印刷电子装备多层套准系统耦合建模与解耦控制研究

Register accuracy is an important index to evaluate the quality of printed electronic products. However, the complex relationships in multilayer register system make the problems of coupling model and decoupling control difficult to be solved, which have limited the improvement of register accuracy for gravure electronic equipments. To solve this problem, the coupling modeling method and decoupling control algorithm of multilayer register system are studied in this proposal. The main research contents are as follows: ① In order to reveal the multi-source mechanism of register error, dynamics model of register error is established by combining with the kinematics research foundation of register error and considering the effects of detection delay, drying temperature and roller’s dynamic characteristics. ② Multi-physics coupling mechanism existing in different printing groups is studied, and then, multivariable coupling dynamics model of multilayer register system is established to expound the multiple coupling relationship of different register errors and the variation of register errors with web running. ③ According to the characteristics of multilayer register system including multi-input multi-output, strong coupling, strong disturbance and large delay, an integrated decoupling control strategy based on active disturbance rejection control is designed to solve the overshoot and concussion problems in the control process and significantly improve the accuracy of multilayer register system. The results of this project not only provide theoretical basis for continuously producing large quantities of high-quality printed electronic products effectively, but also have important significance for development of register control system in printed electronic equipments.

套印精度是衡量印刷电子产品质量的重要指标，然而，多层套准系统的复杂性使其耦合建模与解耦控制问题一直未得到解决，已成为制约凹版印刷电子装备套印精度提高的瓶颈问题。为此，本项目展开多层套准系统耦合机理建模与解耦控制策略的研究，具体包括：①研究检测延时、烘干温度及版辊受力状况与套准误差的内在关系，综合前期运动学研究基础，建立套准误差的动力学模型，揭示误差产生的多源机理；②研究印组间存在的多物理过程耦合机制，建立多层套准系统的多变量耦合动力学模型，阐释各级套准误差间的多重耦合关系和其随料带运行的变化规律；③针对多层套准系统多输入-多输出、强耦合、强干扰、大延时的特点，提出以自抗扰控制技术为核心的组合解耦控制策略，解决控制过程中存在的超调和震荡问题，显著提高多层套准控制精度。研究成果为大批量、高效率生产精密印刷电子产品提供理论基础，对推动凹版印刷电子装备套准数控系统的发展具有重要意义。

相对于传统电子产品制造方法，凹版印刷电子技术是一种增材制造技术，具有低成本、绿色环保、可大面积生产等显著特点，拥有广阔的应用前景，但制约这种新技术走向产业化的瓶颈是凹版印刷的套印精度。由于传统印刷产品套印精度只需±0.1mm，导致直接影响套印精度提高的多层套准系统耦合机理建模与控制等问题一直未得到解决。鉴于此，本研究立足提高多层套准系统的套印精度问题，展开套准误差多源机理、多层套准系统耦合机理建模和解耦控制策略的深入研究，取得的主要成果包括：①研究了检测延时环节、烘干温度产生套准误差的机理，初步分析了版辊的受力关系，建立了套准误差多源机理非线性数学模型，揭示了版辊速度、料带张力、烘干系统温度产生套准误差的内在机理；②采用以前一印层为基准的印刷电子多层套印方案，分析了印刷过程中沿料带传递的耦合变量，研究了各级套准误差间的耦合机理，以各级印组速度为纽带建立了多层套准系统的多变量耦合机理模型，阐释了各级套准误差间的多重耦合关系和其随料带运行的变化规律；③针对多层套准系统强耦合、强干扰、大延时的特点，提出了以自抗扰控制为核心的解耦控制策略，有效地抑制了各种耦合干扰引起的各级套准误差，解决了套准控制过程中存在的超调和震荡问题，大幅度提高了多层套准系统的控制精度和鲁棒性。④发明了基于ARM的凹版印刷电子装备烘干系统控制器，开发了凹版印刷装备实验平台监控系统软件。研究成果最终从根源上解决了多层套准系统控制过程中存在的问题，大幅度提高了多层套印精度，为开发具有自主知识产权的机组式凹版印刷电子装备的多层套准数控系统提供了理论基础和技术支撑。