Development of Core Technologies for High-Precision Roll-to-Roll Continuous Manufacturing Systems

Presented by Jaeyoung Kim, Korea Institute of Machinery and Materials - Dept. of Advanced Battery Manufacturing Systems

This study presents the design and implementation of core technologies for a high-precision roll-to-roll (R2R) continuous manufacturing system. The performance of the proposed system is validated through dynamic analysis and experimental investigations. The R2R system is configured based on tension zones consisting of an unwinder, rewinder, infeeder, and outfeeder. A cascaded control structure is designed, including an inner speed control loop and an outer tension control loop, respectively. To analyze the web behavior, a Kelvin–Voigt-based dynamic model considering the viscoelastic characteristics of the web is introduced. The influence of idle roller mass and structural properties on system resonance characteristics is quantitatively analyzed using frequency response function (FRF) analysis. Based on the identified resonance peaks from the web, idle rollers, and structure profile, a notch filter is designed to reduce resonances and expand the control bandwidth. Experimental results demonstrate that the tension control error is maintained within ±0.25% under both low- and high-speed operating conditions, while the speed and position control of the patterning roller achieve a precision within 1 µm. These results provide dynamic and control-oriented design guidelines for high-precision R2R continuous manufacturing systems and establish a foundation for advanced continuous manufacturing applications.