A closed-loop feedback control process may have numerous advantages over open-loop control processes, such as the one described above. For example, the closed-loop control process may improve accuracy and robustness. The inboard and outboard nips 105, 110 may be the two actuators for a sheet registration system. However, error between desired and actual sheet velocities may occur. Error may be caused by, for example, a discrepancy between the actual sheet velocity and an assumed sheet velocity. Current systems assume that the rotational motion of parts within the device, specifically the drive rolls that contact and impart motion on a sheet being registered, exactly determine the sheet motion. Manufacturing tolerances, nip strain and slip may create errors in the assumed linear relationship between roller rotation and sheet velocity. Also, finite servo bandwidth may lead to other errors. Even if the sheet velocity is perfectly and precisely measured, tracking error may exist in the presence of noise and disturbances. Error may also result as the desired velocity changes for a sheet.
The proposed closed-loop algorithm may take advantage of position feedback during every sample period to increase the accuracy and robustness of registration. Open-loop motion planning cannot take advantage of position feedback. As such, the open-loop approach may be subject to inescapable sheet velocity errors that lead directly to registration error. In contrast, the closed-loop approach described herein may use feedback to ensure that the sheet velocities automatically adjust in real-time based on the actual sheet position measured during registration. As such, the closed-loop approach may be less sensitive to velocity error and servo bandwidth and may be more robust as a result.
In addition, current open-loop algorithms may rely on learning based on performance assessment to satisfy performance specifications. Additional sensors may be required to perform the learning process increasing the cost of the registration system. When a novel sheet is introduced, such as, for example, during initialization of a printing machine, when feed trays are changed, and/or when switching between two sheet types, “out of specification” performance may occur for a plurality of sheets while the algorithm converges. In some systems, the out of specification performance may exist for 20 sheets or more.
Referring back to
To be effective, the input-output linearization module 310 may require the selection of an appropriate reference frame.
x=[x y θ ω1 ω2]T,
where: {x,y} denote the coordinates of the center of mass of the sheet (Ps);
The sheet states q=[x y θ]T are a subset of state vector x. If no slip exists between the drive rolls and the sheet, three kinematic equations may relate the sheet states to the angular velocities:
where: c denotes the radius of the drive rolls: and
x
d(t)=vdt+xdi, yd(t)=ydi, and θd(t)=0,
where: vd denotes the process velocity; and
One problem with the reference frame shown in
xc[X Y Θ ω1 ω2]T,
where: {X, Y} denote the coordinates of the center of the cart (Pc);
The cart states may be defined as a subset of xc, qc=[X Y Θ]T. The transformations between the sheet and the cart states may be defined as:
X=−(x cos θ+y sin θ), Y=−(−x sin θ+y cos θ), Θ=−θ.
The cart and sheet orientations, Θ and θ, may differ in sense because the cart “moves” in the opposite direction of the sheet. In other words, if the sheet were a surface on which the drive wheels propelled the virtual cart, the drive wheels would propel the cart in a direction substantially opposite from the process direction. By substituting these transformations into the desired sheet trajectory determined above, the desired cart trajectory that achieves sheet registration may be determined:
X
d(t)=−vdt−xdi, Yd(t)=−ydi, and Θd(t)=0.
The outputs y may correspond to the position of a center of the virtual cart, which may be determined by using information retrieved from the one or more sensors. A set of desired outputs yd may also be determined. In an embodiment, the desired output values may correspond to the position of a point that is on a line bisecting the nips (wheels of the cart) 105, 110. In operation, the convergence of the outputs y to the desired outputs yd may guarantee convergence of the three sheet states (i.e., the two-dimensional position of the sheet and the rotation of the sheet with respect to a process direction) to the desired (registered) trajectory. The differences between the values of the desired outputs and the corresponding current output values may be used as inputs to a gain-scheduled error dynamics controller 305 that accounts for error dynamics. This controller 305 may have output values v.
Due to the limited amount of time available to perform registration, employing gain-scheduling or a variable set of gains within the error dynamics controller 305 may be a vital component in a sheet registration system employing closed-loop feedback control. Gain scheduling may be used, for example, by sheet registration systems in the presence of otherwise insurmountable constraints with, for example, a static set of gains. A gain schedule effectively minimizes the forces placed on a sheet while still achieving sheet registration. The gain-scheduled error dynamics controller 305 may perform this by, for example, starting with low gains to minimize the high accelerations characteristic of the early portion of registration and then increasing the gain values as the sheet progresses through the sheet registration system to guarantee convergence in the available time.
An input-output linearization module 310 may receive the outputs of the error dynamics controller 305 (v) and state feedback values xc to produce acceleration values u for the nips 105, 110. The state feedback values xc may include, for example, the position and rotation of the sheet and the angular velocities of each drive roll associated with a nip 105, 110. The sheet position and rotation may be determined based on sensor information from, for example, the sensors described above with respect to
Kinematic equations (based on an assumption of no slip) for the cart may include:
{dot over (X)} cos Θ+{dot over (Y)} sin Θ+a{dot over (Θ)}−cω1=0, {dot over (X)} cos Θ+{dot over (Y)} sin Θ−a{dot over (Θ)}−cω2=0, and {dot over (Y)} cos Θ−{dot over (X)} sin Θ=0,
which can be written in matrix form as:
Assuming a set of accelerations u=[u1 u2]T, the resulting cart state equations may be written in companion form:
{dot over (x)}
c
=f(xc)+G(xc)u,
where:
As with the angular velocities of the drive rolls ω, the accelerations of the drive tolls u may be common to the equations of both reference frames.
The position of a point Pb (an exemplary Pb is shown in
In order to perform linearization between the inputs and the outputs, the output must be recursively differentiated until a direct relationship exists between the inputs and the outputs. Differentiating the outputs once provides the following:
Here, ∇h(xc) denotes the Jacobian of h(xc). The Lie derivative of any scalar h with respect to any vector f is a scalar function defined by Lfh=∇hf (essentially the directional derivative of h in an f space: f·∇h). Evaluating the second term of the right hand side of the equation above results in
which establishes that the first differentiation does not introduce the output. Differentiating a second time may provide the following equation:
Both rows of Ψ may be non-zero (i.e., each row contains at least one non-zero element). Accordingly, the value of at least one input may appear in both outputs after two differentiations. The determinant of Ψ may be seen to be nonzero if b is nonzero: i.e., the decoupling matrix is non-singular. The inverse of Ψ may be computed to be:
An input v may be introduced, and u may he defined in terms of v as u=Ψ31 1(v−H). u may be solved in closed form as:
Substituting u into the equation for ÿ, the problem is reduced to the second order vector equation: ÿ=v. This system is linear and uncoupled because each input vi only affects a corresponding output yi.
Having reduced the problem to a linear form, the error e may be defined as e=yd−y. The error dynamics may now be constructed by expressing v as a function of e and yd: v=ÿd+kdė+kpe, which may be rewritten as: ë+kdė+kpe=0. Because these equations are uncoupled, the values of kd
As the output error e converges to zero, the cart state error also converges to zero, but with a phase lag. The amount of phase lag between the convergence of the output and cart state may be adjustable via b. Using a smaller b may result in a smaller lag. In all, five parameters may be used to adjust the rate of convergence: the four gain values (the two-dimensional gain vectors kd and kp) and the value of b.
If no system constraints existed, the gain parameters mentioned above (kd, kp and b) would suffice to determine the control of the sheet. However, the time period for sheet registration is limited based on the throughput of the device. In addition, violating maximum tail wag and or nip force requirements may create image quality defects. Tail wag and nip force refer to effects which may damage or degrade registration of the sheet. For example, excessive tail wag could cause a sheet to strike the side of the paper path. Likewise, if a tangential nip force used to accelerate the sheet exceeds the force of static friction, slipping between the sheet and drive roll will occur.
To satisfy the time constraints for a sheet registration system, high gain (kd, kp) values and a small value of b may be desirable. However, to limit the effects of tail wag and nip force below acceptable thresholds, small gain values and a large value of b may be required. Depending on the input error and machine specifications, a viable solution may not exist if the gain values are static.
In order to circumvent these constraints, gain scheduling may be employed to permit adjustment of the gain values during the sheet registration process. Relatively low gain values may be employed at the onset of the registration process in order to satisfy max nip force and tail wag constraints, and relatively higher gain values may be employed towards the end of the process to guarantee timely convergence. The gain values may be adjusted to maintain a consistent amount of damping. In an alternate embodiment, the damping may also be modified. Although the value of b is not technically a gain value, the value of b may also be scheduled to provide an additional degree of freedom.
Referring back to
The sheet velocity at each drive roll 325 may be defined as the radius (c) of the nip multiplied by the angular velocity of the drive roll. As shown in
The input-output linearization module 310 may utilize position feedback xc that is generated every sample period. An observer module 330 may employ the following kinematic equations for the cart to evolve the cart position xc based on the measured drive roll velocities ω:
The observer module 330 may be initialized by an input position snapshot provided by the sensors. Only the cart position may be needed because the reference frame for the linearization module 310 may be based on the cart state xc. The cart state values xc may be converted to the corresponding sheet state values qc using, for example, a processor 335 to compute the equations defined above,
An exemplary sheet registration system designed according to an embodiment was installed in a Xerox iGen3® print engine. The input velocity of the sheets into the drive rolls was approximately 1.025 m/s. The registration was performed at a process velocity of approximately 1.024 m/s, which correlates to approximately 200 pages per minute. The process velocity reduces to a registration time of approximately 0.145 seconds, which is the time in which input-output linearization must converge in order to function properly in the system.
The sheet feeding mechanism was adjusted to produce approximately 5 mm of input lateral error.
The numerical results for the sheet state error are depicted in Table 1.
It will be appreciated that various of the above-disclosed and other features and functions, or alternatives thereof may be desirably combined into many other different systems or applications. It will also be appreciated that various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the disclosed embodiments.