Mathematical model and method for optimization of shaker fan modes to reduce lateral film displacement in a dtf printing system

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Шепіта П. І., Petriv Yu. I. № 2 (71) 312-323 Image Image

This paper presents a mathematical model describing the influence of the shaker fan control parameter on the lateral deviation of PET film during Direct-to-Film (DTF) printing using the industrial ORIC A-620 Super printer. Lateral film deviation leads to registration errors between CMYK+W color layers and misalignment of adhesive pow-der application, critically affecting print quality and material efficiency. The studied machine integrates a powder shaker and dryer unit, whose fans create a cross-flow of air near the powder fusion and drying zones — a dominant source of perturbations in the transverse direction of the moving film.

The proposed model captures the physical dynamics of film displacement by formulating a second-order differential equation representing the lateral motion of the web-like film under the influence of mechanical tension, span geometry, damping, gravitational sag, and aerodynamic disturbances. The fans are introduced as a controllable variable through the fan activation percentage (0–100%), which is directly linked to the strength of the cross-flow acting on the film edge. The airflow-induced force is further shaped by turbulence and drying temperature gradients, contributing to stochastic deviations modeled via random processes.

An experimental identification protocol was designed and implemented using the ORIC A-620 Super platform (620 mm working width, 4×Epson I3200 heads, integrated shaker/dryer). The protocol includes varying fan power in discrete steps, maintaining constant line speed and film tension, and recording real-time edge deviation, drying temperature, suction level, cold air counterflow, and angular flow orientation. A filtered da­taset was used for parameter estimation via the Nelder–Mead and Levenberg–Mar­quardt methods. The results show a consistent increase in lateral deviation with higher fan power, with partial compensation achieved by increasing web tension, enhancing suction, or optimizing cooling airflow after the drying zone.

The model was validated against experimental data and can be applied as part of a digital twin system for predictive control, optimization, and fault prevention. The inclusion of a controllable aerodynamic parameter (fan activation) extends classical web-handling models and offers a practical tool for tuning DTF printer operation under varying production conditions. The findings are of interest to engineers and researchers in roll-to-roll printing, flexible media processing, and intelligent control of print stability in thermal and aerodynamic environments.

Keywords: DTF printing; ORIC A-620 Super; film; shaker fans; cross-flow; lateral deviation; web tension; drying chamber; turbulence; suction; controllable model; digital twin; LSTM; web-handling.

doi: 10.32403/1998-6912-2025-2-71-312-323


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