Ribbon Support Force Control for Molten-Material Separation
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Solution Overview
Problem
The process of separating a ribbon formed from molten material results in undesired disturbances and imperfections, which are frozen into the ribbon, causing wear on pull rolls and reducing the quality of display devices.
Innovation Solution
A support device with a gripping mechanism that applies controlled forces and profiles to minimize disturbances, using sensors to maintain downward force, provide force profiles, and reduce force differentials and moments, thereby stabilizing the ribbon during handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the ribbon is gripped by the support device during separation from molten material, then the ribbon can be separated and handled, but undesired disturbances travel up the ribbon into the viscous zone causing imperfections to be frozen into the ribbon
Solution Approach 1:
The support device dynamically adjusts its gripping force and position along the ribbon, transitioning from a static grip to an adaptive system that responds to ribbon tension and viscosity changes. This allows the device to minimize disturbances in the viscous zone while maintaining adequate grip for handling and separation.
Solution Approach 2:
The system changes the gripping parameters (force magnitude, distribution along the ribbon length) based on the ribbon's physical state. By adjusting these parameters, the device can handle the ribbon effectively without introducing disturbances that would cause imperfections in the cooling and solidification process.
2Ease of operation
If the ribbon is gripped with conventional support devices, then separation and handling are achieved, but force spikes occur causing undesired wear on the pull rolls
Solution Approach 1:
The support device employs dynamic force control that adapts to the ribbon's mechanical properties during separation. This prevents sudden force spikes that would otherwise transmit to the pull rolls, thereby reducing wear and extending their operational life while maintaining effective ribbon separation.
Solution Approach 2:
The system uses feedback mechanisms to monitor forces during ribbon handling and adjusts gripping forces in real-time. This feedback control prevents excessive forces from being applied to the pull rolls, minimizing wear while ensuring successful ribbon separation and handling.
Data Source
AI summary
Methods can include controlling a support device while supporting a ribbon. The method can include controlling the support device to maintain a downward force (Fx) in a direction of an X-axis within a first range of forces. The method can further include controlling the support device to provide a force profile (Fz) in a direction of aZ-axis that reduces a moment (Mx) about the X-axis. The method can further include controlling the support device to reduce a force differential (Fy) in the direction of the Y-axis that reduces a moment (Mz) about the Z-axis.