Efficient numerical analysis method for 2D roll-to-roll system with the winding web material

Roll-to-roll (R2R) systems have been mainly designed and developed based on expert experience. There are some important issues in the numerical analysis for R2R systems with the winding web that are included in most general R2R systems. We propose numerical modeling improvements for R2R system analysis to make the numerical methods more efficient. The first is the approximated winding length estimation (AWLE) algorithm, which can calculate the length of the flexible web that is wound around a rotating roller. The winder is approximated with line and arc segments in this algorithm. The second is the contact algorithm between the web and rollers. This contact algorithm has to be stable and fast. This paper proposes an efficient R2R system analysis method.