Measurement of web tension using ambient vibrations in roll-to-roll manufacturing of flexible and printed electronics

Web tension measurement and control are important for the quality control of flexible and printed electronics fabricated by roll-to-roll (R2R) manufacturing. The distribution of tension within a R2R web can be calculated from the values of the web's mechanical resonance frequencies. Typically, such measurements require an active external forcing to be generated and applied to the web. In this work, we show it is possible to obtain the web's resonance frequencies from forcing due to ambient noise present in the test environment. This result broadens the applicability of noncontact resonance methods for computing web tension as currently available methods of active external forcing cannot be applied to all web materials and all R2R operating environments. We validate the ambient excitation method by comparing it to speaker-based acoustic excitation at atmospheric pressure and find the two methods agree within 0.5%. A calculation of the experimental motion of the web due to finite temperature effects suggests the observed vibration is generated from air-borne or structure-borne noise in the test environments. To show the effectiveness of the approach, we demonstrate the use of ambient excitation at five externally applied tensions, on three different web materials, and at both atmospheric and vacuum pressures.