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)干法转移是制造柔性电子产品、氢燃料电池、有机太阳能电池和二维(2D)材料的关键工艺。R2R制造的目标是使更快地生产出更好的产品，并从规模经济中受益。尽管预计它将成为各种下一代产品的未来生产方法，但R2R制造受到技术挑战的阻碍，使其无法在工业中广泛采用。这些挑战包括轧辊动态控制、分层力学、在线监测、诊断和质量控制。本研究的目标是建立R2R制造的建模和控制框架，特别是R2R干法转移过程，以在实时操作中实现最佳的系统性能。这项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。这项研究将是多学科的，涉及动态系统建模、控制理论、先进制造和材料科学。它将有助于扩大未被充分代表的群体对研究的参与，并通过技术进步和STEM劳动力发展，为保持美国在先进制造业中的领导地位做出贡献。这项研究将研究干式剥离机理和一种用于实时过程控制的可逆系统凸化方法。将开发一种新的凸模型预测控制方法，以实现可逆凸化，这是评估控制设计和进行知情系统重构的关键性质。R2R干式转移过程是一个高阶开关系统。对这类系统的稳定性和最优性能的研究将导致切换系统控制理论的重要进步。本研究开发的控制算法将能够处理系统的复杂性，并且足够简单，便于实时实现。这项研究将极大地推动R2R制造的技术水平，并使柔性电子产品和2D材料的低成本和高通量生产方法成为可能。这项研究中将要开发的方法将在制造过程和其他涉及非线性和高阶切换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，并通过使用基金会的智力优势和更广泛的影响审查标准进行评估，被认为值得支持。

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.