Abstract:
To address the register errors caused by tension fluctuations in roll-to-roll (R2R) printing during acceleration from low to high speeds, this study proposes an incremental model predictive control (MPC) method to improve printing accuracy and reduce material waste during acceleration. By analyzing the mathematical model during steady-speed phases and the system characteristics during acceleration phases, the register errors induced by acceleration are treated as external disturbances. A mathematical model for the acceleration phase is established, integrating real-time measurement data that reflects disturbance variations. The proposed incremental MPC method leverages this model to enhance control performance. Experimental results demonstrate that compared to existing methods such as fully decoupled proportional-derivative (FDPD) control and disturbance observer-based compensation proportional-derivative (DOCPD) control, the MPC approach exhibits advantages in control effectiveness and performance.