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.
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February 2010
Research Papers
Polymer Film Production: Modeling and Control of the Forward Draw
C. R. MacLaine,
C. R. MacLaine
Power Electronics, Drives and Machines Group, School of Electrical, Electronic and Computer Engineering,
Newcastle University
, Newcastle upon Tyne NE1 7RU, UK
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P. Acarnley,
P. Acarnley
Power Electronics, Drives and Machines Group, School of Electrical, Electronic and Computer Engineering,
Newcastle University
, Newcastle upon Tyne NE1 7RU, UK
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J. Shanahan,
J. Shanahan
Dupont Teijin Films UK Ltd.
, P.O. Box 2002, Wilton Centre, Middlesborough, Cleveland TS90 8JF, UK
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P. Mousalli,
P. Mousalli
Dupont Teijin Films UK Ltd.
, P.O. Box 2002, Wilton Centre, Middlesborough, Cleveland TS90 8JF, UK
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M. Deighton
M. Deighton
Dupont Teijin Films UK Ltd.
, P.O. Box 2002, Wilton Centre, Middlesborough, Cleveland TS90 8JF, UK
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C. R. MacLaine
Power Electronics, Drives and Machines Group, School of Electrical, Electronic and Computer Engineering,
Newcastle University
, Newcastle upon Tyne NE1 7RU, UK
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
Dupont Teijin Films UK Ltd.
, P.O. Box 2002, Wilton Centre, Middlesborough, Cleveland TS90 8JF, UK
P. Mousalli
Dupont Teijin Films UK Ltd.
, P.O. Box 2002, Wilton Centre, Middlesborough, Cleveland TS90 8JF, UK
M. Deighton
Dupont Teijin Films UK Ltd.
, P.O. Box 2002, Wilton Centre, Middlesborough, Cleveland TS90 8JF, UKJ. Manuf. Sci. Eng. Feb 2010, 132(1): 011004 (13 pages)
Published Online: December 28, 2009
Article history
Received:
October 7, 2008
Revised:
November 8, 2009
Online:
December 28, 2009
Published:
December 28, 2009
Citation
MacLaine, C. R., Acarnley, P., Shanahan, J., Mousalli, P., and Deighton, M. (December 28, 2009). "Polymer Film Production: Modeling and Control of the Forward Draw." ASME. J. Manuf. Sci. Eng. February 2010; 132(1): 011004. https://doi.org/10.1115/1.4000712
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