Research Papers

Polymer Film Production: Modeling and Control of the Forward Draw

[+] Author and Article Information
C. R. MacLaine, P. Acarnley

Power Electronics, Drives and Machines Group, School of Electrical, Electronic and Computer Engineering, Newcastle University, Newcastle upon Tyne NE1 7RU, UK

J. Shanahan, P. Mousalli, M. Deighton

 Dupont Teijin Films UK Ltd., P.O. Box 2002, Wilton Centre, Middlesborough, Cleveland TS90 8JF, UK

J. Manuf. Sci. Eng. 132(1), 011004 (Dec 28, 2009) (13 pages) doi:10.1115/1.4000712 History: Received October 07, 2008; Revised November 08, 2009; Published December 28, 2009; Online December 28, 2009

Many industrial processes involve the transportation of a continuous web of material over a series of rollers to obtain a finished product. The manufacture of polymer film is one such web transport process, which utilizes a series of rotating elements that act to manipulate the film. This paper develops a dynamic mathematical model of the “forward draw” in a polymer film production process. The model is capable of being implemented in real-time for control purposes, yet includes significant physical phenomena such as material damping. Experimental results from a pilot production plant are used to validate the model under steady-state and transient conditions. The model is then used as a basis for a feed-forward control scheme, which reduces speed variations in the forward draw by a factor of 8 and therefore improves considerably the film quality.

Copyright © 2010 by American Society of Mechanical Engineers
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Figure 1

Layout of forward draw, with roller numbering convention. Web section immediately preceding a roller is given the same number, e.g., draw point is in web section 8.

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Figure 2

Roller loaded by tensioned web

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Figure 3

Two rollers connected by web spans

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Figure 4

Experimental forward draw system

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Figure 5

Roller surface speed traces, rolls 3, 7, 8, and 10. Note difference in speed-axis scales pre-/postdraw.

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Figure 6

Layout of measurement and DSP system

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Figure 7

Film strain set up by steady-state roller speeds. Note logarithmic scale on strain-axis.

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Figure 8

Pilot plant typical Young’s modulus profile through system

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Figure 9

Roller 9 and 10 surface speeds, speed differential, and strain generated in the web

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Figure 10

Graphs of web section 10 variables. (a) Tension transients calculated from roller speeds. (b) Tension transients from Young's modulus component and strain variation. (c) Inferred tension generated by damping term (A and B). (d) Rate of change in web strain.

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Figure 11

Comparison between measured and modeled postdraw roller speeds in response to real nip disturbance

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Figure 12

Comparison between measured and modeled postdraw roller speeds in response to real nip disturbance with material damping neglected

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Figure 13

Rollers 7 and 8 speed control with additional feed-forward elements to improve nip drive disturbance rejection

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Figure 14

Rollers 7 and 8 surface speeds with control disengaged at t=11 min

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Figure 15

Comparison between roller 8 speed with and without feed-forward control

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Figure 16

Local draw ratio variation with and without feed-forward control

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Figure 17

Small section of web

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Figure 18

Two rollers connected by web spans




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