes three to four seconds.

During acceleration, tension control decoupling ensures the web is stable as soon as full production speed is reached, compared to a delay of five seconds or longer with coupled control. And when tension setpoint changes occur during runtime, the transient response with decoupling takes about one second, compared to about four seconds with coupled control.

Not unlike digital printing, the adoption of roll-to-roll web printing will accelerate as the technology demonstrates its ability to provide high accuracy at high speeds. At the outset, however, the process with tension control offers several bottom-line benefits: the roll-to-roll web starts faster, saving time and increasing output; longer periods of web stability reduce waste and increase yield; and less tension deviation on the substrate improves registration and enables the use of more sensitive material.

And, because printed electronic material can be 10 times the cost, or even significantly more expensive, than typical substrate, decoupled multi-axis tension control technology promises a significant payback. Original equipment manufacturers (OEMs) get an off-the-shelf solution providing the most stable tension solution for roll-to-roll machines. The result is faster time to market and easier implementation thanks to integrated components, including drives, function blocks, and software controls. By enabling tight registration and greater throughput, decoupled tension control can handle the challenges OEMs face when building roll-to-roll presses today—and promises a bright future for large-scale printed electronics manufacturing tomorrow.

- Bosch Rexroth provided the information. Edited by Mark T. Hoske, content manager, CFE Media, Control Engineering and Plant Engineering, mhoske(at)cfemedia.com.

Key concepts

  • Multi-axis tension control solution allows the web to be decoupled into separate tension control zones. Tension can be adjusted as required in one zone area without destabilizing the entire web.

Consider this

  • Could a multi-axis tension controller help improve performance of your web-based application?

Online

Rexroth web tension and printing solutions 

www.boschrexroth-us.com/printing

www.boschrexroth-us.com 


<< First < Previous 1 2 Next > Last >>

No comments
The Engineers' Choice Awards highlight some of the best new control, instrumentation and automation products as chosen by...
Each year, a panel of Control Engineering editors and industry expert judges select the System Integrator of the Year Award winners.
The Engineering Leaders Under 40 program identifies and gives recognition to young engineers who...
Learn how to increase device reliability in harsh environments and decrease unplanned system downtime.
This eGuide contains a series of articles and videos that considers theoretical and practical; immediate needs and a look into the future.
Learn how to create value with re-use; gain productivity with lean automation and connectivity, and optimize panel design and construction.
Go deep: Automation tackles offshore oil challenges; Ethernet advice; Wireless robotics; Product exclusives; Digital edition exclusives
Lost in the gray scale? How to get effective HMIs; Best practices: Integrate old and new wireless systems; Smart software, networks; Service provider certifications
Fixing PID: Part 2: Tweaking controller strategy; Machine safety networks; Salary survey and career advice; Smart I/O architecture; Product exclusives
The Ask Control Engineering blog covers all aspects of automation, including motors, drives, sensors, motion control, machine control, and embedded systems.
Look at the basics of industrial wireless technologies, wireless concepts, wireless standards, and wireless best practices with Daniel E. Capano of Diversified Technical Services Inc.
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
This is a blog from the trenches – written by engineers who are implementing and upgrading control systems every day across every industry.
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.

Find and connect with the most suitable service provider for your unique application. Start searching the Global System Integrator Database Now!

Case Study Database

Case Study Database

Get more exposure for your case study by uploading it to the Control Engineering case study database, where end-users can identify relevant solutions and explore what the experts are doing to effectively implement a variety of technology and productivity related projects.

These case studies provide examples of how knowledgeable solution providers have used technology, processes and people to create effective and successful implementations in real-world situations. Case studies can be completed by filling out a simple online form where you can outline the project title, abstract, and full story in 1500 words or less; upload photos, videos and a logo.

Click here to visit the Case Study Database and upload your case study.