Background technology
Reel-to-reel (Roll-to-Roll) is meant the technology of continuous flexible thin-film material being changed (Converter) and transmission (Transport) by roller structure.Generally form by emptying roller, driven roller, material receiving roller and some guide rollers.The reel-to-reel transmission both can have been adopted the transmission mode of continuous feed, also can realize transmission and location by the batch (-type) feeding mode.Because this mode of production has low manpower, low production cost, high production capacity and satisfies advantage such as size diversity, thereby in relating to the industry of the people's livelihood, weaving, press and articles for daily use etc. are used widely.
In recent years, along with the development of the progress of material science and technology and electronic technology towards filming, lighting and flexibility direction, flexible thin film type material part replaces printed circuit board (PCB) (Printed CircuitBoard is PCB) as the substrate of photoelectron and semiconductor product.As just having adopted the paper material of plastic film materials such as comprising PVC, ABS, PET and low-cost environmental-protecting as substrate in the encapsulation of RFID electronic tag.For reaching mass production, save cost and satisfy the multifarious requirement of size, and be applicable to that the first-selected transmission mode of flexible parent metal is the reel-to-reel transmission.
When flexible material being carried out the batch (-type) transmission with the location, require induction system when realizing accurately feeding and location, to keep the material certain force of strain by the reel-to-reel technology.In addition, for improving transfer efficiency, require in transmission course, should have high as far as possible transmission speed.Can the key that realize above-mentioned requirements be Tension Control.If overtension will cause the excessive stretcher strain of material, influence the quality of product.(as in the encapsulation of RFID electronic tag) if overtension will cause antenna pattern gross distortion on the substrate, makes that chip and antenna can't be accurately interconnected in semiconductor packages, finally causes the encapsulation failure.Simultaneously, raising along with speed and acceleration and deceleration, as not controlling tension force effectively, the quick variation of speed very easily causes big impact tension force, not only can cause the baseplate material distortion, skid between material and running roller, influence the bearing accuracy of substrate, even cause that the fracture of material and system can't operate as normal.Therefore reduce the tension impact that causes because of high-speed cruising and high acceleration feeding, keep the stable of material tension, transmission quality and the bearing accuracy that improves conveying device had very important significance.
In the tension control method of existing roll-to-roll intermittent feeding, the tension impact that causes when reducing the batch (-type) feeding, common way is that each driven roller is adopted speed synchronization control, keeps the stable of material tension by methods such as swing arm or dancers simultaneously.Tension control method when US Patent specification US508694 discloses a kind of batch (-type) feeding.On the basis of each material roller speed synchronization control, for the material that elimination is wound on emptying roller and the material receiving roller is rolled up the change in radius influence synchronous to each material roller linear velocity, before each batch (-type) feeding, automatically revise blowing side material roller velocity profile (Profile) by the pot that is installed in the swing arm, its tension adjustment still adopts dancer rools to finish.
Existing tension control method has the following disadvantages:
1. adopt speed synchronization to control the asynchronous influence that to eliminate because of each material roller speed, but can't eliminate the variation of the asynchronous substrate tension that causes of each the material roller position that causes because of various interference substrate tension.
2. because swing arm or dancer have high relatively machinery inertial, thus at a high speed and high acceleration and deceleration when moving the performance of adjustment of tonicity be subjected to certain restriction.The precision of Tension Control also has been subjected to certain restriction simultaneously.
3. complex mechanical construction has also increased the installation and maintenance cost of equipment.
Thereby existing tension control method can't satisfy in the semiconductor packages batch (-type) feeding fast the time to tension control requirement.
Summary of the invention
The object of the present invention is to provide a kind of tension control method of roll-to-roll intermittent flexible substrate transmission,, keep the stability of its tension force from start to finish even this method still can be avoided big tension impact under the fast-changing situation of speed of feed.
Another object of the present invention is to provides the device of realizing said method, even this device still can be avoided big tension impact under the fast-changing situation of speed of feed, keeps the stability of its tension force from start to finish.
A kind of tension control method of roll-to-roll intermittent flexible substrate transmission, wherein, emptying roller and material receiving roller are driven material roller, and driven roller is the active material roller, and this method is specially:
During the single stepping, gather the initiatively actual displacement of material roller, itself and the displacement reference instruction of setting are compared, according to the initiatively motion of material roller of comparative result control, the actual displacement of initiatively material roller single stepping is equated with the displacement reference instruction, realize initiatively material roller displacement closed-loop control;
Simultaneously, gather driven material roller and the initiatively actual tension value of base material and the actual displacement of driven material roller between material roller, actual tension value and predetermined tension value are compared, again comparative result is converted into the displacement correction instruction, revises the actual displacement reference instruction that above-mentioned displacement reference instruction obtains driven material roller with it; With the actual displacement of driven material roller and actual displacement reference instruction relatively, control the motion of driven material roller, the actual displacement of driven material roller single stepping is equated with the actual displacement reference instruction, realize driven material roller displacement closed-loop control according to comparative result.
As improvement of the present invention, the required angle amount of feeding of the k+1 time stepping of described driven material roller determines that according to the actual angle amount of feeding of the k time stepping of driven material roller k is a positive integer.
A kind of device of realizing the mentioned strain control method comprises the active material roller displacement closed control circuit that active material roller actuator 13, active material roller driver 12, active material roller position control 11 and active material roller displacement transducer 14 connect and compose successively;
And driven material roller position control 20, driven material roller driver 19, driven material roller actuator 23 and the driven material roller displacement transducer 22 driven material roller displacement closed control circuit that joins successively and constitute; Driven material roller position control 20 also connects A/D converter 15, amplifier 17 and tension pick-up 18 successively by tension regulator 16.
Technique effect of the present invention:
(1) the present invention can adapt to the variation of different feeding lengths and different speed of feed.Eliminate of the influence of factors such as base plate deformation and friction force by the overall situation (position synchronous control) and local (tension feedback control) control combination to tension force;
(2) the present invention can adapt to different feeding lengths and differential tension control requirement, by the variation and the study realization of displacement reference instruction and tension force reference instruction;
(3) the present invention can realize the accurately requirement of location (as the 1mm bearing accuracy) in the quick batch (-type) feeding of flexible base, board.
Embodiment
The present invention is described in further detail to control principle and embodiment below in conjunction with accompanying drawing.
Fig. 1 is a reel-to-reel conveying mechanism synoptic diagram.Comprise emptying roller 4, driven roller 7 and material receiving roller 9, and they are coupled by flexible material 6.Driven roller 7 is in torque tau
dEffect is rotation and idler rollers 5 engagements down, drives substrate 6 direction feeding on request by friction force, and emptying roller 4 is in torque tau
uWith can rotate at positive and negative both direction under the effect of flexible base, board tension force, launch or twine thereby drive the flexible base, board that is wrapped on the emptying roller 4.Material receiving roller 9 is at torque t
wWith also can rotate under the effect of substrate tension force at positive and negative both direction, drive the substrate that is wrapped on the material receiving roller 9 and twine or launch.Emptying roller 4, driven roller 7 and material receiving roller 9 have been divided into two different tensile regions with flexible material 6, are called blowing side tensile region and rewinding side tensile region, and claim that driven roller 7 is the active material roller, and emptying roller 4 and material receiving roller 9 are driven material roller.
Fig. 2 is a Tension Control theory diagram of the present invention.Only provided the Tension Control principle of blowing side tensile region among the figure, but this method also can be used for the Tension Control of rewinding side tensile region, and the Tension Control in the centre portion.Initiatively material roller actuator 13 and driven material roller 23 drive driven roller 7 and emptying roller 4 rotations in the conveying mechanism 21 respectively.Initiatively the output of material roller position control 11 drives driven roller 7 and rotates after active material roller driver 12 drives initiatively material roller actuator 13 rotations.Be installed in the initiatively active material roller displacement transducer 14 of material roller actuator 13 rear ends, be used for to driven roller 7 current actual displacement amounts detect and with the displacement reference instruction relatively, realize position closed loop control.The output of driven material roller position control 20 is after driven material roller driver 19 drives driven material roller actuator 23 rotations, and band emptying roller 4 rotates.Be installed in the driven material roller displacement transducer 22 of driven material roller actuator 23 rear ends, be used for to emptying roller 4 actual displacement amounts detect and with the displacement reference instruction relatively, realize position closed loop control.Be installed in the tension force that tension pick-up 18 on the frame (not drawing among the figure) is used to detect emptying roller 4 and 7 flexible base, boards 6 of driven roller, the output signal of tension pick-up 18 is amplified through amplifier 17, and by A/D device 15 conversion backs as the actual tension value with set tension force T
uCompare the value x after tension regulator 16 is regulated
tWith displacement reference instruction x
dStack obtains actual displacement instruction x
u
Further specify concrete Tension Control principle below.When flexible base, board needs a certain length of batch (-type) feeding, each actuator simultaneously with this feeding length as the displacement reference instruction, and by separately independently position closed loop controlling and driving material roller realize being synchronized with the movement.According to mass conservation theorem, when each material roller is realized being synchronized with the movement, the length (or quality) that enters this tensile region material in the unit interval equates with the length of material that goes out this tensile region (quality), therefore, when even speed of feed changes fast by the arbitrary speed section, still can keep the stable of material internal tension force.When actual feeding, since inevitably exist friction force, each actuator dynamic perfromance is inconsistent and the influence of other disturbing factor, the feasible length (or quality) that enters the material of this tensile region is not to equate fully with the length of material that goes out this tensile region (or quality), simultaneously, because the flexible material elastic modulus is inconsistent, thereby cause the fluctuation of tension force.For eliminating the influence of above-mentioned various disturbance to substrate tension force, keep the stable of tension force, tension force has been adopted closed-loop control.Detect the displacement reference instruction of the driven material roller of modifications of substrate tension force between material roller by tension pick-up, thereby reach the purpose that keeps tension stability.
Particularly, when the needs intermittent movement, x
dNon-vanishing.For driven roller 7, displacement reference instruction x as requested
dFinish feed motion by position closed loop control.For emptying roller 4, this moment, position control 20 one side received feeding displacement reference instruction x
d, receive output x on the other hand by tension regulator 16
t, their sums are instructed x as actual displacement
u, after relatively regulating with driven material roller displacement transducer 14 detected actual displacements, drive driven material roller actuator 23 through driven material roller driver 19 and produce motion, and drive emptying roller 4 and rotate.For example, when detecting the actual tension value greater than setting value T
uThe time, tension regulator 16 is output as negative value, through anti-phase be on the occasion of, make actual displacement instruction x
u=x
d+ x
t>x
dThereby actuate actuators 23 increases unreel speed, to reduce tension force.When detecting the actual tension value less than setting value T
uThe time, tension regulator 16 be output as on the occasion of, after anti-phase, be negative value, through and displacement reference instruction x
dAfter the stack, make actual displacement instruction x
u<x
d, make emptying roller 4 rotational speeies reduce by actuate actuators 23, to increase actual tension.
When the non-displacement reference instruction, i.e. x
dBe zero.Driven roller nothing motion 7 this moment.Since the closed-loop control of tension force, the x of the actual displacement of emptying roller 4 instruction at this moment
uOutput x by tension regulator 15
tUnique decision.When the tension feedback value greater than setting value T
uThe time, tension regulator output negative value is the positive displacement instruction after anti-phase, actuate actuators 13 is just being changeed, and drives emptying roller 4 blowings, thereby reduces actual tension force; When the tension feedback value greater than setting value T
uThe time, tension regulator 15 outputs drive servomotor 13 counter-rotatings on the occasion of be negative position command after anti-phase, drive emptying roller 4 rewindings, thereby increase actual tension force, thereby guaranteed still to have kept the stable of tension force when no feed motion.
In said method and since when having avoided feed motion by position synchronous the quick variation of speed to the influence of tension force, therefore, the tension value T of She Dinging as requested
uBoth can be steady state value, also can be the value that changes by a certain rule, and can with the rewinding side different tension values can be set and can not influence the stability of system the blowing side.
In actual applications, when adopting breast roll to drive, the instruction transformation that displacement of the lines need be synchronized with the movement is the corresponding rotation angle displacement commands of each driven roller, so that realize closed-loop control by angular displacement sensor (as scrambler).
In addition, for emptying roller and material receiving roller, owing to be wrapped in material-coil coil-diameter on the material roller and be with the discontinuous variation of variation of the batch (-type) amount of feeding, therefore, before each stepping feeding, need change pre-determining the emptying roller and the required angular displacement amount of feeding of material receiving roller according to the coil diameter of material volume, be synchronized with the movement to keep each material roller displacement of the lines.Fig. 3 has specifically provided the acquisition methods and the process flow diagram of the angular displacement amount of feeding of a kind of emptying roller, material receiving roller.
Remove stepping for the first time, before other each batch (-type) feeding, the current physical location x of the displacement coder by reading emptying roller and material receiving roller at first respectively
Uf(k) and x
Wf(k), then according to the physical location x before the preceding primary feed
Uf(k-1), x
Wf(k-1), thereby can calculate previous actual displacement angle amount, be respectively Δ x
Ua(k)=x
Uf(k)-x
f(k-1) and Δ x
Wa(k)=x
Wf(k)-x
Wf(k-1).Because flexible board is thinner, change in the physical length of double stepping feeding little, therefore can the previous actual amount of feeding is approximate as the current needed amount of feeding, thus obtain the angular displacement feeding instruction that current emptying roller and material receiving roller need, i.e. Δ x
Ur(k)=Δ x
Ua(k) and Δ x
Wr(k)=Δ x
Wa(k).Here determined angular displacement feeding instruction is exactly the described displacement reference instruction of preamble x
dBe converted to emptying roller and the current angular displacement feeding instruction separately of material receiving roller after the angular displacement.After obtaining angular displacement feeding instruction, further speed of feed as requested and acceleration obtain synchronous corresponding angular speed of displacement of the lines and acceleration section, finally finish being synchronized with the movement of each material roller by closed-loop control.
For guaranteeing the stability of substrate tension force, no matter whether batch (-type) feeding program is moved, and makes tension force all be in the closed loop state all the time according to the tension value of setting, and by continuous correction angle displacement commands, adjust the angular displacement of driven material roller indirectly, thereby reach the purpose of final maintenance tension stability.
In order to obtain emptying roller and the required angular displacement reference instruction Δ x of material receiving roller for the first time
Ur(k), Δ x
Wr(k), k=1 wherein.Can be by measuring the coil diameter of emptying roller and material receiving roller material loading volume respectively, then according to formula before feeding
Calculate emptying roller and material receiving roller angular displacement initial reference instruction Δ x respectively
Ur(k), Δ x
Wr(k); Also can when first time feeding, the angular displacement initial reference of emptying roller and material receiving roller be appointed as zero, i.e. Δ x
Ur(k)=0, Δ x
Wr(k)=0, remaining unchanged in the displacement reference instruction of drive roll, still is x
dSituation under, adopt lower angular acceleration section to finish batch (-type) feeding for the first time, be converted to the high-speed intermittent feeding subsequently.Because blowing side tension force and rewinding side tension force are in the closed loop state all the time, even thereby under low acceleration section, move, still can realize pinpointly in the feeding of flexible base, board batch (-type) keeping stablizing of blowing side and rewinding side tension force simultaneously.
The present invention is further described below in conjunction with specific embodiment.Fig. 4 is the control system structured flowchart of specific embodiment.Be used for realizing the batch (-type) feeding and the location of radio frequency recognizing electronic label encapsulation flexible parent metal.Embodiment is with industrial computer, Turbo PMAC multi-axis motion control card, A/D transition card, tension pick-up, amplifier and the actuator of scrambler is installed and supporting driver finishes.Base board delivery device has taken 5 passages of Turbo PMAC motion control card 26 altogether, and one of them passage is controlled the active feeding that is used for substrate with actuator 13, driver 12 and scrambler 14 by position closed loop.Emptying roller 4 and material receiving roller 7 respectively take two passages, realize position and tension closed loop control by driving servomotor 23A, 23B respectively.A/D transition card 30 is ACC-28A, has taken 2 paths and has been used for that respectively the tension force of blowing side and rewinding side is converted to digital signal through tension pick- up 18A, 18B and amplifier 17A, 17B amplified analog signal and inserts Turbo PMAC motion control card 26.Industrial computer 25 is placed in Turbo PMAC motion control card 26 in the industrial computer as the host computer of man-machine interaction, realizes communicating by letter between the upper and lower computer by pci bus.Tension pick- up 18A, 18B and amplifier 17A, 17B can adopt LX-030TD of Mitsubishi and LM-10TA.Because the servomotor dynamic response is fast, safeguard that simply actuator 13,23A, 23B in the present embodiment have all adopted AC servo motor, and are separately installed with photoelectric encoder 14,22A, the 22B of 8192 pulse/commentaries on classics.
For realizing control function of the present invention, the standard control model that Turbo PMAC card provides is made amendment.Dicyclo cascade (Cascading ServoLoops) control model is all adopted in the control of emptying roller 4 and material receiving roller 9, wherein outer shroud is a tension link, its feedback is pointed to the Input Address of A/D conversion, servomotor is not directly controlled in output after regulator is regulated, but points to different working storages respectively; As the position ring of interior ring, its control model is revised as modes of deflection, makes it receive position command x from instruction generator on the one hand
d, receive the output x of above-mentioned working storage on the other hand simultaneously
t, both sums are instructed x as physical location
uRelatively (or putting) material roller position control 20 is regulated after material receiving roller driver 19A (or emptying roller driver 19B) drives material receiving roller servomotor 22A (or emptying roller servomotor 22B) motion through receiving with actual displacement.When actual program, feed shaft, dispensing shaft and collecting shaft are defined in the same coordinate system, by PMAC carry instruction that software provides before each batch (-type) feeding by calculating the angular displacement instruction Δ x of current requirement
Ur(k) and Δ x
Wr(k), and the movement instruction that provides by PMAC software generates synchronic command, further by the angular displacement closed-loop control realize each material roller synchronously.Simultaneously, set blowing side and rewinding side tension value respectively, and make this control loop be in the closed loop state all the time, drive emptying roller and material receiving roller motion by real time modifying angular displacement instruction, thereby reach the stable purpose that keeps material tension.