R2R Operational Insights: Improving Accuracy in R2R Processes - Maplesoft
MapleSim for Web Converting Systems
MapleSim for Web Converting Systems

R2R Operational Insights: Improving Accuracy in R2R Processes

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Modern materials used in roll-to-roll (R2R) processing often impose stricter requirements on handling and tension control. As a result, the tension management system in an R2R machine must deliver exceptional precision and reliability. The interplay between the control architecture—specifically the placement of feedback sensors and drive mechanisms—along with low tension levels and mechanical losses, can create a highly complex dynamic.

MapleSim’s web handling simulation tool enables users to explore and analyze these intricate relationships. It allows for the inclusion of factors such as roller slippage and bearing losses, providing a realistic environment to test and refine control strategies. The modular nature of the control structure makes it easy to experiment with alternative configurations, while dynamic 3D visualization enhances comprehension of system behavior.

For example, simulation results can reveal how tension varies across the web line depending on the control strategy, mechanical losses, tension levels, and direction of operation. Such modeling helps explain phenomena like slippage and web sagging that may occur during forward operation but not in reverse, offering valuable insights for optimizing machine performance.
Bearing losses on a battery machine
Application Example
Bearing losses on a battery machine

For a battery manufacturer in China, MapleSim Web Handling simulation played an important part in analyzing the machine behavior and understanding the influence of bearing losses.

During battery separator production, the allowable tension level is very small because of the thin, sensitive material. A very different behavior was observed on the machine depending on the motion direction of the web line. There was sagging web and slippage (zero tension spans) in the forward direction but not in reverse.

The MapleSim model helped successfully to explain the relationship between the control structure, bearing losses and the tension.


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