柔性基板输送试验平台的机械设计分析与系统实现
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摘要
射频识别技术(Radio Frequency Identification)是21世纪最有发展前景的信息技术之一,作为电子标签生产的RFID标签封装设备的研制意义重大。RFID标签封装设备由基板输送(送料、收料)、点胶、翻转贴装、热压、后检测模块组成。其中基板输送模块要保证非连续进给运动中的张力恒定控制及基板精确位置进给,基板贯穿于整个RFID标签封装设备各个模块,因此对基板输送系统的深入研究十分重要。
本文主要研究内容是面向柔性基板输送试验平台,根据试验要求搭建试验平台,对关键零部件进行有限元优化设计,并对基板输送系统的张力控制进行试验分析。主要内容从以下三个方面展开论述:
首先,根据设计要求,搭建了柔性基板输送试验平台,设计了摆臂浮辊、模组浮辊和张力传感器控制等三种张力部件,改进了以往的张力控制结构,实现了多种张力控制布局方案的转换,为后续关键技术的研究提供了良好的平台。
其次,基于有限元分析对试验平台中对恒定张力控制具有重要影响的摆臂结构进行了优化设计,对摆臂进行了拓扑优化和尺寸优化并进行了强度校核和模态分析,最终确定了摆臂的优化结构,满足性能要求的同时又大大的节省了材料。
最后,根据基板输送的工况要求,对三种张力控制方案进行了介绍与分析,并在不同工况下对基板输送系统控制总图基于运动控制卡的力/位反馈控制方法进行试验,通过对张力波动、进给位置精度及进给时间进行分析,研究了张力波动的影响因素等,实现了间歇进给的恒定张力控制。
本文的研究成果对提高RFID标签封装设备的性能及效率具有重要作用,为基板输送系统的两个关键技术的深入研究提供了良好的基础平台,同时也给类似柔性薄膜输送系统的研发提供技术参考。
The radio frequency identification technology is one of the most promising information technologies in the 21th century. Therefore, it’s very significant to develop RFID tag-package equipments. A RFID tag-package equipment includes five modules, they are web conveyance module, dispensing module, flip-chip bonding module, heat-press module and testing module. As a necessary part of the equipment, Web conveyance module’s function is to make sure the Substrate runs to the designated location under the constant tension.
The main content of this paper is to design the flexible web conveyance test platform and research the tension control system. Including:
Fistly, this paper set up a flexible web conveyance test platform according to experiment requirements, designed a new tension control structure by introducing active dancer axis and passive spring-swing device. This platform could converse a wide range of tension control layoust. It played an important role in the following research on the key technologies.
Secondly, this paper optimized and analysed the swing arm by finite element software-ANSYS. Gained the basic shape by topology optimization, attained geometric structure by thickness of the size optimization, ultimately ascertained the optimal structure of the swing which meets the performance requirements and saves material at the same time.
Finally, this paper put forward three tension control methods according to the requirements of the woking conditions. Experimented the tension/position double loops feedback control solution based on PMAC towards to the general tension control layout, researched the influencing factors of tension fluctuation. The system could achieve constant tension control under intermittent feeding.
The conclusion of this paper could improve the proformance and efficiency of the RFID tag-package equipment, on the other hand, it may provide some useful guidance to the related applications.
本文主要研究内容是面向柔性基板输送试验平台,根据试验要求搭建试验平台,对关键零部件进行有限元优化设计,并对基板输送系统的张力控制进行试验分析。主要内容从以下三个方面展开论述:
首先,根据设计要求,搭建了柔性基板输送试验平台,设计了摆臂浮辊、模组浮辊和张力传感器控制等三种张力部件,改进了以往的张力控制结构,实现了多种张力控制布局方案的转换,为后续关键技术的研究提供了良好的平台。
其次,基于有限元分析对试验平台中对恒定张力控制具有重要影响的摆臂结构进行了优化设计,对摆臂进行了拓扑优化和尺寸优化并进行了强度校核和模态分析,最终确定了摆臂的优化结构,满足性能要求的同时又大大的节省了材料。
最后,根据基板输送的工况要求,对三种张力控制方案进行了介绍与分析,并在不同工况下对基板输送系统控制总图基于运动控制卡的力/位反馈控制方法进行试验,通过对张力波动、进给位置精度及进给时间进行分析,研究了张力波动的影响因素等,实现了间歇进给的恒定张力控制。
本文的研究成果对提高RFID标签封装设备的性能及效率具有重要作用,为基板输送系统的两个关键技术的深入研究提供了良好的基础平台,同时也给类似柔性薄膜输送系统的研发提供技术参考。
The radio frequency identification technology is one of the most promising information technologies in the 21th century. Therefore, it’s very significant to develop RFID tag-package equipments. A RFID tag-package equipment includes five modules, they are web conveyance module, dispensing module, flip-chip bonding module, heat-press module and testing module. As a necessary part of the equipment, Web conveyance module’s function is to make sure the Substrate runs to the designated location under the constant tension.
The main content of this paper is to design the flexible web conveyance test platform and research the tension control system. Including:
Fistly, this paper set up a flexible web conveyance test platform according to experiment requirements, designed a new tension control structure by introducing active dancer axis and passive spring-swing device. This platform could converse a wide range of tension control layoust. It played an important role in the following research on the key technologies.
Secondly, this paper optimized and analysed the swing arm by finite element software-ANSYS. Gained the basic shape by topology optimization, attained geometric structure by thickness of the size optimization, ultimately ascertained the optimal structure of the swing which meets the performance requirements and saves material at the same time.
Finally, this paper put forward three tension control methods according to the requirements of the woking conditions. Experimented the tension/position double loops feedback control solution based on PMAC towards to the general tension control layout, researched the influencing factors of tension fluctuation. The system could achieve constant tension control under intermittent feeding.
The conclusion of this paper could improve the proformance and efficiency of the RFID tag-package equipment, on the other hand, it may provide some useful guidance to the related applications.
引文
[1]张智文.射频识别技术理论与实践.北京:中国科学技术出版社, 2008.1
[2] Marin Konig, Gerhard Klink, Michael Feil,“Fast flip chip assembly for reel-to-rell manufacturing”, IEEE, 2001
[3]徐济仁,陈家松,牛纪海.射频识别技术及应用发展.数据通信, 2009.1
[4] G.P.Crawfor. Flexible_Flat_Panel_Displays. Society for Information Display, 2005
[5] F.Kriebel, Th.Seidowski,“Smart labels-High volume applications using adhesive flip-chip-technologies”, IEEE, 2001
[6]夏熙梅等.射频识别技术及其应用.工业技术经济, 2000, 5:87~89。
[7]孟昱东,金宇. RFID技术及应用解析.环渤海经济瞭望经营管理
[8]冯武锋.电信业的RFID融合与业务创新及高可靠性RFID封装.中国通信学会第五届学术年会论文集. 2008, 01:1625~1630
[9]陈建魁.面向RFID封装的柔性基板输送装置的研究与实现.华中科技大学.硕士学位论文, 2006.
[10]孔国华. RFID标签封装设备点胶系统的结构设计与实现.华中科技大学.硕士学位论文, 2008.
[11]陈克昌,荘佳橙,陈信吉. Roll-to-Roll卷送设备技术分析.机械工业杂志, 258: 122～130
[12] L.Frisk, J.Jarvinen, R.Ristolainen,“Chip on flex attachment with thermoplastic ACF for RFID applications”, Microelectronics Reliability, vol.42, 2002
[13] Saeed Moaveni.有限元分析-ANSYS理论与应用.北京:电子工业出版社, 2005.8
[14]张洪武,关振群,李云鹏等.有限元分析与CAE技术基础.第1版.北京:清华大学出版社, 2004
[15]商跃进等.有限元原理与ANSYS应用指南.北京:清华大学出版社, 2005
[16]胡于进,王璋奇.有限元分析及应用.试用版.武汉:华中科技大学出版社, 2008
[17] Zienkiewicz OC, Taylor RL. The Finite Elements Method: The Basis, 5th edition, Volume1, Butterworth-Heinemann, Oxford, 2000
[18]刘桂芹,江进国,段成龙,黄亚星.有限元法及其在现代机械工程中的应用.机械研究与应用. 2005,18(2): 15-16
[19] M.Lossie, H.V.Brussel. Design Principles in Filament winding CompositesManufacturing. 1994,5(1):5~13
[20]任胜乐.纤维缠绕运动中精密张力控制系统的研究.哈尔滨工业大学.博士学位论文, 2007.
[21] C.W.Cheng,C.H.Hsiao,C.C.Chuang,K.C.Chen and W.-P.Tseng. Observer-Based Tension Feedback Control of Direct Drive Web Transport System.Proceedings of the 2005 IEEE International Conference on Mechatronics.2005,July 10-12,Taipei,Taiwan:745~750
[22] A.F.Lynch,S.A.Bortoff,K.Robenack.Nonlinear Tension Observers for Web Machines. ELSEVIER Automatica.2004,40:1517~1524
[23]张延磊.柔性基板张力控制系统的设计与实现.华中科技大学.硕士学位论文, 2008.
[24]尹周平,权建州,陈建魁等.一种卷到卷间歇式柔性基材传输的张力控制方法.中国专利, CN101324795, 2008
[25] M.Anibal Valenzuela, John Martin Bentley. Sensorless tension control in paper machines. IEEE Transactions on Industry Applications, 2003.39: 294～304
[26] JianKui Chen, ZhouPing Yin, YouLun Xiong and Jianzhou Quan. A Hybrid Control Method of Tension and Position for a Discontinuous Web Transport System.
[27]李智刚.柔性基板输送系统的结构优化及纠偏控制.华中科技大学.硕士学位论文, 2008.
[28] Q.F QI, Y.M HU, Y PENG, et al. An intelligent position and quality detection system in IC production. Procof the IFAC Contf on New Technologies for Computer Control. Hongkong, 2001.193~196
[29]崔明涛.不确定性连续体结构拓扑优化和柔性结构设计研究.西安电子科技大学.博士学位论文, 2006.
[30] Annicchiarico W. and Cerrolaza M. Structural shape optimization 3D finite-element models based on genetic algorithms and geometric modeling. Finite Elements in Analysis and Design, 2001, 37:403~415
[31] T. H. Pian, D. P. chen, etc. A new formulation of hybrid mixed finite elements. Computers&Structures. 1983, 16:81-87
[32] Pedersen N L. Maximization of eigenvalues using topology optimization.Structural and Multidisciplinary Optimization, 2000, 20(1): 2-11.
[33]周传月,腾万秀,张俊堂.工程有限元与优化分析应用实例教程.科学出版社, 2005
[34]杜平安,甘娥忠,于亚婷.有限元法-原理、建模及应用.国防工业出版社, 2006
[35]谢涛,刘静,刘军考.结构拓扑优化综述.机械工程师, 2006. 8.
[36]杨姝.复杂机械结构拓扑优化若干问题研究.大连理工大学.博士学位论文, 2007.
[37] M.P. Bendsoe, O.S. Topology Optimization- Theory, Methods and Application. 2004: Springer.
[38]王化更.液压缸直接驱动盾构刀盘系统结构优化及控制研究.同济大学.博士学位论文, 2006
[39]薛定宇,陈阳泉.高等应用数学问题的MATLAB求解.北京:清华大学出版社, 2004
[40]岳珠峰.航空发动机三维单晶涡轮叶片的多学科设计优化.西北工业大学.硕士学位论文, 2007.
[41]毛坤.某型飞机座舱罩结构强度分析与设计优化.西北工业大学.硕士学位论文, 2007.
[42] M.Anibal Valenzuela, John Martin Bentley, and Robert D.Lorenz. Sensorless Tension Control in Paper Machines. IEEE Transactions on Industry Applications. Vol.39,No.2,2003.294～304.
[43]郭帅.机电张力系统关键控制技术的研究及实践.上海大学.博士学位论文, 2006.
[44] Seung-Ho Song and Seung-Ki Sul. A New Tension Controller for Continuous Strip Processing Line [M]. IEEE Transactions on Industry Application. 2000(36): 633～639
[45] Giannoccaro N.I. & Sakamoto T. Importance of overlapping decomposition for a web tension control system. Advances in production Engineering & Management, 2007(3): 135～145
[46] Chieh-Li Chen, Kuo-Ming Chang, Chih-Ming Chang. Modeling and control of a web-fed machine. Applied Mathematical Modeling, 2004: 863～876
[47] Dominique Knittel and Edouard Laroche. Tension Control for Winding Systems With Two-Degree-of-Freedom H Controllers. IEEE Transactions on Industry Applications.Vol.39,No.1,2003.113～120
[48] Bong-Ju Lee, Sung-Hwan Kim, Chul-Goo Kang. Analysis of nonlinear web-tension control system of a high-speed gravure printing machine. SICE-ICASE International Joint Conference, 2006.10: 893～898
[2] Marin Konig, Gerhard Klink, Michael Feil,“Fast flip chip assembly for reel-to-rell manufacturing”, IEEE, 2001
[3]徐济仁,陈家松,牛纪海.射频识别技术及应用发展.数据通信, 2009.1
[4] G.P.Crawfor. Flexible_Flat_Panel_Displays. Society for Information Display, 2005
[5] F.Kriebel, Th.Seidowski,“Smart labels-High volume applications using adhesive flip-chip-technologies”, IEEE, 2001
[6]夏熙梅等.射频识别技术及其应用.工业技术经济, 2000, 5:87~89。
[7]孟昱东,金宇. RFID技术及应用解析.环渤海经济瞭望经营管理
[8]冯武锋.电信业的RFID融合与业务创新及高可靠性RFID封装.中国通信学会第五届学术年会论文集. 2008, 01:1625~1630
[9]陈建魁.面向RFID封装的柔性基板输送装置的研究与实现.华中科技大学.硕士学位论文, 2006.
[10]孔国华. RFID标签封装设备点胶系统的结构设计与实现.华中科技大学.硕士学位论文, 2008.
[11]陈克昌,荘佳橙,陈信吉. Roll-to-Roll卷送设备技术分析.机械工业杂志, 258: 122～130
[12] L.Frisk, J.Jarvinen, R.Ristolainen,“Chip on flex attachment with thermoplastic ACF for RFID applications”, Microelectronics Reliability, vol.42, 2002
[13] Saeed Moaveni.有限元分析-ANSYS理论与应用.北京:电子工业出版社, 2005.8
[14]张洪武,关振群,李云鹏等.有限元分析与CAE技术基础.第1版.北京:清华大学出版社, 2004
[15]商跃进等.有限元原理与ANSYS应用指南.北京:清华大学出版社, 2005
[16]胡于进,王璋奇.有限元分析及应用.试用版.武汉:华中科技大学出版社, 2008
[17] Zienkiewicz OC, Taylor RL. The Finite Elements Method: The Basis, 5th edition, Volume1, Butterworth-Heinemann, Oxford, 2000
[18]刘桂芹,江进国,段成龙,黄亚星.有限元法及其在现代机械工程中的应用.机械研究与应用. 2005,18(2): 15-16
[19] M.Lossie, H.V.Brussel. Design Principles in Filament winding CompositesManufacturing. 1994,5(1):5~13
[20]任胜乐.纤维缠绕运动中精密张力控制系统的研究.哈尔滨工业大学.博士学位论文, 2007.
[21] C.W.Cheng,C.H.Hsiao,C.C.Chuang,K.C.Chen and W.-P.Tseng. Observer-Based Tension Feedback Control of Direct Drive Web Transport System.Proceedings of the 2005 IEEE International Conference on Mechatronics.2005,July 10-12,Taipei,Taiwan:745~750
[22] A.F.Lynch,S.A.Bortoff,K.Robenack.Nonlinear Tension Observers for Web Machines. ELSEVIER Automatica.2004,40:1517~1524
[23]张延磊.柔性基板张力控制系统的设计与实现.华中科技大学.硕士学位论文, 2008.
[24]尹周平,权建州,陈建魁等.一种卷到卷间歇式柔性基材传输的张力控制方法.中国专利, CN101324795, 2008
[25] M.Anibal Valenzuela, John Martin Bentley. Sensorless tension control in paper machines. IEEE Transactions on Industry Applications, 2003.39: 294～304
[26] JianKui Chen, ZhouPing Yin, YouLun Xiong and Jianzhou Quan. A Hybrid Control Method of Tension and Position for a Discontinuous Web Transport System.
[27]李智刚.柔性基板输送系统的结构优化及纠偏控制.华中科技大学.硕士学位论文, 2008.
[28] Q.F QI, Y.M HU, Y PENG, et al. An intelligent position and quality detection system in IC production. Procof the IFAC Contf on New Technologies for Computer Control. Hongkong, 2001.193~196
[29]崔明涛.不确定性连续体结构拓扑优化和柔性结构设计研究.西安电子科技大学.博士学位论文, 2006.
[30] Annicchiarico W. and Cerrolaza M. Structural shape optimization 3D finite-element models based on genetic algorithms and geometric modeling. Finite Elements in Analysis and Design, 2001, 37:403~415
[31] T. H. Pian, D. P. chen, etc. A new formulation of hybrid mixed finite elements. Computers&Structures. 1983, 16:81-87
[32] Pedersen N L. Maximization of eigenvalues using topology optimization.Structural and Multidisciplinary Optimization, 2000, 20(1): 2-11.
[33]周传月,腾万秀,张俊堂.工程有限元与优化分析应用实例教程.科学出版社, 2005
[34]杜平安,甘娥忠,于亚婷.有限元法-原理、建模及应用.国防工业出版社, 2006
[35]谢涛,刘静,刘军考.结构拓扑优化综述.机械工程师, 2006. 8.
[36]杨姝.复杂机械结构拓扑优化若干问题研究.大连理工大学.博士学位论文, 2007.
[37] M.P. Bendsoe, O.S. Topology Optimization- Theory, Methods and Application. 2004: Springer.
[38]王化更.液压缸直接驱动盾构刀盘系统结构优化及控制研究.同济大学.博士学位论文, 2006
[39]薛定宇,陈阳泉.高等应用数学问题的MATLAB求解.北京:清华大学出版社, 2004
[40]岳珠峰.航空发动机三维单晶涡轮叶片的多学科设计优化.西北工业大学.硕士学位论文, 2007.
[41]毛坤.某型飞机座舱罩结构强度分析与设计优化.西北工业大学.硕士学位论文, 2007.
[42] M.Anibal Valenzuela, John Martin Bentley, and Robert D.Lorenz. Sensorless Tension Control in Paper Machines. IEEE Transactions on Industry Applications. Vol.39,No.2,2003.294～304.
[43]郭帅.机电张力系统关键控制技术的研究及实践.上海大学.博士学位论文, 2006.
[44] Seung-Ho Song and Seung-Ki Sul. A New Tension Controller for Continuous Strip Processing Line [M]. IEEE Transactions on Industry Application. 2000(36): 633～639
[45] Giannoccaro N.I. & Sakamoto T. Importance of overlapping decomposition for a web tension control system. Advances in production Engineering & Management, 2007(3): 135～145
[46] Chieh-Li Chen, Kuo-Ming Chang, Chih-Ming Chang. Modeling and control of a web-fed machine. Applied Mathematical Modeling, 2004: 863～876
[47] Dominique Knittel and Edouard Laroche. Tension Control for Winding Systems With Two-Degree-of-Freedom H Controllers. IEEE Transactions on Industry Applications.Vol.39,No.1,2003.113～120
[48] Bong-Ju Lee, Sung-Hwan Kim, Chul-Goo Kang. Analysis of nonlinear web-tension control system of a high-speed gravure printing machine. SICE-ICASE International Joint Conference, 2006.10: 893～898