High precision roll-to-roll processes are believed to be one of the most promising technologies for manufacturing flexible and large-area thin film electronics. However, broadband frictional disturbances caused by the guiding ball bearings affect the precision of the processing roller in the roll-to-roll system, severely hampering the quality of the manufactured products. Conventional feedback control techniques encounter difficulties in mitigating the broadband frictional disturbances. This paper presents a novel rotary system for high-precision roll-to-roll manufacturing process. Friction isolator (FI), a robust and cost-effective mechatronics method, is implemented in the system to mitigate the undesirable effects of friction during continuous printing processes. Frequency domain analysis shows that the proposed rotary system with FI achieves significantly improved attenuation of frictional disturbance, compared to the case without it. A rotary FI is designed and optimized to minimize the adverse effects of bearing friction without overly sacrificing the high rigidity of the machine. A precision rotary system is then built using the designed FI prototype. Experiments carried out on the prototype friction-isolated rotary system demonstrate up to 61% reduction in root-mean-square tracking error during constant velocity motion, compared to a conventional roll-to-roll system without FI.

高精度的卷对卷工艺被认为是制造柔性和大面积薄膜电子产品的最有前途的技术之一。然而，由导球轴承引起的宽带摩擦干扰会影响卷对卷系统中处理辊的精度，从而严重影响了制成品的质量。传统的反馈控制技术在减轻宽带摩擦干扰方面遇到困难。本文提出了一种用于高精度卷对卷制造过程的新型旋转系统。摩擦隔离器（FI）是一种强大且经济高效的机电一体化方法，已在系统中实施，以减轻连续印刷过程中不希望有的摩擦影响。频域分析表明，与不带FI的旋转系统相比，带有FI的旋转系统可以显着改善摩擦干扰的衰减。旋转FI的设计和优化可以最大程度地减少轴承摩擦的不利影响，而又不会过度牺牲机器的高刚性。然后，使用设计的FI原型构建精密的旋转系统。与没有FI的传统卷对卷系统相比，在原型摩擦隔离旋转系统上进行的实验表明，在匀速运动过程中，均方根跟踪误差最多可降低61％。旋转FI的设计和优化可以最大程度地减少轴承摩擦的不利影响，而又不会过度牺牲机器的高刚性。然后，使用设计的FI原型构建精密的旋转系统。与没有FI的传统卷对卷系统相比，在原型摩擦隔离旋转系统上进行的实验表明，在匀速运动过程中，均方根跟踪误差最多可降低61％。旋转FI的设计和优化可以最大程度地减少轴承摩擦的不利影响，而又不会过度牺牲机器的高刚性。然后，使用设计的FI原型构建精密的旋转系统。与没有FI的传统卷对卷系统相比，在原型摩擦隔离旋转系统上进行的实验表明，在匀速运动过程中，均方根跟踪误差最多可降低61％。