Adaptive Trajectory Bundle Method for Roll-to-Roll Manufacturing Systems

Abstract: Roll-to-roll (R2R) manufacturing demands precise tension and velocity control under strict operational constraints. Model predictive control requires gradient computation, while sampling-based methods such as MPPI struggle with hard constraint satisfaction. This paper presents an adaptive trajectory bundle method that achieves rigorous constraint handling through derivative-free sequential convex programming. The approach approximates nonlinear dynamics and costs via interpolated sample bundles, with adaptive trust regions and penalty parameters ensuring robust convergence without manual tuning. Simulations on a six-zone R2R system demonstrate tracking accuracy comparable to gradient-based MPC with superior constraint satisfaction over sampling-based alternatives.