Modeling and Control of a Roll-to-Roll Manufacturing Process for Dry Transfer of Two-Dimensional Materials and Printed Electronics

该奖项将支持动态系统和制造过程控制的研究，为基础科学和新兴国内产业做出贡献。卷对卷（R2R）干转移是制造柔性电子器件、氢燃料电池、有机太阳能电池和二维（2D）材料的关键工艺。R2R制造的目标是更快地生产更好的产品，并从规模经济中受益。虽然R2R被认为是未来各种下一代产品的生产方法，但它的制造面临着技术挑战，阻碍了它在工业中的广泛应用。这些挑战包括辊动力学控制、分层力学、在线监测、诊断和质量控制。本研究的目标是建立一个建模和控制框架的R2R制造，特别是专注于R2R干转移过程，以实现最佳的系统性能，在实时操作。该研究将使复杂印刷电子产品的设计和制造成为可能，并提高大规模转移的2D材料的质量。该研究将是多学科的，涉及动态系统建模，控制理论，先进制造和材料科学。它将有助于扩大代表性不足的群体在研究中的参与，并有助于通过技术进步和STEM劳动力发展保持美国在先进制造业的领导地位。本研究将探讨乾式剥皮机构及一种可即时控制之可逆系统凸化方法。一个新的凸模型预测控制方法将被开发，使可逆凸化，一个属性，是至关重要的评估控制设计和进行知情的系统重构。R2R干转移过程是一个高阶切换系统。对此类系统稳定性和最优性能的研究将导致开关系统控制理论的重要进展。在这项研究中开发的控制算法将能够处理系统的复杂性，并足够简单的实时实现。该研究将显著推进R2R制造的最新技术水平，并为柔性电子产品和2D材料提供低成本和高产量的生产方法。在这项研究中开发的方法将在制造过程和其他涉及非线性和高阶开关系统动态的复杂工程系统中得到广泛的应用。该奖项反映了NSF的法定使命，并被认为值得通过使用基金会的知识价值和更广泛的影响审查标准进行评估来支持。

This award will support research in dynamic systems and control of a manufacturing process, contributing to fundamental science and emerging domestic industries. Roll-to-Roll (R2R) dry transfer is a critical process in manufacturing flexible electronics, hydrogen fuel cells, organic solar cells, and two-dimensional (2D) materials. The goal of R2R manufacturing is to enable faster production of better products and to benefit from economies of scale. Although it is expected to be the future production method for a variety of next-generation products, R2R manufacturing suffers from technical challenges that prevent it from being widely adopted in industry. These challenges include control of roller dynamics, mechanics of delamination, on-line monitoring, diagnosis, and quality control. The goal of this research is to establish a modeling and control framework for R2R manufacturing, specifically focusing on an R2R dry transfer process, to achieve optimal system performance in real-time operation. The research will enable the design and manufacturing of complex printed electronic products and improve the quality of large-scale transferred 2D material. The research will be multidisciplinary, involving dynamic system modeling, control theory, advanced manufacturing, and materials science. It will help broaden participation of underrepresented groups in research and contribute to maintaining US leadership in advanced manufacturing through technology advancement and STEM workforce development. The research will investigate dry peeling mechanics and a reversible system convexification method for real-time process control. A new convex model predictive control methodology will be developed to enable reversible convexification, a property that is critical for evaluating control design and conducting informed system reconfiguration. The R2R dry transfer process is a high-order switched system. Research on the stability and optimal performance of such a system will lead to important advancements in switched-system control theory. Control algorithms developed in this research will be able to handle the complexity of the system and be simple enough for real-time implementation. The research will significantly advance the state of the art of R2R manufacturing and enable a low-cost and high-throughput production method for flexible electronics and 2D materials. The methodologies to be developed in this research will find a wide range of applications in manufacturing processes and other complex engineering systems that involve nonlinearity and high-order switched-system dynamics.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.