Observer-based decentralized pole–zero cancellation tension control with gain booster and surface stabilizer for roll-to-roll systems

This article presents an advanced parameter-free velocity observer-based nonlinear decentralized tension control scheme for roll-to-roll systems governed by nonlinear dynamics. The system parameter uncertainties and nonlinear dynamics yield the second-order perturbed nominal open-loop systems, which are used for devising the web velocity and tension control law for each station. The features of this result are summarized as follows: (a) the tension-derivative observers including the disturbance observer mechanism as a subsystem, (b) the observer-based active-damping pole–zero cancellation velocity error stabilizer for each tension loop, and (c) the closed-form nonlinear feedback gain boosters and exponential surface stabilizers to secure the improved transient performance and robustness for web velocity and each tension loop. The various simulation results based on MATLAB/Simulink show both the qualitative and quantitative advantages of the proposed technique.