LARGE FORMAT INTEGRATED ROLL-TO-ROLL MANUFACTURING SYSTEM: DESIGN, MODELLING AND CONTROL

Abstract

Roll-to-roll (R2R) processing on flexible plastic web is fast becoming the state-of-the-art manufacturing technique for electronics sectors due to its high volume, high speed and lower cost than conventional methods. In this thesis, three major aspects of web handling on the A*STAR SIMTech R2R setup are dealt with. Firstly, a novel Nip Pressure Uniformity Regulation System (NPURS) based on Force Sensing Linear Potentiometer (FSLP) is proposed and demonstrated to regulate the nip pressure to within acceptable levels with Proportional-Integral (PI) control. Secondly, a new web lateral dynamics model for flexible plastic web at offset-pivoted web guide (OPG) is proposed and the interrelationship between the system parameters and the web response established. Lastly, an unconventional method of R2R web handling for thin membrane inspection is designed, implemented and shown to consistently pick up every randomly punctured pinhole in the test rolls, indicating the effectiveness and thoroughness of the proposed inspection system.