Sheet Conveyance Control System for Tension and Flexure Management
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Solution Overview
Problem
Conventional sheet conveyance systems with multiple rotating rollers lack precise control over sheet motion state quantities and tension, leading to issues like flexure and ink droplet deviation, which affect image quality in image formation systems.
Innovation Solution
A conveyance system comprising multiple rollers, motors, and measuring devices, controlled by a controller that performs determination, drive control, reaction force estimation, tension estimation, and control input computation processes to accurately manage sheet tension and state quantities, ensuring precise control of sheet conveyance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple rotating rollers are used to convey sheets, then conveyance capability is improved, but control precision of sheet tension and motion state deteriorates
Solution Approach 1:
The control system is segmented into multiple independent control loops, each managing a specific roller. Each roller has its own motor with individual control capabilities, allowing the system to handle multiple sheets simultaneously while maintaining precise control over each roller's motion and the sheet tension in its section. This segmentation enables parallel processing of multiple sheets without sacrificing control precision.
Solution Approach 2:
The system incorporates feedback mechanisms that continuously monitor the motion state quantities (position, speed, acceleration) of each roller and the sheet tension. This feedback information is used to dynamically adjust motor commands, ensuring precise control of sheet tension and motion state even when multiple rollers operate simultaneously. The feedback loop compensates for variations in sheet properties and external disturbances.
2Manufacturing precision
If sheet tension is controlled to prevent flexure, then image quality is improved, but control complexity of motion state increases
Solution Approach 1:
The system dynamically changes control parameters (motor torque, roller speed, acceleration profiles) based on real-time sheet tension measurements and desired motion states. By adjusting these parameters, the system maintains optimal sheet tension to prevent flexure and ensure high image quality, while adapting to varying sheet properties and conveyance conditions. The controller modifies control parameters on-the-fly to balance tension control with motion requirements.
3Adaptability or versatility
If multiple motors control multiple rollers, then conveyance flexibility is improved, but system complexity increases
Solution Approach 1:
Each motor-roller unit is designed as a universal module capable of performing multiple functions: conveying sheets, controlling sheet tension, measuring motion state quantities, and responding to various control strategies. This modular universal design allows the system to handle different sheet types, conveyance speeds, and tension requirements without increasing overall system complexity, as each module operates independently with the same core capabilities.
Data Source
AI summary
There is provided a conveyance system including a plurality of rollers, a plurality of motors, a plurality of measuring devices, and a controller. The controller is configured to carry out the processes of: determining a control input on each of the plurality of motors, inputting a drive signal according to the control input, calculating an estimated reaction force value for each of the rollers, calculating an estimated tension value for each pair of the adjacent rollers, calculating a tension control input for each pair, and calculating a state control input on a particular one of the rollers. The controller determines the control input on each of the plurality of motors based on the tension control input for each pair and the state control input on the particular roller.