Improvement of a Splicing Machine to Decrease Abrupt Tension Changes and Tail Defects during the Roll Exchange Process in a Roll-to-Roll Manufacturing System

  • Jongsu Lee
  • Changwoo LeeEmail author
Regular Paper


The use of the splicing system is necessary to exchange a fully unwound roll to a new one without stopping the roll-to-roll manufacturing machine. However, abrupt tension changes and tail defects, which is an overlap of completely unwound films with films in the process of being unwound, could occur during the roll exchange phase causing film loss and deterioration of product quality. Herein, we improved the splicing machine in an industrial scale R2R manufacturing system to decrease abrupt tension errors and tail defects. First, the effects of the factors generating the tail defects in the splicing machine on the net tail lengths were analyzed using designed mathematical models. Furthermore, the reason for the abrupt tension disturbance in the roll exchange process was determined. Based on the analyses, a passive dancer system was applied to the unwinding section to attenuate the tension error, and the time interval between the pressing and cutting phases was decreased by changing the signal processing method of the previous version of the splicing machine. Experimental results showed that the abrupt tension change was decreased by an average of 46.5%, while tail lengths were decreased by more than 2.5 times, thereby verifying the superior performance of the upgraded splicing machine.


Roll-to-roll Winding Splicing machine Signal processing Tail Tension 



tail length generated by the distance between the nip roll and knife


tail length in the attaching phase


tail length in the cutting phase


net tail length in the splicing process


distance between nip-roll and knife


the radius of the new roll


the radius of the dancer roll


bearing friction coefficient of dancer roll


bearing friction coefficient of hinge


web moving velocity


rod length of dancer arm to pneumatic cylinder


length of dancer arm


equivalent moment of inertia of dancer


moment of inertia of dancer roll


length of unwinder to the dancer roll


length of dancer roll to the infeed roll


tension of unwinder to LC#1


tension of LC#1 to passive dancer


tension after passive dancer


velocity variation of film before dancer


velocity variation of film after dancer


time interval between pressing and cutting phases


time interval between attaching and cutting phases


time period between the start and end of pressing


period of one cycle rotation of unwinding roll


scan time of unwinding tension controller


cross-sectional area of substrate


elastic modulus of substrate


difference of the angular positions of the adhesive tape at the attaching and nipping phases


L3s + v


AERd2 / (Jds + bd)


AEl22s / (Jeqs2 + bs + 3.077l1)


A(s) + B(s) + C(s)


(B(s) + v - C(s)) / D(s)


(B(s) - C(s)) / D(s)


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Copyright information

© Korean Society for Precision Engineering and Springer-Verlag GmbH Germany, part of Springer Nature 2018

Authors and Affiliations

  1. 1.Department of Mechanical Design and Production EngineeringKonkuk UniversitySeoulRepublic of Korea
  2. 2.School of Mechanical EngineeringChangwon National UniversityGyeongsangnam-doRepublic of Korea

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