Design Of Tension Distribution Detection Roller For Flexible Electronics Roll-to-Roll Preparation

R2R process and its control technology, as one of the key aspects of flexible electronics batch preparation, has developed rapidly and obtained widespread attention in recent years. Tension control, which is the core technology in the flexible material R2 R production process, determines product quality and production efficiency. The effect of tension control is substantially influenced by the accuracy, timeliness, and completeness of the flexible membrane tension detection. To meet urgent needs of the flexible film tension detection, this study developed a tension detection roller to achieve accurate detection of film tension distribution and total tension. This paper(or thesis) presented the structure design, control system design and experimental verification of the tension detection roller. The outcomes of this study include:(1) A program of the detection roller to achieve total tension detection and tension distribution detection of flexible film was established. The factors that influence tension stability, axial distribution and circumferential distribution of the film tension on the roller were analyzed. The results of the program were verified by simulation analysis.(2) A control scheme of the tension detecting roller was completed. A hardware circuit of the total tension signal, the tension distribution signal, and other modules were designed on the basis of strain gauge sensors selection and flexible sensor selection, and the characteristic curve of the sensor. The scheme also included a software design of the tension detection system.(3) A functional verification scheme of the tension detecting roller was developed. The conclusions of the theoretical calculation and simulation analysis were justified through total tension detection experiments and tension distribution detection experiments. The calibration experiments of tension detection roller showed that the tension distribution detection roller had a good detection effect. The results of the tension detection experiments were: 1) In start-stop stage, the film total tension was negatively related with acceleration, the number of rollers and other factors; 2) Within the entire contact range, the index of the circumferential tension distribution of the film presents index increasing trend after the first index decline trend, and has a symmetrical features. 3) Within the entire contact range, the index of the axial tension distribution of the film presents increasing trend after the first decline trend, and tension distribution is in parabolic form.In conclusion, the functionality and performance indicators of the tension detection roller, which was designed for measuring the total tension and the tension distribution of the flexible film, meet the needs of conventional flexible electronics R2 R preparation process. It has been verified by the actual winding test of the flexible RFID tags, and has the potential to be applied in similar processes and fields.