1

A Mechatronic Approach to Full

Sheet Control Using a Steer-able
Nips Mechanism
Rene Sanchez
University of California Berkeley
2
Outline
Problem Statement: Limitation and Goals
Proposed Solution Approach
Steer-able Nips Mechanism
Experimental Setup
Dynamic Model
Control Strategy
Converge Analysis of Closed Loop System
Simulation and Experimental Results
Conclusion
3
System under control is a System under control is a printer paperpath printer paperpath: :
Mostly open loop control! Mostly open loop control!
Problem Statement
4
Current Paper Path Limitations
Shut down rates are reduce by designing
Paper Path for a specific media.
Longitudinal error can not be corrected a high
speeds.
Changes in environmental conditions
increases shutdown rates.
5
Paper Path Goals:
Decrease shut down rate due to Decrease shut down rate due to
environmental conditions. environmental conditions.
Allow the use of a wider selection of media. the use of a wider selection of media.
Increase the speed of correction of Increase the speed of correction of
longitudinal, lateral and skew errors. longitudinal, lateral and skew errors.
6
11--2 sections 2 sections multiple, multiple, independent independent sections sections
Steer-able Nips Section
Nonsteerable Nips Section
Proposed Paper Path Design
Multiple Independent
sections
Feeder unit
Image transfer
Section (ITS)
Original document
Fuser rolls
Exposure
Photo-receptor
belt
7
Steer-able Nips Mechanism
Why do we need an Steer-able Nips Mechanism?
Allows the fast correction of lateral error
without the lateral movement of the
actuators itself.
Allows the correction of errors without
marking the sheet.
8
Steer-able Nips Mechanism - Design
Allows the correction of longitudinal, lateral, and
angular errors.
Paper
Steer Motors
Process Motors

y
x
Spring Loaded Ball
9
Steer-able Nips Mechanism - Sensing
Laser Sensors
Laser Sensors
Image Station
Optical Sensor
1 2
3
Longitudinal Position:
Optical Sensors
Lateral Position:
Laser Sensor 1
Angle Position:
Laser Sensor 1 and 2
Buckle:
Laser Sensor 1 and 3
10
Experimental Setup
11
Experimental Setup - Hardware
12
Experimental Setup - Sensor
13
Experimental Setup - Electronics
dSpace board:
20 ADC channels
8 DAC channels
6 Digital Incremental Encoder
32 bit digital I/O
4 External Interrupt channels
dSpace Software:
Simulink
C programing
14
Dynamic Model
Assumptions:
Paper can still rotate when it is buckled
Neglect Dynamic due to the paper mass
Angular Rotation of Nip 1 and 2
Steering angle of Nip 1 and 2
Position of Point C
Angle of the Sheet
Amount of Buckle on Sheet
15
Dynamic Model
Sheet Kinematic Relation
(sheet has negligible mass)
Where: ) , , , , (
2 1 2 1
J J U U

y f y =
T
y x y ] [ o J =
)

+

'
+

'

'
+

'

+ +
=
1 1 1 2 2 2
2 2 2 1 1 1
2 2
2
1 1 1 1
1
2 2 2 2 1 1
1
cos sin
cos cos
2
1
cos
2
) (
cos cos
2
) (
sin cos
2
cos
2
U J U J
U J U J
U J U J J
U J J U J




r r
r r
b
b
r b x
r
b
r b x
b
y
r
b
y r
f
16
Dynamic Model
Actuator Dynamics
Steer Motors
Process Motors

y
x
2 2 2 2 2
1 1 1 1 1
2 2 2 2 2
1 1 1 1 1
s s s
s s s
p p p
p p p
V
V
V
V
F J E J
F J E J
F U E U
F U E U
= +
= +
= +
= +




2 1 2 1
, , ,
s s p p
V V V V
:Voltage Input
17
Dynamic Model
Paper coordinates
Paper States
, ) ( ) (
2
1
2
1

+ =
J
J
U
U

x N x m y
2 2 2 2 2
1 1 1 1 1
2 2 2 2 2
1 1 1 1 1
s s s
s s s
p p p
p p p
V
V
V
V
F J E J
F J E J
F U E U
F U E U
= +
= +
= +
= +




. J
T
y x y x x o J o J

=
. J
T
y x x h y o J = = ) (
18
Dynamic Model
,
0
0
) (

=
x
y
x m

J
J

'
+

'
+

'
+

'
+
+
+

=
2 2 2 1 1 1 2 2 1 1
2 2
2
1 1
1
2
2
1
1
2 2
2
1 1 1 2
2
1 1
2 2 2 2
2
1 1
1
2 2 2
2
1
1
cos cos sin sin
sin
2
sin
2
cos
2
cos
2
sin
2
) (
sin
2
) (
1 cos
2
) (
cos
2
) (
1
cos sin
2
sin
2
sin cos
2
cos
2
) (
U J U J J J
U J U J J J
U J U J J J
U J J U J J J J




r r r r
b
r
b
r
b
r
b
r
b
r b x
r
b
b x
b
r b x
r
b
b x
r
b
yr
b
yr
r
b
yr
b
yr
x N
, ) ( ) (
2
1
2
1

+ =
J
J
U
U

x N x m y
19
Longitudinal Position
Control Strategy
Sheets need to track to desired trajectories:

=
0
0
) (
0
t g y
x
y
d
d
d
d
d
o
J
) ( ) ( t y x y
d
p
20
Control Strategy
Internal loops to locally control the actuators angular positions and
velocities
Nonlinear Feedback Linearization Law:
FBL
C
21
Control Strategy
Nonlinear Feedback Linearization Control Law:
. J )) ( ) ( )( (
1
2 1 2 1
x m x v x N
T
d d d d
=

J J U U

+ + +
+ + +
+ + +
+ + +
=
) ( ) )( (
) ( ) )( (
) ( ) )( (
) ( ) )( (
o o o o o
J J J J J


o o o o
J J J J
d d d
d d d
d y y d y y d
d x x d x x d
K K
K K
y y K y y K y
x x K x x K x
v




o o J J
, , , , , , K K K K
y y x x
Feedback Linearization Control Gains:
22
Control Strategy
Local controllers loops are given by:

'
+

'

+ = + =
s
s C
s
s C
pi
pi
FF
pi
pi FB
pi pi
E
F
K
L 1
1
) ( , ) ( ) 2 , 1 ( = i

'
+

'

+ = + =
s
s C s s C
si
si
FF si si FB
si si
E
F
K L 1
1
) ( , ) ( ) 2 , 1 ( = i
Control Gains: si si pi pi
K L K L , , ,
Actuator Coefficients:
si si pi pi
F E F E , , ,
To use feedforward for steering position control, we estimate the steering
acceleration through the use of a first order filter. This technique is sometimes
referred as dynamics surface control DSC.
Note that the success of the complete control strategy depends on the
invertibility of matrix N(x). N(x) matrix is invertible as long as the sheet
always moves in the longitudinal direction:
0 ,
2 1
{ U U

) 2 , 1 ( = i
) 2 , 1 ( = i
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Convergence Analysis of Closed
Loop System
Local Asymptotic Converge of the Closed-Loop
System can be proved by:
Defining paper errors and actuator errors:
o o o J J J = = = =
d d d d
y y y x x x
~
,
~
,
~
,
~
id i i i id si i id pi
J J I J J I U U I = = =


, ,
) 2 , 1 ( = i
o o J J
o o J J
~ ~
,
~ ~
,
~ ~
,
~ ~
+ = + = + = + =


s s y y s x x s
y y x x
Surface Errors:
2 2 1 1 2 2 1 1
2 2 1 1 2 2 1 1
, , ,
s s s s p p p p
s s s s p p p p
s s s s I I I I I I I I
I I I I I I I I
+ = + = + = + =
18 states
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Convergence Analysis of Closed
Loop System
Taking the time derivative of the previous defined
errors and surface errors and substitute the
dynamics of the system:
/

2 2 1 2
1 1 1 1
) (
) (
) ( ) (
~ ~
) ( ) (
~ ~
1 1
1 1
2 2 44 1 1 43 2 42 1 41
2 2 14 1 1 13 2 12 1 11
s s s
p p p
s s
s s
n n n n s K s
s
n n n n s K s
s x x
s s s
p p p
s s p p
s s p p x x x
x x
I I I
I I I
o o o
o o
L F E
L F E
I I I I I I
o o
I I I I I I

+ =
+ =
+ + + + + + =
+ =
+ + + + + + =
+ =
25
Convergence Analysis of Closed
Loop System
We assume a simple desired trajectory
) 0 , 0 , , 0 , 0 , 0 , , 0 ( ) , , , , , , , ( v vt y x y x
d d d d d d d d
= o J o J


Linearize the error and surface errors dynamics around:
0
~ ~
~ ~
2 1 2 1
= = = = = = = =
s s p p
y x I I I I o J


0
2 1 2
2 1 1
= = = = = = = = = = I I
I I I I o J
s s p
s s s s s s s s
y x

we get:
) ( ) ( ) ( t e t G t e =
. J
T
s s p p
y x t e I I I I I o J
2 1 2 1
) ( =
. J ,
~
T
x
s x x = . J ,
~
T
y
s y y = . J,
~
T
s
J
J J = . J,
~
T
s
o
o o =
. J,
1
1 1
T
p p
p
s
I
I I =
. J
T
p p
p
s
2
2 2 I
I I =
. J,
2
2 2
T
s s
s
s
I
I I =
. J,
1
1 1
T
s s s
p
s I I =
. J ,
2 1
T
I I I =
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Convergence Analysis of Closed
Loop System
Elements of the matrix depend on system parameters and controller gains

=
I
I
I
I
I
I
I
I
I
o
I
J
I I
I
I
I
I
I
o
I
o
I
o o
I
J
I
J J
I I
I I
I I
A B B t B t B B t B B
A
A
A
A
B B B A
B B A
B B A
B B t B t B A
t G
s s
p p
s
s
p
p
s s
p p
p p
s
p p
x
y y y
x x x x x
2 1
2 1
2
1
2
1
2 1
1 1
2 1
1
2 1
) ( ) ( ) ( 0
0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0
0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
0 ) ( ) ( 0 0 0
) (
Some matrix elements depend explicitly on time, and they do so linearly.
By proper selection of the controller gains, we can make matrices
and Hurwitz.
I I I I I o J
A A A A A A A
s s p p
, , , , , ,
2 1 2 1
, ,
y x
A A
I
A
Thus and will
converge to zero asymptotically
) ( ), ( ), ( ), ( ), ( ), ( ), ( ), (
2 1 2 1
t t t t t t t y t x
s s p p
I I I I o J
) (t I
27
Working Fixture
28
Simulation and Experimental Results
Simulation parameters:
Letter-sized sheet : 280 mm v 216 mm,
Forward velocity : vn = 0.5 m/s (100 ppm),
Total transfer time : T = 0.43 s,
Available control time : T } 0.35 s,
Initial errors : = 5.2 mm, = -50 mm, = 0.7.
Final errors : 0.5 mm, 0.5 mm, 0.2 .
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Simulation and Experimental Results
30
Simulation and Experimental Results
31
Simulation and Experimental Results
32
Conclusion
The control strategy successfully corrected
position errors within the allowable time.
Errors are reduced to less than what is
required.
Discrepancies between the simulation and
experimental results can be attributed to
sensor noise and sensor accuracy.
Discrepancies between experimental and
simulated results of paper buckle can be
attributed to paper slip.