Theoretical control and experimental verification of a calender roller system part I: dynamic system modeling and model predictive controller design

Abstract

The objective of this study is to deal with the control of the pressed roller to get high quality of the calendering products. First, the pressed roller is assumed as an Euler-Bernoulli beam and the forces which are produced by the pressing roller are considered as distributed forces. The mathematical model of the system is derived as a continuous system using Hamilton’s principle, Lagrange’s equations and assumed-modes method. Originally, the achieved model is a two-input with one-output system. Since the distributed forces are constants, the model can be simplified to a single-input single-output system by changing variables. An advanced control technique, Model Predictive Control (MPC), is used and a state estimator is designed in order to set up a realizable control system. The control system is implemented for experimental verification as well. It includes pressed and pressing rollers, a personal computer with VisSim software, RT-DAC4/PCI card, inductive proximity sensor and electro-hydraulic actuator. The performance of the proposed control system can be shown through a real implementation.